Zebra Technologies Printer Z4Mplus User Manual

Zebra® Z4Mplus/Z6Mplus™  
Industrial/Commercial Printer  
User Guide  
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Contents  
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Contents  
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Contents  
®
ZebraNet Wired and Wireless Print Server LCD Displays . . . . . . . . . . . . . . . . . . . . 72  
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Contents  
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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 expressed  
written permission 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.  
FCC Compliance Statement  
This device complies with Part 15 rules. Operation is subject to the following two conditions:  
1. This device may not cause harmful interference, and  
2. This device must accept any interference received, including interference that may cause  
undesired operation.  
This equipment has been tested and found to comply with the limits for Class B Digital Devices,  
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection  
against harmful interference when the equipment is operated in a residential environment. This  
equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in  
accordance with the product manuals, may cause harmful interference to radio communications.  
However, there is no guarantee that interference will not occur in a particular installation. If this  
equipment does cause harmful interference to radio or television reception, the user is encouraged  
to do one or more of the following measures:  
Reorient or relocate the receiving antenna.  
Increase the separation between the equipment and receiver.  
Connect the equipment into an outlet on a circuit different from that to which the receiver is  
connected.  
Consult the dealer or an experienced radio/TV technician for help.  
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Proprietary Statement  
The user is cautioned that any changes or modifications not expressly approved by Zebra  
Technologies could void the user’s authority to operate the equipment. To ensure compliance,  
this printer must be used with Shielded Communication Cables.  
Canadian DOC Compliance Statement  
This Class B digital apparatus complies with Canadian ICES-003.  
Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.  
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.  
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Declaration of Conformity  
Declaration of Conformity  
I have determined that the Zebra printers identified as the  
Z4Mplus/Z6Mplus™-series  
manufactured by:  
Zebra Technologies Corporation  
333 Corporate Woods Parkway  
Vernon Hills, Illinois 60061-3109 U.S.A.  
Have been shown to comply with the applicable technical standards of the FCC  
For Home, Office, Commercial, and Industrial use  
If no unauthorized change is made in the equipment,  
and if the equipment is properly maintained and operated.  
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Declaration of Conformity  
Notes • ___________________________________________________________________  
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__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
To provide feedback on this document, please send your comments to [email protected], or  
write your comments on this page and fax to the following:  
Fax: 1.847.821.1795  
Attention: TechPubs — CTC  
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Warranty Information  
Effective December 30, 2002  
All new Zebra products are warranted by the manufacturer to be free from defect in material  
and workmanship.  
Printers and Related Hardware Products  
Proof of purchase or shipment date is required to validate the warranty period. The warranty  
becomes void if the equipment is modified, improperly installed or used, damaged by accident  
or neglect, or if any parts are improperly installed or replaced by the user.  
Products returned must be packaged in the original or comparable packing and shipping  
container. In the event equipment is not so packaged, or if shipping damage is evident, it will  
not be accepted for service under warranty. Surface transportation charges for return to  
customers in the continental United States is paid by Zebra. Otherwise, Zebra pays CPT  
(carriage paid to) nearest airport; customer pays customs, duties, taxes, and freight from  
airport to destination. If Zebra determines that the product returned for warranty service or  
replacement is not defective as herein defined, the customer will pay all handling and  
transportation costs.  
Printers  
All printers (excluding printheads) are warranted against defect in material or workmanship  
for twelve (12) months from the purchase date.  
Printheads  
Since printhead wear is part of normal operation, the original printhead is covered by a limited  
warranty as indicated below. Warranty period begins on purchase date.  
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Warranty Information  
Printhead  
Warranty Period  
Bar code label and receipt printer printheads 6 months  
Plastic card printer printheads 12 months  
To qualify for this warranty, the printhead must be returned to the factory or to an authorized  
service center. Customers are not required to purchase Genuine Zebra Supplies (media and/or  
ribbons) for warranty qualification.  
However, if it is determined that the use of inappropriate or inferior supplies has caused any  
defect in the printhead for which a warranty claim is made, the user is responsible for Zebra’s  
labor and material charges required to repair the defect. The warranty becomes void if the  
printhead is physically worn or damaged; also if it is determined that failure to follow the  
preventive maintenance schedule listed in the User Guide has caused defect in the thermal  
printhead for which a warranty claim is made.  
Related Hardware Items  
Products are warranted to be free of defects in material and workmanship from the date of  
purchase according to this chart:  
Product  
Warranty Period  
1 month  
3 months  
1 month  
1 year  
Accessories  
Batteries  
Cables  
Chargers/Power Supplies  
Hardware Keys  
Keyboard Display Units  
Parts  
1 year  
6 months  
3 months  
1 year  
®
Pocket Eye  
Software  
1 month  
3 years  
®
ZebraNet Print Servers  
Defective product must be returned to Zebra for evaluation. In the event of notification of  
defect within the warranty period, Zebra will replace the defective item provided there had not  
been damage resulting from user abuse, modification, improper installation or use, or damage  
in shipping or by accident or neglect.  
Supplies Products  
Supplies are warranted to be free from defect in material and workmanship for a period of  
six (6) months for media and twelve (12) months for ribbon from the date of shipment by  
Zebra. This is provided the user has complied with storage guidelines, handling, and usage of  
the supplies in Zebra printers.  
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Warranty Information  
Zebra’s sole obligation under these warranties is to furnish parts and labor for the repair or  
possible replacement of products found to be defective in material or workmanship during the  
warranty period. Zebra may in its discretion issue a credit for any such defective products in  
such amount as it deems reasonable.  
Repair Services  
Zebra repairs are warranted against defects in material and workmanship for 90 days from the  
date of repair by Zebra. This excludes printheads, which are warranted separately. This  
warranty does not cover normal wear and tear. This warranty becomes void if the item is  
modified, improperly installed or used, or damaged by accident, neglect, or abuse.  
Warranty Exclusions & Conditions Statement  
The warranties given above are the only warranties given to you. No other warranties, express  
or implied, are given. Zebra does not make any implied warranty of merchantability or fitness  
for a particular purpose in connection with its sale of products or services. While Zebra’s  
desire is to be responsive to your specific needs and questions, Zebra does not assume  
responsibility for any specific application to which any Products are applied, including, but not  
limited to, compatibility with other equipment. All statements, technical information, or  
recommendations relating to Zebra Products are based on tests believed to be reliable, but do  
not constitute a guaranty or warranty.  
Zebra’s maximum liability for warranty claims is limited to the invoice price of the Product  
claimed defective. Zebra does not assume responsibility for delays in replacement or repair of  
products. Zebra shall not under any circumstances whatsoever be liable to you or any other  
party for loss or profits, lost data, diminution of goodwill, or any other special or consequential  
damages whatsoever with respect to any warranty claim made by you. Specifically for  
software, Zebra is not liable for any incidental or consequential damages caused by abuse or  
misapplication of the software or by its use in violation of the U.S. copyright law or  
international treaty. No salesperson, representative, or agent of Zebra is authorized to make  
any guaranty, warranty, or representation that contradicts the foregoing. Any waiver,  
alteration, addition, or modification to the foregoing warranties must be in writing and signed  
by an executive officer of Zebra to be valid.  
Zebra Technologies  
333 Corporate Woods Parkway  
Vernon Hills, IL 60061-3109 U.S.A.  
Phone +1 847.634.6700 or +1 800.423.0442  
Fax + 1 847.913.8766  
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Warranty Information  
Notes • ___________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
To provide feedback on this document, please send your comments to [email protected], or  
write your comments on this page and fax to the following:  
Fax: 1.847.821.1795  
Attention: TechPubs — CTC  
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Preface  
Contacts  
Contacts  
You can contact Zebra Technologies Corporation, USA at any of the following:  
Our Mailing Address:  
Zebra Technologies Corporation  
333 Corporate Woods Parkway  
Vernon Hills, Illinois 60061.3109 U.S.A  
Telephone: +1 847.634.6700  
Facsimile: +1 847.913.8766  
Zebra Technologies Europe Limited  
Zebra House  
The Valley Centre, Gordon Road  
High Wycombe  
Buckinghamshire HP13 6EQ, UK  
Telephone: +44 (0)1494 472872  
Facsimile: +44 (0)1494 450103  
Support  
You can contact Zebra support at any of the following:  
Note • The Web address is case-sensitive.  
US Phone Number: +1 847.913.2259  
UK/International Phone Number: +44 (0) 1494 768289  
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Preface  
Document Conventions  
Document Conventions  
The following conventions are used throughout this document to convey certain information:  
Alternate Color (online only) Cross-references contain hot links to other sections in this  
guide. If you are viewing this guide online in .pdfformat, you can click the cross-reference  
(blue text) to jump directly to its location.  
Command Line Examples All command line examples appear in CourierNew font.  
For example, you would type the following to get to the Post-Install scripts in the bin  
directory:  
Ztools  
Files and Directories All file names and directories appear in Courier Newfont. For  
example, the Zebra<version number>.tarfile and the /root directory.  
Cautions, Important, Note, and Example  
Electrostatic Discharge Caution • Warns you of the potential for electrostatic discharge.  
Electric Shock Caution • Warns you of a potential electric shock situation.  
Caution • Warns you of a situation where excessive heat could cause a burn.  
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.  
Important • Advises you of information that is essential to complete a task.  
Note • Indicates neutral or positive information that emphasizes or supplements important  
points of the main text.  
Example • Provides an example, often a scenario, to better clarify a section of text.  
Tools • Tells you what tools you need to complete a given task.  
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Preface  
Related Documents  
Illustration Callouts Callouts are used when an illustration contains information that needs  
to be labeled and described. A table that contains the labels and descriptions follows the  
illustration. Figure 1 provides an example.  
Figure 1 • Example of an Illustration with Callouts  
2
3
4
1
PAUSE  
Power LED  
Pause LED  
Error LED  
Data LED  
1
2
3
4
Related Documents  
The following documents might be helpful references:  
®
ZPL II Programming Guide Volume I (part number 45541L) and Volume II (part  
number 45542L).  
®
ZebraNet Wireless Print Server User Guide (part number 13422L)  
ZebraNet 10/100 Print Server User and Reference Guide (part number 47619L-001)  
ZebraNet PrintServer IIInstallation and User Guide (part number 45537L).  
The Z4Mplus and Z6Mplus Maintenance Manual (Zebra part number 13358L) contains  
the information you need to maintain your printer.  
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Introduction  
External View  
External View  
Figure 2 shows the outside of the printer.  
Figure 2 • External View  
1
2
3
Electronics cover  
Front panel  
Media door  
1
2
3
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Introduction  
Front Panel  
Front Panel  
The front panel keys and lights are shown in Figure 3.  
Figure 3 • Front Panel Controls and LEDs  
2
3
1
4
5
12  
11  
6
7
8
10  
9
PAUSE  
Power LED  
Pause LED  
Error LED  
1
2
3
Data LED  
4
LCD  
5
PLUS (+) Key  
SETUP/EXIT Key  
CANCEL Key  
PAUSE Key  
FEED Key  
6
7
8
9
10  
11  
12  
SELECT Key  
MINUS (–) Key  
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Introduction  
Front Panel  
LCD Display Settings  
Table 1 shows front panel LCD display settings that you may wish to adjust and what they  
mean. Refer to Basic Configuration on page 53 for more detailed information on each setting.  
Table 1 • Front Panel LCD Display Settings  
LCD Display  
Meaning/Available Settings  
PRINTER READY  
Ready to print labels or to configure the printer. All printer self-  
tests have been performed successfully.  
DARKNESS  
The larger the number, the darker the print. The range is 0 to 30,  
with a default setting of 10.  
PRINT SPEED  
TEAR OFF  
The print speed is given in inches per second. The larger the  
number, the faster the label prints.  
Establishes the position of the media over the tear-off bar after  
printing.  
PRINT MODE  
Tear-Off (default setting), Peel-Off, Cutter, Rewind. For more  
details, see Table 2.  
MEDIA TYPE  
Non-continuous (default setting), Continuous  
Web (default setting), Mark  
SENSOR TYPE  
SENSOR SELECT  
PRINT METHOD  
Auto Select (default setting), Reflective, Transmissive  
Thermal transfer (default setting using a ribbon),  
Direct thermal (no ribbon)  
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Introduction  
Front Panel  
Print Modes  
You can view the current print mode on the LCD on the front panel of the printer. Refer to  
Configuration and Calibration LCD Displays on page 57 for more detailed information. Print  
modes should match the media and printer options chosen. Print mode choices are listed in  
Table 2 • Print Mode Options  
Mode  
Printer Option  
Action  
Tear-Off Mode  
(Default setting)  
Use for most applications.  
Each label or strip of labels can be torn off  
after printing.  
Peel-Off Mode  
Use only if printer has the peel option.  
Use only if printer has a cutter option.  
Liner material is peeled away from the  
label as it is printed. After the printed label  
is removed the next label prints.  
Cutter Mode  
Printer automatically cuts the label after it  
is printed.  
Rewind Mode  
Use only if printer has the rewind option. The media and/or liner are rewound onto a  
core as they are printed.  
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Introduction  
Printer Media Compartment  
Printer Media Compartment  
Figure 4 shows a simplified view of your printer. Depending on installed options, your  
printer may look slightly different.  
Figure 4 • Media Compartment  
3
2
1
5
4
6
7
Printhead Assembly  
Transmissive Sensor  
Label Supply Guide  
Label Supply Hanger  
Dancer  
1
2
3
4
5
6
7
Label Guide  
Printhead Open Lever  
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2
Printer Setup  
The chapter provides the tasks that you must complete and the issues that you must consider  
before you load and configure your printer.  
Contents  
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Printer Setup  
Before You Begin  
Before You Begin  
Review this checklist, and resolve any issues before you begin setting up your printer. When  
you are ready, continue with Printer Operation on page 21.  
Unpack and Inspect Have you unpacked the printer and inspected it for damage? If  
Select a Site Have you selected an appropriate location for the printer? If you have not,  
Attach Power Cord Do you have the correct power cord for your printer? If you are  
unsure, see Power Cord Specifications on page 11. To attach the power cord and connect the  
printer to a power source, see Connect the Printer to a Power Source on page 11.  
Connect to a Data Source Have you determined how the printer will be connected to  
a data source (usually a computer)? For more information, see Select a Communication  
Select Media Do you have the correct media for your application? If you are unsure,  
Select Ribbon Do you need to use ribbon, and is the appropriate ribbon available, if  
needed? If you are unsure, see Ribbon on page 17.  
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Printer Setup  
Unpack and Inspect the Printer  
Unpack and Inspect the Printer  
Check all exterior surfaces.  
Raise the media door, and inspect the media compartment.  
Save the carton and all packing material in case the printer needs to be shipped. Contact  
your authorized Zebra reseller for instructions.  
Report Damage  
If you discover shipping damage:  
Immediately notify the shipping company and file a damage report.  
Important • Zebra Technologies Corporation is not responsible for any damage incurred  
during the shipment of the equipment and will not repair this damage under warranty  
Keep the carton and all packing material for inspection.  
Notify your local Zebra reseller.  
Storage  
If you are not placing the printer into operation immediately, repackage it using the original  
packing materials. The printer may be stored under the following conditions:  
Temperature: –40°F to 140°F (–40°C to 60°C)  
Relative humidity: 5% to 85%, non-condensing  
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Printer Setup  
Select a Site for the Printer  
Select a Site for the Printer  
Consider the following when selecting an appropriate location for your printer.  
Select a Surface  
Select a solid, level surface of sufficient size and strength to accommodate the printer and  
other equipment (such as a computer), if necessary. The choices include a table, countertop,  
desk, or cart.  
Provide Proper Operating Conditions  
Because the printer was designed and is fabricated as an industrial-type unit, it functions  
satisfactorily in a location that conforms to specified environmental and electrical conditions,  
including a warehouse or factory floor. For more information on the required conditions, see  
Table 3 shows the temperature and relative humidity requirements for the printer when it is  
operating.  
Table 3 • Operating Temperature and Humidity  
Mode  
Temperature  
Relative Humidity  
Thermal Transfer  
Direct Thermal  
41° to 104°F (5° to 40°C)  
32° to 104°F (0° to 40°C)  
20 to 85% non-condensing  
20 to 85% non-condensing  
Allow Proper Space  
The printer should have enough space around it for you to be able to open the media door. To  
allow for proper ventilation and cooling, leave open space on all sides of the printer.  
Caution • Do not place any padding or cushioning material behind or under the printer  
because this restricts air flow and could cause the printer to overheat.  
Provide a Data Source  
If the printer will be located away from the data source, the selected site must provide the  
appropriate connections to that data source. For more information on the types of  
communication interfaces, see Select a Communication Interface on page 13.  
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Printer Setup  
Connect the Printer to a Power Source  
Connect the Printer to a Power Source  
Electric Shock Caution • For personnel and equipment safety, always use an approved  
three-conductor power cord specific to the region or country intended for installation. This  
cord must use an IEC 320 female connector and the appropriate region-specific three-  
conductor grounded plug configuration.  
To connect the printer to a power source, complete these steps:  
1. Turn the printer power switch (located on the rear of the printer) to the Off (O) position.  
2. Plug the power cord into the mating connector on the rear of the printer.  
3. Plug the other end of the power cord into the power source.  
Power Cord Specifications  
Depending on how your printer was ordered, a power cord may or may not be included. The  
power cord used must meet your local electrical requirements. If a power cord is not included  
or if the one included is not suitable for your requirements, refer to the following guidelines.  
Your power cord must meet these standards:  
The overall length must be less than 9.8 ft. (3.0 m).  
It must be rated for at least 5A, 250 VAC.  
The chassis ground (earth) must be connected to ensure safety and reduce electromagnetic  
interference. The ground connection is handled by the third wire (earth) in the power cord  
as shown in Figure 5.  
Figure 5 • Power Cord Specifications  
1
2
3
4
AC power plug for your country  
3-conductor HAR cable  
IEC 320 connector  
1
2
3
4
Neutral earth live in contact view  
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Printer Setup  
Connect the Printer to a Power Source  
The AC power plug and IEC 320 connector must bear the certification mark of at least one  
of the known international safety organizations shown in Figure 6.  
Figure 6 • International Safety Organization Marks  
+
R
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Printer Setup  
Select a Communication Interface  
Select a Communication Interface  
The way that you connect your printer to a data source depends on the communication options  
installed in the printer.  
Standard interfaces: The RS-232 DB-9 serial data port and the IEEE 1284 compliant  
bidirectional parallel port. For further information, see Data Connections on page 101.  
Optional Print Servers:  
ZebraNet Wireless Print Server. For more information on this option, see the ZebraNet  
Wireless Print Server User Guide (Zebra part number 13422L-001).  
ZebraNet 10/100 Print Server (10/100 PS). For more information on 10/100 PS, see the  
ZebraNet 10/100 Print Server User and Reference Guide (Zebra part number  
47619L-001).  
ZebraNet PrintServer II (PSII). For more information on PSII, see the PrintServer II User  
and Reference Guide (Zebra part number 45537L).  
Serial Port Communicating using a serial data port (see Figure 7) requires choosing the  
baud rate, number of data bits, stop bits, parity, and handshake (default settings are 9600 baud,  
8 data bits, 1 stop bit, no parity, and XON/XOFF). Parity only applies to data transmitted by  
the printer since the parity of received data is ignored. See Serial Data Port on page 102 to  
configure the communication parameters. The values selected must be the same as those used  
by the host equipment connected to the printer.  
Figure 7 • Communicating Using a Serial Data Port  
Printer  
Computer  
Male  
9
25  
9
9
Null modem adaptor  
(if using a standard  
modem cable)  
50 ft. (15 mm) maximum  
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Printer Setup  
Select a Communication Interface  
Parallel Port Communicating using the parallel port (see Figure 8) does not require special  
settings. The serial settings do not affect the parallel port. Refer to Parallel Data Port  
on page 107 for further information.  
Figure 8 • Communicating Using a Parallel Port  
Computer  
Printer  
36-pin  
male  
PC  
25-pin  
female  
25-pin  
male  
10 ft. (3 mm) maximum  
Cable Requirements  
Data cables must be fully shielded and fitted with metal or metallized connector shells.  
Shielded cables and connectors are required to prevent radiation and reception of electrical  
noise.  
To minimize electrical noise pickup in the cable:  
Keep data cables as short as possible.  
Do not bundle the data cables tightly with the power cords.  
Do not tie the data cables to power wire conduits.  
Note • Zebra printers comply with FCC Rules and Regulations, Part 15 for Class B Equipment  
using fully shielded, 6.5 ft (2 m) data cables. Use of unshielded cables may increase radiation  
above the Class B limits.  
Note • RS-422 and RS-485 applications should use twisted shielded pairs as recommended in  
the TIA/EIA-485 Specification.  
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Printer Setup  
Types of Media  
Types of Media  
Your printer is capable of using various forms of media. These include roll and fanfold media  
(Figure 9) that may be labels or card stock and that may have optional perforations, black  
marks, or registration holes. The following sections contain descriptions of the various types  
of media approved for use in your printer.  
Figure 9 • Roll and Fanfold Media  
Roll Media  
(non-continuous shown)  
Fanfold Media  
Selecting Media  
We strongly recommend the use of Zebra-brand supplies for continuous high-quality printing.  
A wide range of paper, polypropylene, polyester, and vinyl stock has been specifically  
engineered to enhance the printing capabilities of the printer and to ensure against premature  
printhead wear.  
Important • Certain printing conditions may require that you adjust printing parameters, such  
as print speed, darkness, or print mode. These conditions include (but are not limited to):  
printing at high speeds  
cutting or peeling the media  
the use of extremely thin, small, synthetic, or coated labels  
Because print quality is affected by these and other factors, it is important that you run tests  
to determine the best combination of printer settings and media for your application. A poor  
match may limit print quality or print rate, or the printer may not function properly in the  
desired print mode.  
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Printer Setup  
Types of Media  
Non-Continuous Media  
Non-continuous web media refers to individual labels that are separated by a gap, notch, or  
hole (Figure 10). When you look at the media, you can tell where one label ends and the next  
one begins.  
Figure 10 • Non-Continuous Web Media  
1
2
3
Hole  
Label Gap  
Notch  
1
2
3
Important • When using media that has holes or notches, position the sensor directly over a  
hole or notch.  
Non-continuous black mark media has black marks printed on the back, which indicate the  
start and end of each label. Figure 11 shows a sample of non-continuous black mark media.  
Figure 11 • Non-Continuous Black Mark Media  
Continuous Media  
Continuous media (Figure 12) is one uninterrupted roll of material without gaps, holes,  
notches, or black marks. This allows the image to be printed anywhere on the label. The  
individual labels can be cut apart or stored in a roll for later use.  
Figure 12 • Continuous Media  
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Printer Setup  
Ribbon  
Ribbon  
Ribbon is a thin film that is coated on one side with wax or wax resin, which is transferred to  
the media during the thermal transfer process. The media determines whether you need to use  
ribbon and how wide the ribbon must be.  
When to Use Ribbon  
Thermal transfer media requires ribbon for printing while direct thermal media does not.  
To determine if ribbon must be used with a particular media, perform a media scratch test.  
To perform a label scratch test, complete these steps:  
1. Scratch the print surface of the media with your fingernail.  
2. Did a black mark appear on the media?  
If a black mark...  
Then...  
Does not appear on the media  
The media is thermal transfer. A ribbon is  
required with this type of media.  
Appears on the media  
The media is direct thermal. No ribbon is required  
for this type of media, though ribbon may be used  
to help protect the printhead from abrasion with the  
media.  
Ribbon Width  
When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is  
narrower than the media, areas of the printhead are unprotected and subject to premature wear.  
Coated Side of Ribbon  
Ribbon can be wound with the coated side on the inside or outside (see Figure 13), which  
affects how the ribbon will be loaded in the printer. If you are unsure which side of a particular  
roll of ribbon is coated, perform an adhesive test or a ribbon scratch test to determine which  
side is coated.  
Figure 13 • Ribbon Coated on Outside or Inside  
Outside  
Inside  
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Printer Setup  
Ribbon  
Adhesive Test  
If you have labels available, perform the adhesive test to determine which side of a ribbon is  
coated. This method works well for ribbon that is already installed.  
To perform an adhesive test, complete these steps:  
1. Peel a label from its backing.  
2. Press a corner of the sticky side of the label to the outer surface of the roll of ribbon.  
3. Peel the label off of the ribbon.  
4. Observe the results. Did flakes or particles of ink from the ribbon adhere to the label?  
If ink from the ribbon... Then...  
Adhered to the label  
The ribbon is coated on the outer surface.  
Did not adhere to  
the label  
The ribbon is likely coated on the inner surface.  
a. Press a corner of the sticky side of the label to the inner  
surface of the roll of ribbon.  
b. Peel the label off of the ribbon.  
c. Observe the results again. The ink from the ribbon  
should have adhered to the label. If the ink did not stick  
either time, repeat the adhesive test with a stickier  
adhesive, or perform the ribbon scratch test.  
Ribbon Scratch Test  
If you do not have labels available, perform the ribbon scratch test. This method works best if  
the ribbon is not installed.  
To perform a ribbon scratch test, complete these steps:  
1. Unroll a short length of ribbon.  
2. Place the unrolled section of ribbon on a piece of paper with the outer surface of the  
ribbon in contact with the paper.  
3. Scratch the inner surface of the unrolled ribbon with your fingernail.  
4. Lift the ribbon from the paper.  
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Printer Setup  
Ribbon  
5. Observe the results. Did the ribbon leave a mark on the paper?  
If the ribbon...  
Then...  
Left a mark on the paper The ribbon is coated on the outer surface.  
Did not leave a mark on The ribbon is likely coated on the inner surface.  
the paper  
a. Flip the ribbon over on the paper so the inner side of the  
ribbon comes in contact with the paper.  
b. Scratch the outer surface of the unrolled ribbon with  
your fingernail.  
c. Lift the ribbon from the paper.  
d. Observe the results again. The ribbon should have left a  
mark on the paper. If not, repeat the test, starting with  
the first side again. You may need to scratch the surface  
of the ribbon harder.  
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Printer Setup  
Ribbon  
Notes • ___________________________________________________________________  
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__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
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__________________________________________________________________________  
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__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
To provide feedback on this document, please send your comments to [email protected], or  
write your comments on this page and fax to the following:  
Fax: 1.847.821.1795  
Attention: TechPubs — CTC  
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3
Printer Operation  
If you have completed the tasks and resolved the issues in the checklist in Before You Begin  
on page 8, follow the instructions in this chapter to load and calibrate your printer and to print  
configuration labels.  
Contents  
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Printer Operation  
Front Panel  
Front Panel  
The front panel display shows the printer’s operating status and allows you to change settings  
as needed to work with your media and label formats.  
The front panel keys and lights are shown in Figure 14. Descriptions for each are located in  
Figure 14 • Front Panel  
2
1
3
4
5
12  
11  
6
7
8
10  
9
PAUSE  
Power LED  
Pause LED  
Error LED  
1
2
3
Data LED  
4
LCD  
5
PLUS (+) Key  
SETUP/EXIT Key  
CANCEL Key  
PAUSE Key  
FEED Key  
6
7
8
9
10  
11  
12  
SELECT Key  
MINUS (–) Key  
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Printer Operation  
Front Panel  
Front Panel Keys  
Table 4 • Front Panel Keys  
Key  
Function  
FEED  
Forces the printer to feed one blank label each time the key is pressed.  
• Printer not printing: one blank label immediately feeds.  
• Printing: one blank label feeds after the current batch of labels is complete.  
PAUSE  
Starts and stops the printing process.  
• Printer not printing: no printing occurs. (Press PAUSE again to resume printing.)  
• Printing: printing stops after the current label is complete.  
CANCEL  
Cancels print jobs when in the pause mode.  
• Printer not printing: the next stored label format does not print.  
• Printing: current label completes printing, and the next label format is cancelled.  
Press and hold for several seconds to cancel all print jobs in memory.  
SETUP/EXIT  
SELECT  
Enters and exits the configuration mode.  
Toggles the function of PLUS (+) and MINUS () between the Scroll and Change  
Modes.  
• Press once to use PLUS (+) and MINUS () to change the values of the selection.  
• Press again to use PLUS (+) and MINUS () to scroll through the menu items.  
PLUS (+)  
Scrolls to the next selection.  
(scroll mode)  
PLUS (+)  
(change mode)  
• Increases the value.  
• Answers yes.  
• Prints a label (when applicable).  
MINUS ()  
Scrolls to the previous selection.  
(scroll mode)  
MINUS ()  
• Decreases the value.  
(change mode)  
• Selects the digit you wish to change.  
• Answers no.  
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Printer Operation  
Front Panel  
Front Panel Lights  
Table 5 • Front Panel Lights  
Light  
Status  
Off  
Indication  
POWER  
The printer is off or no power is applied.  
The printer is on.  
On  
PAUSE  
Off  
Normal printer operation.  
On  
The printer has stopped all printing operations.  
Flashing  
The Pause light flashes when initializing FLASH or PCMCIA memory  
and in Peel-Off Mode when the label is available.  
ERROR  
DATA  
Off  
Normal printer operation (no errors).  
Slow flashing  
RIBBON IN warning, HEAD UNDER TEMP warning, or HEAD  
OVER TEMP error.  
Fast flashing  
On  
HEAD OPEN error.  
PAPER OUT, RIBBON OUT, or CUTTER JAM errors.  
Normal printer operation (no data being received or processed).  
CANCEL is pressed and a format is successfully cancelled.  
The printer is unable to accept more data from the host.  
The printer is receiving data.  
Off  
One flash  
Slow flashing  
Fast flashing  
On  
A partial format has been received and no subsequent data activity.  
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Printer Operation  
Load Roll Media  
Load Roll Media  
Tear-Off Mode  
Tear-Off Mode is the default mode. The printer is set to this mode in the factory. The option is  
shown in Figure 15.  
Figure 15 • Tear-Off Mode  
3
2
1
4
8
7
6
5
Printhead Assembly  
Transmissive Sensor  
Label Supply Guide  
Label Supply Hanger  
Dancer  
Label Guide  
Printhead Open Lever  
Printed Label  
1
2
3
4
5
6
7
8
To load media in Tear-Off Mode, complete these steps:  
1. Press the printhead open lever. The printhead assembly springs up.  
Caution • Ensure that the printhead is fully open and engaged in the upright position.  
If you fail to latch the printhead, it could fall on your hand during the procedure.  
2. Flip down the media supply guide.  
3. Slide out the media guide as far from the printer frame as possible.  
4. Place the roll of media on the media supply hanger and orient the media properly.  
5. Flip up the media supply guide.  
6. Slide in the media supply guide until it touches, but does not restrict, the edge of the roll.  
7. Feed the media under the dancer, through the slot in the transmissive sensor, under the  
ribbon sensor, and out the front of the printer.  
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Printer Operation  
Load Roll Media  
8. Ensure the media is against the back of the transmissive sensor. Slide in the media guide  
until it touches, but does not restrict, the edge of the label.  
9. Close the printhead assembly.  
10. The printer is paused (the Pause light is on), press PAUSE to enable printing.  
Cutter Mode  
Cutter Mode requires that the cutter be installed. The option is shown in Figure 16.  
Figure 16 • Cutter Mode  
3
2
1
8
9
5
4
6
7
Printhead Assembly  
Transmissive Sensor  
Label Supply Guide  
Label Supply Hanger  
Dancer  
Label Guide  
Printhead Open Lever  
Cutter Module  
1
2
3
4
5
6
7
8
9
Catch Tray  
To load media in Cutter-Off Mode, complete these steps:  
1. Press the printhead open lever. The printhead assembly springs up.  
Caution • Ensure that the printhead is fully open and engaged in the upright position.  
If you fail to latch the printhead, it could fall on your hand during the procedure.  
2. Flip down the media supply guide.  
3. Slide out the media guide as far from the printer frame as possible.  
4. Place the roll of media on the media supply hanger and orient the media properly.  
5. Flip up the media supply guide.  
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Printer Operation  
Load Roll Media  
6. Slide in the media supply guide until it touches, but does not restrict, the edge of the roll.  
7. Feed the media under the dancer, through the slot in the transmissive sensor, under the  
ribbon sensor, and through the cutter module.  
Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers.  
8. Ensure that the media is against the back of the transmissive sensor. Then, slide in the  
media guide until it touches, but does not restrict, the edge of the media.  
9. Close the printhead assembly.  
10. If the printer is paused (the Pause light is on), press PAUSE to enable printing.  
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Printer Operation  
Load Roll Media  
Peel-Off Mode  
This setting works only with the Peel-Off Option installed on the printer. Figure 17 shows the  
printer with the Peel-Off Option.  
Figure 17 • Peel-Off Mode  
3
2
11  
1
101  
5
9
6
4
7
8
Printhead Assembly  
Transmissive Sensor  
1
2
Media Supply Guide  
Media Supply Hanger  
Dancer  
3
4
5
Media Guide  
6
Printhead Open Lever  
Peel Assembly  
Label  
7
8
9
Peel Lever  
Tear-Off/Peel/Off Bar  
10  
11  
To load media in Peel-Off Mode, complete these steps:  
1. Press the printhead open lever. The printhead assembly springs up.  
Caution • Ensure that the printhead is fully open and engaged in the upright position.  
If you fail to latch the printhead, it could fall on your hand during the procedure.  
2. Flip down the media supply guide.  
3. Slide the media guide as far from the printer main frame as possible.  
4. Place a roll of media onto the media supply hanger as shown.  
5. Flip up the media supply guide.  
6. Slide in the media supply guide until it just touches, but does not restrict, the edge of the  
media.  
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Printer Operation  
Load Roll Media  
7. Feed the media under the dancer, through the slot in the transmissive sensor, under the  
ribbon sensor, and through the Peel Assembly.  
8. Pull approximately 12 in. (30 mm) of media through the front of the printer.  
9. Ensure the media is against the rear of the transmissive sensor. Slide in the media guide  
until it just touches, but does not restrict, the edge of the media.  
10. Pull down the peel lever to open the peel assembly.  
11. Feed the liner over the tear-off/peel-off bar and behind the peel assembly.  
12. Close the printhead assembly.  
13. Close the peel assembly using the peel lever.  
14. The printer is paused (the Pause light is on), press PAUSE to enable printing.  
Peeling starts automatically. Press FEED to test.  
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Printer Operation  
Load Roll Media  
Liner Take-Up Mode  
The Liner Take-up option must be installed to use this mode. The option is shown in  
Figure 18.  
Note • This option is available on the Z4Mplus printer only  
Figure 18 • Liner Take-Up Mode  
3
2
12  
1
11  
6
7
10  
4
9
5
8
Printhead Assembly  
Transmissive Sensor  
Label Supply Guide  
Label Supply Hanger  
Liner Take-Up  
Dancer  
1
2
3
4
5
6
Label Guide  
7
Printhead Open Lever  
Peel Assembly  
Label  
Peel Lever  
Tear-Off/Peel-Off Bar  
8
9
10  
11  
12  
To load media in Liner Take-Up Mode, complete these steps:  
1. Press the printhead open lever. The printhead assembly springs up.  
Caution • Ensure that the printhead is fully open and engaged in the upright position.  
If you fail to latch the printhead, it could fall on your hand during the procedure.  
2. Flip down the media supply guide.  
3. Slide the media guide as far from the maim frame as possible.  
4. Place a roll of media onto the media supply hanger as shown.  
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Printer Operation  
Load Roll Media  
5. Flip up the media supply guide.  
6. Slide in the media supply guide until it just touches, but does not restrict, the edge of the  
media.  
7. Feed the media under the dancer, through the slot in the transmissive sensor, and under the  
ribbon sensor.  
8. Pull approximately 18 in. (500 mm) of media through the front of the printer.  
9. Remove the labels from the exposed media until only liner remains.  
10. Ensure that the media is against the back of the transmissive sensor. Slide in the media  
guide until it just touches, but does not restrict, the edge of the media.  
11. Pull down the peel lever to open the peel assembly.  
12. Feed the media over the tear-off/peel-off bar and behind the peel assembly.  
13. Close the printhead assembly.  
14. Close the peel assembly.  
15. Slide the liner into the slot (see Figure 19) in the spindle of the liner take-up. Ensure that  
the liner is resting against the back plate of the spindle assembly.  
Figure 19 • Liner Take-Up Spindle  
Slot  
16. Turn the spindle assembly counterclockwise a few times to snug the liner.  
17. If the printer is paused (the pause light is on), press PAUSE to enable printing. Peeling  
starts automatically. Press FEED to test.  
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Printer Operation  
Load Roll Media  
Liner Removal  
1. Pull the liner slide toward you (see inset) until it stops (about a third of the way down the  
liner take-up spindle).  
Figure 20 • Removing Liner from Liner Take-Up Spindle  
Liner Slide  
Liner Slide Tab  
2. Slide the liner from the take-up spindle.  
Note • The liner slide moves back in place after the liner is removed.  
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Printer Operation  
Load Roll Media  
Rewind/Peel-Off Mode  
The Rewind option must be installed to use this mode. The option is shown in Figure 21.  
Figure 21 • Rewind/Peel Mode  
2
3
1
15  
14  
4
13  
12  
11  
5
10  
9
7
6
8
Printhead Assembly  
Transmissive Sensor  
Label Supply Guide  
Label Supply Hanger  
Rewind Spindle  
Rewind Label Guide  
Thumbscrew  
1
2
3
4
5
6
7
Dancer  
8
Label Guide  
9
Media Alignment Spindle  
Printhead Open Lever  
Peel Assembly  
10  
11  
12  
13  
14  
15  
Label  
Rewind Base Assembly  
Peel Lever  
To load media in Rewind/Peel-Off Mode, complete these steps:  
1. Press the printhead open lever. The printhead assembly springs up.  
Caution • Ensure that the printhead is fully open and engaged in the upright position.  
If you fail to latch the printhead, it could fall on your hand during the procedure.  
2. Flip down the media supply guide.  
3. Slide the media guide as far from the main frame as possible.  
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Printer Operation  
Load Roll Media  
4. Place the roll of labels on the media supply hanger as shown.  
5. Flip up the media supply guide.  
6. Slide in the media supply guide until it just touches, but does not restrict, the edge of the  
media.  
7. Feed the labels under the dancer, through the slot in the transmissive sensor, and under the  
ribbon sensor.  
8. Pull approximately 36 in. (900 mm) of label through the front of the printer.  
9. Remove the labels from the first 18 in. (450 mm) of media.  
10. Ensure the media is against the back of the transmissive sensor. Slide in the media guide  
until it touches, but does not restrict, the edge of the media.  
11. Pull down the peel lever to open the peel assembly.  
12. Feed the media over the tear-off/peel-off bar, and through the slot in the peel assembly.  
13. Loosen the thumbscrew and slide out the rewind media guide to the end of the take-up  
spindle.  
14. Slide an empty core onto the take-up spindle; wrap the liner around the core and turn the  
take-up spindle counterclockwise to wind up the excess liner.  
Note • The liner must be attached to the take-up spindle for the printer to operate properly.  
Ensure the edge of the liner is flush against the backplate of the take-up spindle.  
15. Slide the rewind media guide against the liner and tighten the thumbscrew.  
16. Close the printhead assembly.  
17. Close the peel assembly using the peel lever.  
18. If the printer is paused (the Pause light is on), press PAUSE to enable printing.  
Peeling starts automatically. Press FEED to test.  
Liner Removal  
To remove liner from the rewind spindle, complete these steps:  
1. Cut the liner between the media alignment spindle and the rewind spindle.  
2. Rotate the take-up spindle counterclockwise until the rewind media guide is in the  
12 o’clock position.  
3. Loosen the thumbscrew and slide the rewind media guide to the end of the take-up  
spindle.  
4. Slide the core with the liner from the take-up spindle.  
Figure 22 •  
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Printer Operation  
Load Roll Media  
Rewind Mode  
The Rewind option must be installed to use this mode. The option is shown in Figure 23.  
Figure 23 • Rewind Mode  
2
3
1
14  
4
13  
12  
5
11  
10  
7
6
9
8
Printhead Assembly  
Transmissive Sensor  
Label Supply Guide  
Label Supply Hanger  
Rewind Spindle  
1
2
3
4
5
Rewind Label Guide  
Thumbscrew  
6
7
Dancer  
8
Label Guide  
9
Media Alignment Spindle  
Printhead Open Lever  
Rewind Base Assembly  
Peel Assembly  
10  
11  
12  
13  
14  
Peel Lever  
To load media in Rewind Mode, complete these steps:  
1. Press the printhead open lever. The printhead assembly springs up.  
Caution • Ensure that the printhead is fully open and engaged in the upright position.  
If you fail to latch the printhead, it could fall on your hand during the procedure.  
2. Flip down the media supply guide.  
3. Slide the media guide as far from the main frame as possible.  
4. Place a roll of media on the media supply hanger as shown.  
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Printer Operation  
Load Roll Media  
5. Flip up the media supply guide.  
6. Slide in the media supply guide until it just touches, but does not restrict, the edge of the  
media.  
7. Feed the media under the dancer, through the slot in the transmissive sensor, and under the  
ribbon sensor.  
8. Pull approximately 36 in. (900 mm) of media through the front of the printer.  
9. Remove the labels from the first 18 in. (450 mm) of media.  
10. Ensure the media is against the back of the transmissive sensor. Slide in the media guide  
until it just touches, but does not restrict, the edge of the media.  
11. Feed the media over the peel assembly and through the rewind base assembly.  
12. Loosen the thumbscrew and slide out the rewind media guide to the end of the take-up  
spindle.  
13. Slide an empty core onto the take-up spindle; wrap the media liner around the core, and  
turn the take-up spindle counterclockwise to wind up the excess material.  
Note • The liner must be attached to the take-up spindle for the printer to operate properly.  
Ensure that the edge of the liner is flush against the backplate of the take-up spindle.  
14. Slide the rewind media guide against the media, and tighten the thumbscrew.  
15. Close the printhead assembly.  
16. If the printer is paused (the Pause light is on), press PAUSE to enable printing.  
Media Removal  
To remove printed media from the rewind spindle, complete these steps:  
1. Cut the media between the media alignment spindle and the rewind spindle.  
2. Rotate the take-up spindle counterclockwise until the rewind media guide is in the  
12 o’clock position.  
3. Loosen the thumbscrew and slide out the rewind media guide to the end of the take-up  
spindle.  
4. Slide the core with the roll of media from the take-up spindle.  
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Printer Operation  
Load Roll Media  
Adjust Media Alignment for Rewind Option  
The instructions below apply only if the printer has a Rewind option. The liner should be  
installed flush against the backplate of the rewind spindle to prevent the media/backing from  
winding too loosely. See Figure 24.  
Do the adjustments in the order given. Do only what is needed to solve the problem.  
Figure 24 • Rewind Option Adjustment Dial  
4
1
2
3
Rewind Spindle Backplate  
Rewind Spindle  
Adjustment Dial  
1
2
3
4
Printhead Assembly  
To adjust the Media Alignment for Rewind Mode, complete these steps:  
1. Turn the adjustment dial clockwise to move the media toward the mainframe.  
2. Turn the dial counter clockwise to move the media away from the mainframe.  
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Printer Operation  
Load Fanfold Media  
Load Fanfold Media  
Fanfold media feeds through either the bottom or rear access slot. See Figure 25.  
Figure 25 • Loading Fanfold Media  
Rear Feed  
3
1
2
4
6
2
5
7
Bottom Feed  
3
1
4
6
5
7
Printhead Assembly  
Transmissive Sensor  
Label Supply Guide  
Label Supply Hanger  
Dancer  
1
2
3
4
5
6
7
Label Guide  
Printhead Open Lever  
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Printer Operation  
Load Fanfold Media  
To load fanfold media, complete these steps:  
1. Press the printhead open lever. The printhead assembly springs up.  
Caution • Ensure that the printhead is fully open and engaged in the upright position.  
If you fail to latch the printhead, it could fall on your hand during the procedure.  
2. Flip down the media supply guide.  
3. Slide the media guide as far from the main frame as possible.  
4. Pass the fanfold media over the media supply hanger.  
5. Flip up the media supply guide. Slide in the media supply guide until it just touches, but  
does not restrict, the edge of the media.  
6. Thread the media under the dancer, through the slot in the transmissive sensor, under the  
ribbon sensor, and out the front of the printer.  
7. Ensure the media is against the back of the transmissive sensor. Then, slide in the media  
guide until it just touches, but does not restrict, the edge of the media.  
8. Close the printhead assembly.  
9. Press PAUSE.  
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Printer Operation  
Load the Ribbon  
Load the Ribbon  
The ribbon supply spindle in your printer is a dual-tension variety. Most applications require  
the spindle to be in the normal position. The low tension position is recommended only when a  
wide ribbon is used or if normal tension hampers the ribbon movement.  
Note • Always use ribbon that is wider than the media. The smooth liner of the ribbon protects  
the printhead from wear. For direct thermal printing, do not load ribbon in the printer.  
Figure 26 • Ribbon Path  
4
5
3
2
1
6
7
8
Strip Plate  
1
2
3
4
5
6
7
8
Printhead Assembly  
Release Knob  
Tension Blades  
Ribbon Take-Up Spindle  
Ribbon Supply Spindle  
Ribbon Sensor  
Printhead Open Lever  
To load ribbon, complete these steps:  
1. Set the spindle for normal or low tension.  
To place the spindle in the normal position, firmly pull out the spindle end cap until it  
extends and clicks in place, as shown in Figure 27.  
To place the spindle in the low-tension position, firmly push in the end cap until it  
retracts and clicks in place, as shown in Figure 27.  
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Printer Operation  
Load the Ribbon  
Figure 27 • Ribbon Spindle—Normal and Low Tension  
1
2
Normal Position (Spindle End Cap Extended)  
Low-Tension Position (Spindle End Cap Retracted)  
1
2
2. See Figure 26. Press the printhead open lever.  
The printhead assembly springs up.  
Caution • Ensure that the printhead is fully open and engaged in the upright position.  
If you fail to latch the printhead, it could fall on your hand during the procedure.  
3. Orient the ribbon as shown. Push the ribbon roll completely onto the ribbon supply  
spindle.  
4. Pull the end of the ribbon over the ribbon sensor, under the printhead assembly, and out  
the front of the printer.  
5. Hold the ribbon snug and free of wrinkles and in line with the guide mark near the left  
edge of the strip plate. Close the printhead assembly.  
6. Wind the ribbon clockwise onto the ribbon take-up spindle.  
Remove the Ribbon  
To remove used ribbon, complete these steps:  
1. If the ribbon has not run out, break it between the strip plate and the ribbon take-up  
spindle.  
Caution • Do not cut the ribbon on the ribbon take-up spindle. Doing so may damage  
the spindle.  
2. While turning the ribbon take-up spindle release knob counterclockwise, squeeze the  
ribbon against the ribbon take-up spindle tension blades.  
3. When the tension blades collapse into the ribbon take-up spindle, hold the release knob  
and rotate the spent ribbon toward the rear of the printer. Then, slide the ribbon off the  
ribbon take-up spindle.  
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Printer Operation  
Calibrate the Printer  
Calibrate the Printer  
Auto Calibration  
The Z4Mplus and Z6Mplus automatically calibrate on power up. During auto calibration, the  
printer determines the label length and sensor settings.  
Auto calibration occurs when the printer is turned on and each time the printer recovers from  
an error condition. To clear an error, open and close the printhead assembly and then press  
PAUSE. The printer begins auto calibration when all errors have been cleared.  
The results of the auto calibration are stored in the printer’s memory and are retained even if  
printer power is removed. These parameters remain in effect until the next calibration is  
performed.  
,
Note • If the front panel settings for MEDIA POWER UP or HEAD CLOSE are set to  
LENGTH, NO MOTION, or FEED, the printer starts printing without auto calibrating.  
Manual Calibration  
Perform a media and ribbon sensor calibration to reset the sensitivity of the sensors so the  
media and ribbon are detected more accurately. If you change the type of ribbon or media,  
your printer may operate better if this calibration is performed.  
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Printer Operation  
Print a Configuration Label  
Print a Configuration Label  
Print a configuration label to test the printer setup. Do this when the printer is first installed, or  
when the printer cannot properly detect the top of the label.  
To print a configuration label, complete these steps:  
1. Turn the printer power Off (O).  
2. Press and hold CANCEL while turning the printer On (l). See Figure 3, Front Panel  
Controls and LEDs, on page 3.  
3. Release CANCEL after the DATA light turns off (approximately five seconds).  
A configuration label prints showing the printer’s currently stored parameters (similar to  
the labels shown in Figure 28).  
Figure 28 • Sample Configuration Labels  
Z4Mplus - 200dpi  
Z6Mplus - 300dpi  
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Printer Operation  
Print a Configuration Label  
4. Did the configuration label print correctly?  
If the label...  
Then...  
Printed correctly  
1. Go to Configuration on page 49.  
Did not print or is aligned 1. Review the following items in the order shown. Do  
improperly  
only as many steps as needed to solve the printing  
problem.  
• Review Types of Media on page 15 to make sure that  
you have the correct type of media for your  
application.  
• Review Ribbon on page 17. If you are using direct  
thermal media, you do not need to use ribbon. If you  
are using thermal media, ribbon is required for  
printing.  
• Review Load Roll Media on page 25 or Load Fanfold  
Media on page 38.  
• Configure the printer according to the directions given  
in Basic Configuration on page 53.  
• Check the position of the media sensor and move if  
necessary. Follow the directions in Position the Label  
Sensor on page 84.  
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Printer Operation  
Print a Network Configuration Label  
Print a Network Configuration Label  
If you are using a print server, you can print a network configuration label after the printer is  
hooked to the network. A network configuration label lists the settings for the wired ZebraNet  
PrintServer II (PSII) and the ZebraNet Wireless Print Server (if installed).  
To print a network configuration label, complete these steps:  
1. From the front panel, press SETUP/EXIT.  
2. Scroll through the parameters until you reach LIST NETWORK  
.
3. Confirm printing.  
A network configuration label prints (Figure 29).  
Figure 29 • Network Configuration Label  
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Printer Operation  
Adjust Printhead Pressure  
Adjust Printhead Pressure  
See Figure 30. This adjustment may be necessary if printing is too light on one side or if thick  
media is used.  
Figure 30 • Printhead Pressure Adjustment Dials  
Pressure Adjustment Dials  
L
R
The pressure adjustment dials for the Z4Mplus each have four possible settings designated by  
blocks of increasing size embossed on the print mechanism. The smallest block (fully  
counterclockwise) is considered position 1 and the largest block (fully clockwise) is  
considered position 4. The same is true for the Z6Mplus, except it has seven positions.  
Set Printhead Pressure  
Depending on which printer you have, use Table 6 or Table 7 to select the initial dial settings  
for your media.  
Some media types require higher pressure to print well. For these media, increase both dials  
one position. If the media tends to shift to the left while printing, increase the right dial setting  
one position or decrease the left dial setting one position. If the media tends to shift to the right  
while printing, increase the left dial setting one position or decrease the right dial setting one  
position.  
Table 6 • Z4Mplus Printhead Pressure  
Media Width  
Left Dial  
Right Dial  
1 in. (25.4 mm)  
3
4
3
3
1
1
2
3
2 in. (51 mm)  
3 in. (76 mm)  
3.5 in. and up (89 mm and up)  
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Printer Operation  
Adjust Printhead Pressure  
Table 7 • Z6Mplus Printhead Pressure  
Media Width  
Left Dial  
Right Dial  
2 in. (50 mm)  
6
6
7
7
6
1
2
3
4
6
3 in. (75 mm)  
4 in. (100 mm)  
5 in. (125 mm)  
5.5 in. and up (140 mm and up)  
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Printer Operation  
Install Memory Card  
Install Memory Card  
The printer can use Type I or Type II compliant PCMCIA memory cards.  
Electrostatic Discharge Caution • Observe proper electrostatic safety precautions when  
handling any static-sensitive components such as circuit boards and printheads.  
Note • The PCMCIA card is hot-swappable. It can be installed while the printer is On (l).  
To install the PCMCIA memory card, complete these steps:  
1. Remove the PCMCIA card shield from the rear of the printer.  
2. Insert the PCMCIA card, with the notch UP, into the card slot as shown (see Figure 31).  
Insert the card far enough to cause the eject button to pop out.  
Figure 31 • Installing the PCMCIA Card  
Notch  
Card Eject  
Button  
e
s
F
u
u
F
s
e
PCMCIA  
Card  
3. Reinstall the PCMCIA card shield over the PCMCIA card and card slot.  
The printer is now ready to operate with the additional memory or font option.  
Note • Initialization of the PCMCIA card may take a few minutes; the PAUSE LED flashes  
while the card initializes. If the card is already initialized, the PAUSE LED flashes only once  
or twice. To verify that the card has successfully initialized, print a configuration label and  
review it to see if the new memory card information is listed.  
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Configuration  
Overview  
Overview  
After you have installed the media and ribbon and the Power-On Self Test (POST) is complete  
(see Power-On Self Test on page 95 for more information), the front panel displays PRINTER  
READY. Use the front panel display and the four keys directly below it to set printer  
parameters for your application.  
Note • Printers that are operating on an IP network can be quickly configured in the following  
ways:  
®
• with the ZebraLink™ WebView (ZebraNet PrintServer II required). For information, see  
the ZebraNet Networking: PrintServer II Installation and User Guide.  
• with the SetWLAN configuration utility (ZebraNet Wireless Print Server required). For  
information, see the ZebraNet Wireless Print Server User Guide.  
Enter Configuration Mode  
To enter configuration mode, complete these steps:  
1. From the front panel, press SETUP/EXIT:  
2. Press PLUS (+) or MINUS () to scroll to the setting you wish to change.  
3. Press SELECT to toggle the functionality of PLUS (+) and MINUS () keys.  
4. Press PLUS (+) or MINUS () to increase or decrease the value, answer yes or no, print a  
label, or select the digit you wish to change.  
Note • An asterisk (*) in the upper left-hand corner of the display indicates that the value  
displayed is different than the currently stored value.  
5. Press SELECT again to use PLUS (+) and MINUS () to scroll to the desired menu item.  
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Configuration  
Overview  
Exit Configuration Mode  
You can leave configuration mode at any time.  
To exit configuration mode, complete these steps:  
1. From the front panel, press SETUP/EXIT.  
The SAVE CHANGESdisplay appears.  
2. Press PLUS (+) or MINUS () to scroll through the choices (Table 8):  
Table 8 • Save Options When Leaving Setup Mode  
Description  
LCD Display  
Permanently saves the changes. Values are stored in the printer even when power  
is turned off.  
PERMANENT  
Saves the changes until you change them again or until power is turned off.  
TEMPORARY  
CANCEL  
Cancels all changes from the time you pressed SETUP/EXIT except the  
darkness and tear-off settings (if they were changed).  
Sets all parameters other than the network settings back to the factory defaults.  
To see the factory default values, see Configuration and Calibration LCD  
Displays on page 57.  
LOAD DEFAULTS  
Note • Loading factory defaults causes the printer to auto-calibrate.  
Loads values from the last permanent save.  
LOAD LAST SAVE  
DEFAULT NET  
Sets the wired and wireless network settings back to factory defaults.  
3. Press SELECT to select the displayed choice.  
4. Press SETUP/EXIT to save your choice.  
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Configuration  
Overview  
Change Password-Protected Parameters  
Certain parameters are password-protected by factory default. If you press SELECT when a  
password-protected parameter is displayed on the front panel, the printer prompts you for a  
password. If you do not know the password, press SETUP/EXIT to leave the prompt. You will  
not be allowed to modify the parameter without entering the password.  
Note • After you enter the password correctly, you do not have to enter it again until you leave  
and reenter the configuration mode.  
The default password is 1234. You can change the password using the ^KP(Define Password)  
ZPL II command.  
Password-Protect All Parameters You have the option of making all parameters  
password protected. Refer to the Password Level parameter for details.  
Disable Password You can disable the password protection feature to no longer prompt for  
a password by setting the password to ØØØØvia the ^KPØZPL/ZPL II command. To  
reenable the password-protection feature, send the ZPL/ZPL II command ^KPx, where x can  
be any number that is one to four digits in length, except Ø(zero).  
To enter a password, complete these steps:  
1. From the front panel, enter a four-digit password at the ENTER PASSWORDprompt.  
MINUS () changes the selected digit position.  
PLUS (+) increases value of the selected digit.  
2. After entering the password, press SELECT.  
The parameter that you selected is displayed, and the value may be modified if the  
password was entered correctly.  
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Configuration  
Basic Configuration  
Basic Configuration  
If your labels are not printing correctly, the configuration may need to be changed because the  
printer defaults may not reflect the options that you need. Media, ribbon, darkness, print mode,  
media type, sensor type, and print method all affect the way the printer is configured. This  
section covers how to change these basic configuration options for your printer through the  
printer’s front panel. Review Figure 3 on page 3 to familiarize yourself with the front panel  
controls.  
information on all of the configuration options available on your printer.  
Many printer settings may also be controlled by your printer’s driver or label preparation  
software. See the driver or software documentation for more information.  
To perform basic a configuration, complete these steps:  
1. Enter the configuration mode by pressing SETUP/EXIT.  
DARKNESSdisplays.  
Adjust Darkness  
2. Is the printed image too dark or too light? Or does the ribbon stick to the media?  
If...  
Then...  
No  
1. Press PLUS (+) to move to the next option: PRINT SPEED  
2. Continue with Adjust Image Crispness and Print Speed.  
1. Press SELECT.  
.
Yes  
2. If the labels moved forward, but the print is light or there is no print, press  
PLUS (+) to increase the darkness. If the print is too dark, or the ribbon  
sticks to the media, press MINUS () to decrease the darkness.  
3. Press SELECT to accept the change.  
4. Press PLUS (+) to move to the next option.  
PRINT SPEEDdisplays.  
5. Continue with Adjust Image Crispness and Print Speed.  
Adjust Image Crispness and Print Speed  
3. Is the printed image crisp?  
If...  
Then...  
Yes  
1. Press PLUS (+) to move to the next option: TEAR-OFF  
2. Continue with Adjust Tear-Off Position.  
.
No  
Slow down the print speed by completing the following steps. Print speed is  
given in inches per second (ips).  
1. Press SELECT.  
2. Press PLUS (+) to increase the speed or MINUS () to decrease the  
speed.  
3. Press SELECT to accept the changes.  
4. Press PLUS (+) to move to the next option.  
TEAR OFFdisplays. Continue with Adjust Tear-Off Position.  
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Configuration  
Basic Configuration  
Adjust Tear-Off Position  
The Tear-Off position defines the position of the label on the tear-off bar. When working with  
non-continuous labels, the inter-label gap should be on the tear bar. This setting does not apply  
to continuous media.  
4. Are you using continuous media?  
If...  
Then...  
Yes  
1. Press PLUS (+) to move to the next option: PRINT MODE  
2. Continue with Select Print Mode.  
1. Continue with Step 5.  
.
.
No  
5. Does the inter-label gap line up on the tear bar?  
If...  
Then...  
Yes  
1. Press PLUS (+) to move to the next option: PRINT MODE  
2. Continue with Select Print Mode.  
1. Press SELECT.  
No  
2. Press PLUS (+) to move the label forward or MINUS () to move the  
label backward. Repeat this until the label lines up correctly.  
3. Press SELECT to accept the changes.  
4. Press PLUS (+) to move to the next option.  
PRINT MODEdisplays. Continue with Select Print Mode.  
Select Print Mode  
When the wrong Print Mode is selected, the top of the label is not found by the printer.  
Examples of common problems include when the gaps between noncontinuous labels do not  
line up on the tear bar or when continuous media is not being cut at the right interval.  
6. Do the labels line up or cut correctly?  
If...  
Then...  
Yes  
1. Press PLUS (+) to move to the next option: MEDIA TYPE  
2. Continue with Select Media Type.  
.
No  
Review the media and the printer options, then complete the following steps:  
1. Press SELECT.  
2. Press PLUS (+) or MINUS () to scroll through the setting options. Stop  
at the setting that matches your printer options (Tear-Off, Peel-Off, Cutter,  
or Rewind).  
3. Press SELECT to accept the change.  
4. Press PLUS (+) to move to the next option.  
MEDIA TYPEdisplays. Continue with Select Media Type.  
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Configuration  
Basic Configuration  
Select Media Type  
For examples of non-continuous and continuous media, see Types of Media on page 15.  
7. Does the media type on the display match the type of media that you are using?  
If...  
Then...  
Yes  
1. Press PLUS (+) to move to the next option: SENSOR TYPE  
2. Continue with Select Sensor Type.  
1. Press SELECT.  
.
No  
2. Press PLUS (+) or MINUS () to scroll through the setting options. Stop  
at the setting that matches your printer options (Continuous or  
Noncontinuous).  
3. Press SELECT to accept the change.  
4. Press PLUS (+) to move to the next option.  
SENSOR TYPEdisplays. Continue with Select Sensor Type.  
Select Sensor Type  
Web sensor is used with most labels, unless the label liner has black marks on the back. For  
more information on black mark labels, see Non-Continuous Media on page 16.  
8. Does your liner have black marks?  
If...  
Then...  
No  
1. Press PLUS (+) to move to the next option: SENSOR SELECT  
2. Continue with Sensor Select.  
.
Yes  
1. Press SELECT.  
2. Press PLUS (+) or MINUS () to scroll through the setting options. Stop  
at the setting that matches your printer options (Web or Mark).  
3. Press SELECT to accept the change.  
4. Press PLUS (+) to move to the next option.  
SENSOR SELECTdisplays. Continue with Sensor Select.  
Sensor Select  
Auto Select is the default setting. Do not make any changes.  
9. Press PLUS (+) to move to the next option.  
PRINT METHODdisplays. Continue with Select Print Method.  
Select Print Method  
The two choices for print method are thermal transfer and direct thermal transfer. You can find  
out if a label is thermal transfer or direct thermal transfer by scratching it with your fingernail.  
If your nail leaves a black mark, the media is direct thermal. If it does not leave a mark, the  
media is thermal transfer.  
Use Thermal Transfer if you are using ribbon with your label material.  
Use Direct Thermal if you are not using ribbon. Direct thermal label media has ink  
embedded in the label material that is brought out by the heat of the printhead.  
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Configuration  
Basic Configuration  
10. Does the Print Method setting match your media type?  
If...  
Yes  
No  
Then...  
1. Continue with Save Changes and Exit.  
1. Press SELECT.  
2. Press PLUS (+) or MINUS () to scroll through the setting options. Stop  
at the setting that matches your printer options (Thermal Transfer or  
Direct Thermal).  
3. Press SELECT to accept the change.  
4. Continue with Save Changes and Exit.  
Save Changes and Exit  
11. Press SETUP/EXIT to leave the front panel menu.  
SAVE CHANGES PERMANENTdisplays. For other save options, see Exit  
Configuration Mode on page 51.  
12. Press SETUP/EXIT again.  
SAVING PERMANENTdisplays. One or more labels may feed out, depending on your  
settings. The LCD displays PRINTER READY  
.
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Configuration and Calibration LCD Displays  
Configuration and Calibration LCD Displays  
Table 9 shows the configuration options for your printer. Parameters are shown in the order in  
which they are displayed when you press PLUS (+) after entering the setup mode. Table 10  
on page 72 shows the front panel parameters that display when an optional print server is  
installed.  
Throughout this process, press PLUS (+) to continue to the next parameter, or press  
MINUS () to return to the previous parameter in the cycle. Refer to Basic Configuration  
on page 53 for information on changing just the basic print settings.  
Table 9 • Printer Parameters and Other LCD Displays (Sheet 1 of 15)  
Action/Explanation  
Parameter  
Adjusting Print Darkness  
DARKNESS  
Set the darkness to the lowest setting that provides good print quality. Darkness set too  
high may cause ink to smear or the printer may burn through the ribbon.  
Darkness settings are dependent upon a variety of factors, including ribbon type, media,  
and the condition of the printhead. You may adjust the darkness for consistent  
high-quality printing. Darkness settings also may be changed by the driver or software  
settings. To determine if your print darkness setting is optimal, perform the FEED Self  
You may want to adjust the printer’s darkness while performing the PAUSE Self Test  
on page 97. Because the darkness setting takes effect immediately, you can see the  
results on labels that are currently printing during the test.  
Default: +10  
Range: 0 to +30  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to increase darkness if printing is too light or if there are voids in  
printed areas.  
3. Press MINUS () to decrease darkness if printing is too dark or if there is spreading  
or bleeding of printed areas.  
4. Press SELECT to accept any changes and deselect the parameter.  
Adjusting Print Speed  
PRINT SPEED  
Speed is measured in inches per second (ips).  
Default: 2 ips  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to increase print speed.  
3. Press MINUS () to decrease print speed.  
4. Press SELECT to accept any changes and deselect the parameter.  
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Configuration and Calibration LCD Displays  
Table 9 • Printer Parameters and Other LCD Displays (Sheet 2 of 15)  
Parameter  
Action/Explanation  
Adjusting the Tear-Off Position  
TEAR OFF  
This parameter establishes the position of the media over the tear-off/peel-off bar after  
printing. The label and liner can be torn off or cut between labels.  
Default: +0  
Range: –120 to +120  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to increase the value. Each press adjusts the tear-off position by  
four dot rows.  
3. Press MINUS () to decrease the value.  
4. Press SELECT to accept any changes and deselect the parameter.  
Selecting Print Mode  
PRINT MODE  
Print mode settings tell the printer the method of media delivery that you wish to use.  
Be sure to select a print mode that your hardware configuration supports as some  
selections displayed are for optional printer features.  
Default: Tear-off  
Selections: Tear-off, cutter, peel-off, rewind  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Setting Media Type  
MEDIA TYPE  
This parameter tells the printer the type of media you are using. Selecting continuous  
media requires that you include a label length instruction in your label format  
(^LLxxxx if you are using ZPL or ZPL II).  
When non-continuous media is selected, the printer feeds media to calculate label  
length (the distance between two detections of the inter-label gap, webbing, or  
alignment notch or hole).  
Default: Non-Continuous  
Selections: Non-Continuous, Continuous  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Setting the Sensor Type  
SENSOR TYPE  
This parameter tells the printer whether you are using media with a web (gap or space  
between labels, notch, or hole) to indicate the separation between labels or if you are  
using media with a black mark printed on the back. If your media does not have black  
marks on the back, leave your printer at the default setting (web).  
Default: Web  
Selections: Web, mark  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
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Table 9 • Printer Parameters and Other LCD Displays (Sheet 3 of 15)  
Action/Explanation  
Parameter  
Selecting Sensor  
SENSOR SELECT  
This parameter tells the printer the sensor that you wish to use. Auto Select is  
compatible with most types of media. However, if you encounter difficulties with  
calibration, see Types of Media on page 15 to help you choose the appropriate sensor  
for your media. Select the reflective sensor with either continuous or non-continuous  
black mark media; choose the transmissive sensor if you are using noncontinuous web  
media.  
Default: Auto select  
Selections: Auto select, reflective, transmissive  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Selecting Print Method  
PRINT METHOD  
The print method parameter tells the printer the method of printing you wish to use:  
direct thermal (no ribbon) or thermal transfer (using thermal transfer media and  
ribbon).  
Selecting direct thermal when using thermal transfer media and ribbon creates a  
warning condition, but printing continues.  
Default: Thermal transfer  
Selections: Thermal transfer, direct thermal  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) for the next value.  
3. Press MINUS () for the previous value.  
4. Press SELECT to accept any changes and deselect the parameter.  
Setting Print Width  
PRINT WIDTH  
Print width determines the printable area across the width of the label.  
Default, Range: The default and range of acceptable values may vary depending on  
what printer you have. See Printing Specifications on page 111 for further information  
about the ranges available for your model.  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to increase the value of the selected digit.  
3. Press MINUS () to move to the next digit.  
4. To change the unit of measurement, press MINUS () until the unit of  
measurement is active, then press PLUS (+) to toggle to a different unit of measure  
(inches, mm, or dots).  
5. Press SELECT to accept any changes and deselect the parameter.  
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Configuration  
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Table 9 • Printer Parameters and Other LCD Displays (Sheet 4 of 15)  
Parameter  
Action/Explanation  
Setting Maximum Length  
MAXIMUM LENGTH  
Always set the value to at least 1 in. (25.4 mm) longer than the longest label to be used  
in the printer.  
Default: 39 in. (991 mm) for non-continuous material  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to increase the value  
3. Press MINUS () to decrease the value.  
4. Press SELECT to accept any changes and deselect the parameter.  
List Fonts  
LIST FONTS  
This selection is used to print a label that lists all of the fonts currently available in the  
printer, including standard printer fonts plus any optional fonts. Fonts may be stored in  
RAM, FLASH memory, font EPROMs, or font cards.  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to print a label listing all of the available fonts.  
3. Press SELECT to deselect the parameter.  
List Bar Codes  
LIST BAR CODES  
This selection is used to print a label that lists all of the bar codes currently available in  
the printer.  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to print a label listing all of the available bar codes.  
3. Press SELECT to deselect the parameter.  
List Images  
LIST IMAGES  
This selection is used to print a label that lists all of the images currently stored in the  
printer’s RAM, FLASH memory, optional EPROM, or optional memory card.  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to print a label listing all of the available images.  
3. Press SELECT to deselect the parameter.  
List Formats  
LIST FORMATS  
This selection is used to print a label that lists all of the formats currently stored in the  
printer’s RAM, FLASH memory, optional EPROM, or optional memory card.  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to print a label listing all of the available formats.  
3. Press SELECT to deselect the parameter.  
List Setup  
LIST SETUP  
This selection is used to print a configuration label, which lists the current printer  
configuration information. (Same label as Figure 40 on page 96.)  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to print a configuration label.  
3. Press SELECT to deselect the parameter.  
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Configuration and Calibration LCD Displays  
Table 9 • Printer Parameters and Other LCD Displays (Sheet 5 of 15)  
Action/Explanation  
Parameter  
List Network Settings  
LIST NETWORK  
This selection is used to print a network configuration label, which lists the settings for  
the wired ZebraNet PrintServer II (PSII) and the ZebraNet Wireless Print Server (if  
installed). (Same label as Figure 29 on page 45.)  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to print a network configuration label.  
3. Press SELECT to deselect the parameter.  
List All Settings  
LIST ALL  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to print a label listing all of the available fonts, bar codes, images,  
formats, the current printer configuration, and the current network settings.  
3. Press SELECT to deselect the parameter.  
Initialize Memory Card  
FORMAT CARD  
Caution • Perform this operation only when it is necessary to erase all previously  
stored information from the optional memory card.  
A
B
1. Press SELECT to select the parameter.  
If your printer is set to require a password, you are prompted to enter the password.  
2. Enter the password, then press SELECT.  
3. Press the PLUS (+) to select B memory (PCMCIA card) or press MINUS () to  
select the A memory (internal compact flash).  
The front panel LCD asks ARE YOU SURE?  
.
4. Press MINUS () to select Noand cancel the request.  
The INITIALIZE CARDprompt is displayed.  
OR  
Press PLUS (+) to select YESand begin initialization.  
FORMATTING CARDdisplays. Depending on the amount of memory in the  
memory card, initialization may take up to three minutes to complete. When  
formatting is complete, FORMAT CARDdisplays.  
5. Press SELECT to continue with the next prompt.  
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Table 9 • Printer Parameters and Other LCD Displays (Sheet 6 of 15)  
Parameter  
Action/Explanation  
Initialize Flash Memory  
INIT FLASH MEM  
Caution • Perform this operation only when it is necessary to erase all previously  
stored information from the FLASH memory. Press PLUS (+) to bypass this  
function.  
1. Press SELECT to select the parameter.  
If your printer is set to require a password, you are prompted to enter the password.  
2. Enter the password, then press SELECT.  
3. Press PLUS (+) to select YES.  
The display asks INITIALIZE FLASH?  
4. Press PLUS (+) to select YES  
The front panel LCD asks ARE YOU SURE?  
.
.
.
5. Press MINUS () to select NOand cancel the request. The INITIALIZE FLASH  
prompt is displayed.  
or  
Press PLUS (+) to select YESand begin initialization. Depending on the amount  
of free FLASH memory, initialization may take up to one minute to complete.  
6. Press SETUP/EXIT followed by SELECT. If initialization is still in process,  
the front panel display flashes back and forth between the phrases  
CHECKING E: MEMORY and PRINTER IDLE  
.
When initialization is complete, the printer automatically exits the configuration  
mode and the front panel displays PRINTER READY  
.
7. Press SELECT to continue with the next prompt.  
Sensor Profile  
SENSOR PROFILE  
The media sensor profile may be used to troubleshoot registration problems that may be  
caused when the media sensor detects preprinted areas on the media or experiences  
difficulty in determining web location. If the sensitivity of the media and/or ribbon  
sensors MUST be adjusted, use the manual calibration procedure.  
Figure 32 • Media Sensor Profile  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to print a media sensor profile.  
3. Press SELECT to deselect the parameter.  
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Table 9 • Printer Parameters and Other LCD Displays (Sheet 7 of 15)  
Action/Explanation  
Parameter  
Media and Ribbon Sensor Calibration (Manual Calibration)  
Performing the manual calibration procedure resets the sensitivity of the sensors to  
detect the media and ribbon you are using more accurately. With the sensors at their  
new sensitivity, the printer then performs the manual calibration. Changing the type of  
ribbon and/or media may require resetting the sensitivity of the media and ribbon  
sensors.  
MEDIA AND  
RIBBON  
1. Press SELECT to display CALIBRATE  
.
2. Press PLUS (+) to start the calibration procedure.  
LOAD BACKiNGis displayed.  
3. Open the printhead.  
4. Remove approximately 8 in. (200 mm) of labels from the media roll, enough so  
that only the liner material is threaded between the media sensors when the media  
is loaded.  
5. Press PLUS (+) to continue. To cancel the operation, press MINUS ().  
REMOVE RiBBONis displayed.  
6. Remove the ribbon (sliding it as far to the right as possible has the same effect as  
removing it).  
7. Close the printhead.  
8. Press PLUS (+) to continue. To cancel the operation, press MINUS ().  
CALIBRATING PLEASE WAITis displayed.  
The printer automatically adjusts the scale (gain) of the signals it receives from the  
media and ribbon sensors based on the specific media and ribbon combination you  
are using. On the sensor profile, this corresponds to moving the graph up or down  
to optimize the readings for your application.  
RELOAD ALLis displayed.  
9. Open the printhead and pull the media forward until a label is positioned under the  
media sensor.  
10. Move the ribbon back to its proper position.  
11. Close the printhead.  
MEDIA AND RIBBONis displayed.  
Now that the scale has changed, the printer performs another calibration. During  
this process, the printer checks the readings for the media and ribbon based on the  
new scale that you established, determines the label length, and determines whether  
you are in Direct Thermal or Thermal Transfer Print Mode. The process is now  
complete. To see the new readings, print a sensor profile. See Sensor Profile  
12. Press SELECT to deselect the parameter.  
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Table 9 • Printer Parameters and Other LCD Displays (Sheet 8 of 15)  
Parameter  
Action/Explanation  
Setting Communication Parameters (next nine parameters)  
Communication parameters must be set correctly for the printer to communicate with the host computer. These  
parameters make sure that the printer and host computer are speaking the same language. All communication  
parameters are password protected.  
Setting Parallel Communications  
Note • Unidirectional will not support ZebraNet two-way communications.  
PARALLEL COMM.  
SERIAL COMM  
BAUD  
Default: BIDIRECTIONAL  
Selections: BIDIRECTIONAL, UNIDIRECTIONAL  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Setting Serial Communications  
Select the communications port that matches the one being used by the host computer.  
Default: RS232  
Selections: RS232, RS422/485, RS485MULTIDROP  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Setting Baud  
The baud setting of the printer must match the baud setting of the host computer for  
accurate communications to take place. Select the value that matches the one being  
used by the host computer.  
Default: 9600  
Selections: 110, 300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 28800, 38400,  
57600, 115200  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Setting Data Bits  
DATA BITS  
The data bits of the printer must match the data bits of the host computer for accurate  
communications to take place. Set the data bits to match the setting being used by the  
host computer.  
Note • This parameter must be set to 8 BITS to use Code Page 850.  
Default: 8 BITS  
Selections: 7 BITS, 8 BITS  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
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Table 9 • Printer Parameters and Other LCD Displays (Sheet 9 of 15)  
Action/Explanation  
Parameter  
Setting Parity  
PARITY  
The parity of the printer must match the parity of the host computer for accurate  
communications to take place. Select the parity that matches the one being used by the  
host computer.  
Default: NONE  
Selections: NONE, ODD, EVEN  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Setting Host Handshake  
HOST  
HANDSHAKE  
The handshake protocol of the printer must match the handshake protocol of the host  
computer for communications to take place. Select the handshake protocol that matches  
the one being used by the host computer.  
Default: XON/XOFF  
Selections: XON/XOFF, DSR/DTR, RTS/CTS  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Setting Protocol  
PROTOCOL  
Protocol is a type of error checking system. Depending on the selection, an indicator  
may be sent from the printer to the host computer signifying that data has been  
received. Select the protocol that is requested by the host computer. Further details on  
protocol can be found in the ZPL II Programming Guide Volume I.  
Default: NONE  
Selections: NONE, ZEBRA, ACK_NAK  
ZEBRAis the same as ACK_NAKexcept that ZEBRAresponse messages are  
sequenced. If ZEBRAis selected, set the host handshake protocol to DSR/DTR.  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Setting Network ID  
NETWORK ID  
Network ID is used to assign a unique number to a printer used in an RS-422/RS-485  
network, which gives the host computer the means to address a specific printer. If the  
printer is used in a network, you must select a network ID number. This does not affect  
TCP/IP or IPX networks.  
Default: 000  
Range: 000 to 999  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to increase the value of the selected digit.  
3. Press MINUS () to move to the next digit.  
4. Press SELECT to accept any changes and deselect the parameter.  
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Table 9 • Printer Parameters and Other LCD Displays (Sheet 10 of 15)  
Parameter  
Action/Explanation  
Setting Communication Diagnostics Mode  
COMMUNICATIONS  
The communication diagnostics mode is a troubleshooting tool for checking the  
interconnection between the printer and the host computer. When “diagnostics” is  
selected, all data sent from the host computer to the printer is printed as straight ASCII  
hex characters. The printer prints all characters received, including control codes, such  
as CR (carriage return). A sample printout is shown in Figure 33.  
Figure 33 • Communication Diagnostics Test Printout  
Default: NORMAL MODE  
Selections: NORMAL MODE, DIAGNOSTICS  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
4. Turn the printer Off (O) to exit the communication diagnostics test and return to  
Normal mode.  
Notes on diagnostic printouts  
• FE indicates a framing error  
• OE indicates an overrun error  
• PE indicates a parity error  
• NE indicates noise  
For any errors, check that your communication parameters are correct. Set the print  
width equal to or less than the label width used for the test. See Setting Print Width  
on page 59 for more information.  
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Table 9 • Printer Parameters and Other LCD Displays (Sheet 11 of 15)  
Action/Explanation  
Parameter  
Selecting Prefix and Delimiter Characters (next three parameters)  
Prefix and delimiter characters are 2-digit hex values used within the ZPL/ZPL II formats sent to the printer.  
The printer uses the last prefix and delimiter characters sent to it, whether from a ZPL II instruction or from the  
front panel.  
Do not use the same hex value for the control, format, and delimiter characters. The printer must see different  
characters to function properly.  
Control Prefix Character  
The printer looks for this 2-digit hex character to indicate the start of a ZPL/ZPL II  
control instruction.  
CONTROL PREFIX  
FORMAT PREFIX  
DELIMITER CHAR  
Default: 7E (tilde - displayed as a black square)  
Range: 00 to FF  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to increase the value of the selected digit.  
3. Press MINUS () to move to the next digit.  
4. Press SELECT to accept any changes and deselect the parameter.  
Format Prefix Character  
The printer looks for this 2-digit hex character to indicate the start of a ZPL/ZPL II  
format instruction.  
Default: 5E (caret)  
Range: 00 to FF  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to increase the value of the selected digit.  
3. Press MINUS () to move to the next digit.  
4. Press SELECT to accept any changes and deselect the parameter.  
Delimiter Character  
The delimiter character is a 2-digit hex value used as a parameter place marker in  
ZPL/ZPL II format instructions. See the ZPL II Programming Guide Volume I for more  
information.  
Default: 2C (comma)  
Range: 00 to FF  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to increase the value of the selected digit.  
3. Press MINUS () to move to the next digit.  
4. Press SELECT to accept any changes and deselect the parameter.  
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Configuration and Calibration LCD Displays  
Table 9 • Printer Parameters and Other LCD Displays (Sheet 12 of 15)  
Parameter  
Action/Explanation  
Selecting ZPL Mode  
ZPL MODE  
The printer remains in the selected mode until it is changed by this front panel  
instruction or by using a ZPL/ZPL II command. The printer accepts label formats  
written in either ZPL or ZPL II. This eliminates the need to rewrite any ZPL formats  
you already have. See the ZPL II Programming Guide Volume II for more information  
on the differences between ZPL and ZPL II.  
Default: ZPL II  
Selections: ZPL II, ZPL  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Media Power Up  
MEDIA POWER UP  
Establishes the action of the media when the printer is turned on.  
Default: CALIBRATION  
Selections:  
CALIBRATION: Recalibrates the media and ribbon sensors.  
LENGTH: Determines the length of the label.  
NO MOTION: Media does not move.  
FEED: Feeds the label to the first web.  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Head Close  
HEAD CLOSE  
Determines the action of the media after the printhead has been opened and then closed.  
Default: Calibration  
Selections:  
CALIBRATION: Recalibrates the media and ribbon sensors.  
LENGTH: Determines the length of the label.  
NO MOTION: Media does not move.  
FEED: Feeds the label to the first web.  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
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Table 9 • Printer Parameters and Other LCD Displays (Sheet 13 of 15)  
Action/Explanation  
Parameter  
Backfeed Sequence  
BACKFEED  
This parameter establishes when and how much label backfeed occurs after a label is  
removed or cut in the peel-off or cutter modes. It has no effect in rewind or tear-off  
modes. This parameter setting can be superseded by the ~JS instruction when  
received as part of a label format (see the ZPL II Programming Guide Volume I).  
The difference between the value entered and 100% establishes how much backfeed  
occurs before the next label is printed. For example, a value of 40 means that 40% of  
the backfeed takes place after the label is removed or cut. The remaining 60% takes  
place before the next label is printed. A value of “before” means that all backfeed takes  
place before the next label is printed.  
Default: Default (90%)  
Selections: Default, after, before, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, off  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Adjusting Label Top Position  
LABEL TOP  
The label top position adjusts the print position vertically on the label. Positive numbers  
adjust the label top position further down the label (away from the printhead); negative  
numbers adjust the position up the label (toward the printhead).  
Default: +0  
Range: –120 to +120 dot rows  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to increase the value. The displayed value represents dots.  
3. Press MINUS () to decrease the value.  
4. Press SELECT to accept any changes and deselect the parameter.  
Adjusting Left Position  
LEFT POSITION  
This parameter establishes how far from the left edge of a label the format begins to  
print by adjusting horizontal positioning on the label. Positive numbers adjust the  
printing to the left by the number of dots selected; negative numbers shift printing to the  
right.  
Default: 0000  
Range: –9999 to +9999  
1. Press SELECT to select the parameter.  
2. Press MINUS () to move to the next position.  
3. Press PLUS (+) to change between +/– or to increase the value of the digit. The  
displayed value represents dots. For a negative value, enter the value before  
changing to the minus sign.  
4. Press SELECT to accept any changes and deselect the parameter.  
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Configuration  
Configuration and Calibration LCD Displays  
Table 9 • Printer Parameters and Other LCD Displays (Sheet 14 of 15)  
Parameter  
Action/Explanation  
These parameters are automatically set during the calibration procedure. They should  
be changed only by a qualified service technician. See the Maintenance Manual for  
more information on these parameters.  
WEB S.  
MEDIA S.  
RIBBON S.  
TAKE LABEL  
MEDIA LED  
RIBBON LED  
Press PLUS (+) repeatedly to skip these parameters.  
LCD Display Adjustment  
LCD ADJUST  
This parameter allows you to adjust the brightness of your display if your display is  
difficult to read.  
Range: 0 to 19  
1. Press SELECT to select the parameter.  
2. Press MINUS () to decrease the value (reduce brightness).  
3. Press PLUS (+) to increase the value (increase brightness).  
4. Press SELECT to accept any changes and deselect the parameter.  
Format Convert  
FORMAT  
CONVERT  
The Format Convert setting is used when upgrading from a printer of lower resolution  
to a printer of higher resolution and the user does not wish to modify their formats.  
Example: If your original formats were written for a 150 dpi printer and your new  
printer is 300 dpi, you would choose 150–>300.  
Default: None  
Selections: None, 150–>300, 150–>600, 200–>600, 300–>600  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Idle Display  
IDLE DISPLAY  
If a real-time clock (RTC) is installed, this parameter selects the LCD options for the  
RTC.  
Default: FW Version  
Selections: FW Version, MM/DD/YY 24HR, MM/DD/YY 12HR, DD/MM/YY 24HR,  
DD/MM/YY 12HR  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
RTC Date  
RTC DATE  
If the RTC is installed, this parameter allows changing of the date.  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to increase the value of the selected digit.  
3. Press MINUS () to move to the next digit.  
4. Press SELECT to accept any changes and deselect the parameter.  
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Configuration  
Configuration and Calibration LCD Displays  
Table 9 • Printer Parameters and Other LCD Displays (Sheet 15 of 15)  
Action/Explanation  
Parameter  
RTC Time  
RTC TIME  
If the RTC is installed, this parameter allows changing of time.  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) to increase the value of the selected digit.  
3. Press MINUS () to move to the next digit.  
4. Press SELECT to accept any changes and deselect the parameter.  
Password Level  
PASSWORD  
LEVEL1  
This parameter allows you to select whether certain Zebra-selected menu items  
(selected items) or all menu items (all items) are password protected.  
Default: Selected items  
Selections: Selected items, all items  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
Selecting the Display Language  
LANGUAGE  
This parameter allows you to change the language used on the front panel display.  
Default: English  
Selections: English, Spanish, French, German, Italian, Norwegian, Portuguese,  
Swedish, Danish, Spanish2, Dutch, Finnish, Japan  
1. Press SELECT to select the parameter.  
2. Press PLUS (+) or MINUS () to display other choices.  
3. Press SELECT to accept any changes and deselect the parameter.  
1 Appears when a ZebraNet wired or wireless print server is installed.  
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Configuration  
Configuration and Calibration LCD Displays  
ZebraNet® Wired and Wireless Print Server LCD Displays  
The menu options shown in Table 10 display only if you have the ZebraNet PrintServer II,  
10/100 PrintServer, or Wireless Print Server installed.  
Table 10 • Print Server LCD Displays  
LCD  
Explanation  
IP PROTOCOL1  
IP Protocol  
Allows either the user (permanent) or the server (dynamic) to select the IP address.  
If a dynamic option is chosen, this selection determines the method(s) by which the  
print server (wired or wireless) receives the IP address from the server.  
• Press the right or left oval to display other choices.  
Default: ALL  
Selections: ALL, GLEANING ONLY, RARP, BOOTP, DHCP, DHCP AND BOOTP,  
PERMANENT  
Note • Use of GLEANING ONLY is not recommended when the Wireless Print  
Server is installed.  
IP ADDRESS1  
IP Address  
This parameter allows you to select the IP address if PERMANENT was chosen in  
IP PROTOCOL. (If a dynamic option was chosen, the user cannot select the address.)  
1. Press the left oval to move to the next digit position.  
2. Press the right oval to increase the value of the digit.  
SUBNET MASK1  
Subnet Mask  
This parameter selects the part of the IP address that is considered to be part of the  
local network. It can be reached without going through the default gateway.  
1. Press the left oval to move to the next digit position.  
2. Press the right oval to increase the value of the digit.  
Default Gateway  
DEFAULT  
GATEWAY1  
This parameter allows you to select the IP address that the network traffic is routed  
through if the destination address is not part of the local network.  
1. Press the left oval to move to the next digit position.  
2. Press the right oval to increase the value of the digit.  
MAC ADDRESS2,3  
ESSID2,3  
MAC Address  
This parameter cannot be changed through the front panel.  
ESSID  
This parameter cannot be changed through the front panel.  
1 These parameters appear after the system recognizes the existence of a ZebraNet print server (wired or wireless). After the  
print server is recognized, all zeroes (000.000.000.000) will display until the printer obtains an IP address or defaults to  
address 192.168.254.254.  
2 Appears only when the ZebraNet Wireless Print Server is installed.  
3 If a wireless password is set, you must enter the wireless password (not the printer password) to access this parameter.  
4 This parameter appears 1) when no wireless card is inserted or 2) when the wireless card is associated to the WLAN and the  
card supports LEAP.  
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Configuration  
Configuration and Calibration LCD Displays  
Table 10 • Print Server LCD Displays (Continued)  
LCD  
Explanation  
AUTH. TYPE2,3  
Authentication Type  
Default: OPEN  
Selections: OPEN, SHARED  
LEAP MODE3,4  
An encryption method that is available with some wireless cards. Set the LEAP user  
name and password through the printer web pages.  
Accepted Values: ON, OFF  
Default Value: OFF  
Encryption Mode  
Default: OFF  
ENCRYPTION  
MODE2,3  
Selections: OFF, 40-BIT, 128-BIT  
Encryption Index  
Default: 1  
ENCRYPTION  
INDEX2,3  
Selections: 1, 2, 3, 4  
RESET NETWORK1,3  
Reset Network  
This option resets the wireless card and the print server when the wireless option is  
running. Selecting this option has no effect when the wireless option is not running,  
when there is no card inserted, or when the wireless password is anything other than  
the default (zero).  
1. Press the right oval to select YES  
.
The LCD prompts ARE YOU SURE?  
.
• Press the left oval to select NOto cancel the request.  
• Press the right oval to select YESand reset the network.  
1 These parameters appear after the system recognizes the existence of a ZebraNet print server (wired or wireless). After the  
print server is recognized, all zeroes (000.000.000.000) will display until the printer obtains an IP address or defaults to  
address 192.168.254.254.  
2 Appears only when the ZebraNet Wireless Print Server is installed.  
3 If a wireless password is set, you must enter the wireless password (not the printer password) to access this parameter.  
4 This parameter appears 1) when no wireless card is inserted or 2) when the wireless card is associated to the WLAN and the  
card supports LEAP.  
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Configuration  
Configuration and Calibration LCD Displays  
Notes • ___________________________________________________________________  
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To provide feedback on this document, please send your comments to [email protected], or  
write your comments on this page and fax to the following:  
Fax: 1.847.821.1795  
Attention: TechPubs — CTC  
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Routine Care and Adjustments  
Cleaning Procedures  
Cleaning Procedures  
Specific cleaning procedures are provided on the following pages. Table 11 shows a  
recommended cleaning schedule.  
.
Table 11 • Recommended Cleaning Schedule  
Area  
Method  
Solvent*  
Solvent*  
Air blow  
Air blow  
Solvent*  
Solvent*  
Solvent*  
Interval  
Printhead  
Direct Thermal Mode: After every roll of media  
(or 500 feet of fanfold media).  
Platen roller  
Media sensors  
Ribbon sensor  
Media path  
Ribbon path  
Thermal Transfer Mode: After every roll of  
ribbon or three rolls of media.  
These intervals are intended as guidelines only.  
You may have to clean more often, depending  
upon your application and media.  
Pinch roller. (Optional peel-off option  
required. Refer to Clean the Peel-Off  
Cutter  
If cutting continuous,  
Solvent*  
After every roll of media (or more often,  
Module  
pressure-sensitive media  
depending upon your application and media).  
If cutting tag stock or label Solvent* and  
After every two or three rolls of media.  
liner material  
air blow  
Solvent*  
Air blow  
Tear-off/peel-off bar  
Take label sensor  
Once a month.  
Once every six months.  
* Zebra recommends using the Preventive Maintenance Kit, Part Number 47362 or a solution of 90%  
Isopropyl and 10% deionized water)  
Note • Zebra Technologies Corporation will not be responsible for damage caused by the use  
of cleaning fluids on the Z4Mplus/Z6Mplus printer.  
Clean the Exterior  
The exterior surfaces of the printer may be cleaned with a lint-free cloth. Do not use harsh or  
abrasive cleaning agents or solvents. If necessary, a mild detergent or desktop cleaner may be  
used sparingly.  
Clean the Interior  
Remove any accumulated dirt and lint from the interior of the printer using a soft bristle brush  
or vacuum cleaner.  
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Routine Care and Adjustments  
Cleaning Procedures  
Clean the Printhead and Platen Roller  
You can minimize printhead wear and maintain print quality with regular preventive measures.  
Over time, the movement of media/ribbon across the printhead wears through the protective  
ceramic coating, exposing and eventually damaging the print elements (dots). In order to avoid  
abrasion:  
Clean your printhead frequently and use well-lubricated thermal transfer ribbons with  
packagings optimized to reduce friction.  
Minimize printhead pressure and burn temperature settings by optimizing the balance  
between the two.  
Ensure that the thermal transfer ribbon is as wide or wider than the label media to prevent  
exposing the elements to the more abrasive label material.  
For best results, perform the following cleaning procedure after changing every roll of ribbon.  
Inconsistent print quality, such as voids in the bar code or graphics, may indicate a dirty  
printhead.  
Note • The printer can remain on while you are cleaning the printhead. In this way all label  
formats, images, and all temporary parameter settings stored in the printer’s internal memory  
are saved. In addition, keep the peel engaged while cleaning the platen roller (media must be  
unloaded to do this) to reduce the risk of bending the tear-off/peel-off bar.  
Figure 34 • Cleaning the Printhead and Platen Roller  
1
2
Printhead Assembly  
Platen Roller  
1
2
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Routine Care and Adjustments  
Cleaning Procedures  
To clean the printhead and platen roller, complete these steps:  
1. Refer to Figure 34. Open the printhead assembly.  
Caution • Ensure that the printhead is fully open and engaged in the up position. If the  
printhead is not latched in the up position, it could fall on your hand during the  
procedure.  
2. Remove the media and ribbon.  
3. Use the Preventive Maintenance Kit (Zebra part number 47362) or a solution of  
90% Isopropyl alcohol and 10% deionized water and swab. Wipe along the print elements  
from end to end. The print elements are on the brown strip just behind the chrome strip on  
the printhead. Allow the solvent to evaporate.  
4. Manually rotate the platen roller and clean thoroughly with solvent and a pad.  
5. Brush or vacuum any accumulated paper lint and dust away from the media and ribbon  
paths.  
6. Reload media or ribbon, and close the printhead assembly.  
Note • If performing this procedure does not improve print quality, try cleaning the  
printhead with Save-A-Printhead cleaning film. This specially coated material removes  
contamination buildup without damaging the printhead. Call your authorized Zebra  
reseller for more information.  
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Routine Care and Adjustments  
Cleaning Procedures  
Clean the Sensors  
Brush or vacuum any accumulated paper lint and dust away from the printer sensors. Refer to  
Figure 35. The reflective sensor, transmissive sensor, and ribbon sensor should be cleaned on a  
regular basis to ensure proper operation of the printer. For printers with the peel-off, liner  
take-up, and/or rewind option(s) installed, clean the take label sensor as well.  
Figure 35 • Cleaning the Sensors  
1
4
2
3
Transmissive Sensor  
Reflective Sensor  
Ribbon Sensor  
1
2
3
4
Take-Label Sensor  
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Routine Care and Adjustments  
Cleaning Procedures  
Clean the Rewind Option  
The Rewind option is required. Refer to Figure 36 and perform the following procedure if  
adhesive buildup begins to affect peel performance.  
Figure 36 • Cleaning the Rewind Option  
1
2
3
4
Printhead Assembly  
Tear-Off/Peel-Off Bar  
Pinch Roller  
1
2
3
4
Peel Assembly  
To clean the Rewind option, complete these steps:  
1. Open the printhead assembly.  
Caution • Ensure that the printhead is fully open and engaged in the up position. If the  
printhead is not latched in the up position, it could fall on your hand during the  
procedure.  
2. Close the peel assembly to prevent bending the tear-off/peel-off bar during cleaning.  
3. Use the Preventive Maintenance Kit (Zebra part number 47362) or a solution of  
90% Isopropyl alcohol and 10% deionized water and swab to remove excess adhesive  
from the tear-off/peel-off bar. Allow the solvent to evaporate.  
Note • Apply minimum force when cleaning the tear-off/peel-off bar. Excessive force can  
cause the tear-off/peel-off bar to bend, which can have a negative effect on peel  
performance.  
4. Open the peel assembly by pivoting the module toward you.  
5. Manually rotate the pinch roller and clean thoroughly with solvent and a swab. Allow the  
solvent to evaporate.  
6. Close the peel assembly.  
7. Close the printhead assembly.  
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Routine Care and Adjustments  
Cleaning Procedures  
Clean the Peel-Off Assembly  
The Peel-Off option is required.  
If adhesive buildup affects peel-off performance, complete these steps:  
1. Open the printhead assembly.  
Caution • Ensure that the printhead is fully open and engaged in the up position. If the  
printhead is not latched in the up position, it could fall on your hand during the  
procedure.  
2. Close the peel assembly to prevent bending the tear-off/peel-off bar during cleaning.  
3. Use the Preventive Maintenance Kit (Zebra part number 47362) or a solution of  
90% Isopropyl alcohol and 10% deionized water and swab to remove excess adhesive  
from the tear-off/peel-off bar. Allow the solvent to evaporate.  
4. Open the peel assembly by pivoting the module toward you.  
Important • Apply minimum force when cleaning the tear-off/peel-off bar. Excessive  
force can cause the tear-off/peel-off bar to bend, which could have a negative effect on  
peel performance.  
5. Manually rotate the pinch roller and clean thoroughly with solvent and a swab.  
6. Close the peel assembly.  
Note • When cleaning the tear-off/peel-off bar or the pinch roller, remove excess solvent  
with a pad to ensure the solvent has dried before printing.  
7. Close the printhead assembly.  
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Routine Care and Adjustments  
Cleaning Procedures  
Clean the Cutter Module  
Cutter option required.  
Caution • For personnel safety, always power off and unplug the printer before performing  
this procedure.  
Figure 37 • Cleaning the Cutter Module  
3
2
1
4
5
Thumbscrew and Lock Washer  
Cutter Shield  
Upper Cutter Blade  
Lower Cutter Blade  
1
2
3
4
To clean the cutter module, complete these steps:  
1. Remove the cutter shield by removing the thumbscrew and lock washer.  
Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers.  
2. See Figure 37. Using the Preventive Maintenance Kit (Zebra part number 47362) or a  
solution of 90% Isopropyl and 10% deionized water and swab, wipe along the upper cutter  
blade. Allow the solvent to evaporate.  
3. To expose the lower cutter blade, turn the cutter motor thumbnut counterclockwise until  
you see the V-shaped lower cutter blade.  
4. Using the Preventive Maintenance Kit (Zebra part number 47362) or a solution of 90%  
Isopropyl and 10% deionized water and swab, wipe along the lower cutter blade. Allow  
the solvent to evaporate.  
5. Replace the cutter shield.  
6. When you have finished cleaning the cutter module, plug in and turn on the printer. The  
lower cutter blade returns to its correct operating position.  
7. If the cutter continues to perform unsatisfactorily, contact an authorized service  
technician.  
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Routine Care and Adjustments  
Lubrication  
Lubrication  
No lubrication is needed for this printer.  
Caution • Some commercially available lubricants will damage the finish and the  
mechanical parts if used on this printer.  
Fuse Replacement  
A user-replaceable AC power fuse is located just below the AC power switch at the rear of the  
printer. The replacement fuse is a 5 × 20 mm fast-blow style rated at 5 Amp/250 VAC.  
Electric Shock Caution • Before replacing the fuse, turn off the AC power switch, and  
unplug the AC power cord.  
To replace the fuse, complete these steps:  
1. To replace the fuse, insert the tip of a flat blade screwdriver into the slot in the end of the  
fuse holder end cap.  
2. Press in slightly on the end cap and turn the screwdriver slightly counter clockwise. This  
disengages the end cap from the fuse holder and permits removal of the fuse.  
3. To install a new fuse, remove the old fuse and insert the new fuse into the fuse holder.  
4. Push the end cap in slightly, then insert the tip of a flat blade screwdriver into the slot in  
the end cap and turn clockwise to engage it.  
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Routine Care and Adjustments  
Position the Label Sensor  
Position the Label Sensor  
There are two media sensors in this printer: reflective and transmissive.  
Adjust the Reflective Sensor  
The reflective sensor detects the start-of-label indicator (the notch, hole, black mark, or gap  
between die-cut labels).  
The reflective sensor must be positioned:  
directly under the notch, hole, or black mark  
anywhere along the width of the media if there is a gap between labels  
The glow of the red light through the media may help you accurately position the reflective  
sensor.  
Note • If you are using continuous media, position the reflective sensor anywhere under the  
media to detect an out-of-paper condition. The reflective sensor is compatible with most types  
of media. If you have difficulties with calibration, use the transmissive sensor. See Select the  
Figure 38 • Adjusting the Reflective Sensor  
1
2
3
4
Printhead Assembly  
Reflective Sensor  
Adjustment Lever  
Printhead Open Lever  
1
2
3
4
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Routine Care and Adjustments  
Position the Label Sensor  
To adjust the reflective sensor, complete these steps:  
1. See Figure 38. Open the printhead assembly by pressing the printhead open lever.  
Caution • Ensure that the printhead is fully open and engaged in the up position. If the  
printhead is not latched in the up position, it could fall on your hand during the  
procedure.  
2. Locate the reflective sensor positioning lever.  
3. Move the reflective sensor positioning lever across the width of the media until the  
reflective sensor aligns with the gap or notch. The glow of the red light assists in the  
proper placement of the reflective sensor.  
4. Close the printhead assembly.  
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Routine Care and Adjustments  
Position the Label Sensor  
Select the Transmissive Sensor  
The standard transmissive sensor is in a fixed position and enabled from the front panel. For  
more detailed information, see Selecting Sensor on page 59.  
Figure 39 • Location of Transmissive Sensors  
1
2
Standard Transmissive Sensor  
Adjustable Transmissive Sensor (optional)  
1
2
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Troubleshooting  
LCD Error Conditions and Warnings  
LCD Error Conditions and Warnings  
The LCD displays error condition messages and warnings if the printer detects a problem. The  
messages, along with their causes and solutions, are listed in Table 12.  
Table 12 • Error Conditions and Warnings  
Error  
Potential Problem  
Recommended Solution  
RIBBON OUT  
In thermal transfer mode, the  
ribbon is not loaded or loaded  
incorrectly.  
Load the ribbon correctly. See Load the  
In thermal transfer mode, the  
ribbon sensor is not sensing  
correctly loaded ribbon.  
Perform the media and ribbon sensor  
RIBBON IN  
In direct thermal mode, when  
ribbon is not used:  
Remove the ribbon and set the printer to  
direct thermal mode. See Selecting Print  
Ensure that the printer driver or software  
settings are correctly set.  
PAPER OUT  
The media is not loaded or  
loaded incorrectly.  
Reload the media. See Load Roll Media  
The media sensor is not  
positioned properly.  
Check the position of the reflective sensor.  
The printer is set for  
non-continuous media, but  
continuous media is loaded.  
Either load the correct media or set the  
printer for the correct media type via the  
front panel.  
Ensure that the printer driver or software  
settings are correctly set.  
Calibrate the printer (see Media and Ribbon  
The incorrect media sensor is  
being used.  
Via the front panel, locate the SENSOR  
SELECT menu item (see Selecting Sensor  
on page 59) and manually select the correct  
sensing method.  
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Troubleshooting  
LCD Error Conditions and Warnings  
Table 12 • Error Conditions and Warnings (Continued)  
Potential Problem Recommended Solution  
Error  
HEAD OPEN  
The printhead is not fully closed. Close the printhead.  
The ribbon is loaded incorrectly; Correctly align the ribbon with the guide  
it is covering the head open  
sensor.  
mark on the strip plate before closing the  
printhead assembly. See Position the Label  
Print method is incorrectly set. Via the front panel, locate the PRINT  
METHOD menu item and select thermal  
transfer mode. See Selecting Print Method  
Ensure that the printer driver and/or  
software settings are correctly set.  
The ribbon is loaded.  
Remove the ribbon and set the printer to  
direct thermal mode. See Selecting Print  
Ensure that the printer driver and/or  
software settings are correctly set.  
HEAD OVER TEMP  
Caution • The printhead is hot and can cause severe burns.  
Allow the printhead to cool.  
The printhead is over  
temperature.  
Allow the printer to cool. Printing  
automatically resumes when the printhead  
elements cool to an acceptable operating  
temperature.  
HEAD UNDER TEMP  
Caution • An improperly connected printhead data or power  
cable can cause this error message. The printhead can still be  
hot enough to cause severe burns. Allow the printhead to cool.  
The printhead is under  
temperature.  
Continue printing while the printhead  
reaches the correct operating temperature.  
The environment may be too cold for proper  
printing. Relocate the printer to a warmer  
area.  
CUTTER JAM  
Caution • The cutter blade is sharp. Do not touch or rub the blade  
with your fingers.  
Cutter blade is in the media path. Turn off the printer power and unplug the  
printer. Inspect the cutter module for debris  
and clean as needed following the cleaning  
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Troubleshooting  
LCD Error Conditions and Warnings  
Table 12 • Error Conditions and Warnings (Continued)  
Error  
Potential Problem  
Recommended Solution  
OUT OF MEMORY*  
*There is not enough memory to Insufficient DRAM for the label length,  
perform the function shown on downloaded fonts/graphics, and images.  
the second line of the error  
Ensure that the device, such as FLASH  
message.  
memory or PCMCIA card, is installed and  
not write protected or full.  
Ensure that the data is not directed to a  
device that is not installed or available.  
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Troubleshooting  
Print Quality Problems  
Print Quality Problems  
Table 13 • Print Quality Problems and Solutions  
Potential Problem Recommended Solution  
Issue  
General print quality issues You are using an incorrect media Consult your authorized reseller/distributor  
and ribbon combination for your for information and advice.  
application.  
The printer is set at an excessive For optimal print quality, set the print speed  
print speed to achieve optimal  
quality.  
to a lower setting via ZPL II, the driver, the  
software, or the front panel.  
The printer is set at an excessive For optimal print quality, set the darkness  
darkness level to achieve optimal level to a lower setting via the front panel,  
quality.  
the driver, or the software.  
The printhead is dirty.  
Clean the printhead according to the  
There is light printing (or no  
The pressure adjustment dials need to be  
printing) on the left or right side adjusted. Follow the printhead pressure  
of the label or the printed image adjustment instructions on Set Printhead  
is not sharp.  
Gray lines on blank labels  
with no consistent pattern  
The printhead is dirty.  
Clean the printhead according to the  
Light, consistent vertical lines The printhead or platen roller is Clean the printhead, platen roller, or both  
running through all labels  
dirty.  
according to the instructions in Clean the  
Intermittent creases on the  
left and right edges of the  
label  
There is too much pressure on the Reduce the printhead pressure. See Set  
printhead.  
Wrinkled ribbon  
The ribbon is not loaded  
correctly.  
Load the ribbon correctly. See Load the  
The darkness setting is incorrect. Set the darkness to the lowest possible  
setting for good print quality. See  
Incorrect printhead pressure or  
balance.  
Set the pressure to the minimum required for  
good print quality. See Set Printhead  
The media is not feeding  
Make sure that the media guide and media  
correctly. It is walking from side supply guide touch the edge of the media.  
to side.  
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Troubleshooting  
Calibration Problems  
Calibration Problems  
Table 14 • Calibration Problems and Solutions  
Problem  
Recommended Solution  
Loss of printing registration on  
labels.Excessive vertical drift in top-of-form  
registration.  
Ensure that the media guides are properly positioned.  
Set the printer for the correct media type. See MEDIA TYPE  
Adjust the reflective sensor position. See Adjust the Reflective  
Via the front panel, locate the SENSOR SELECT menu item  
(see SENSOR SELECT on page 59) and manually select the  
correct sensing method.  
Reload the media. Check the reflective sensor position (see  
Clean the platen roller according to the instructions in Clean  
Auto Calibrate failed.  
Perform a manual calibration (see Media and Ribbon Sensor  
Reload the media and ensure that the reflective sensor is  
properly positioned (see Adjust the Reflective Sensor  
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Troubleshooting  
Communication Problems  
Communication Problems  
Table 15 • Communication Problems and Solutions  
Issue  
Potential Problem  
Recommended Solution  
The printer does not respond to Loose or improperly connected Make sure that the communication cable is  
print requests. The DATA light cable.  
does not flash.  
connected properly.  
The communication parameters Check the printer driver or software  
are incorrect.  
communications settings.  
Confirm that you are using the correct  
communication cable. See Cable  
Via the front panel, check the protocol  
setting. It should be set to the default  
Ensure that the correct driver is being used.  
Several labels print, then the  
The host is set to EPP parallel Change the settings on the computer host  
printer skips, misplaces, misses, communications.  
or distorts the image on the label  
to standard parallel communications.  
The serial communication  
Standard RS-232 cables are appropriate for  
lengths under 50 ft. (15.2 m); RS-422 and  
RS-485 cables allow serial transmission up  
to 4000 ft.(1.2 km). Check cable length and  
shielding, and confirm the appropriate RS-  
232, RS-422, or RS-485 setting is being  
used.  
after a label is sent to the printer.  
settings are incorrect.  
Check the printer driver or software  
communications settings.  
A label format was sent to the The prefix and delimiter  
Verify the prefix and delimiter characters.  
printer but not recognized. The characters set in the printer do See Selecting Prefix and Delimiter  
DATA light flashes but no  
printing occurs.  
not match the ones in the label Characters (next three parameters)  
format.  
Incorrect data is being sent to  
the printer.  
Check the communication settings on the  
computer. Ensure that they match the  
printer settings.  
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Troubleshooting  
Miscellaneous  
Miscellaneous  
Table 16 • Miscellaneous Problems and Solutions  
Recommended Solution  
Issue  
The printer is displaying a  
language that I cannot read.  
1. Press SETUP/EXIT to enter configuration mode.  
2. Press MINUS ().  
The printer displays the LANGUAGE parameter in the current  
language. Even if you cannot recognize the characters in the current  
language, you can still scroll to another one.  
3. Use PLUS (+) or MINUS () to select another language.  
4. Press SETUP/EXIT twice to exit configuration mode and save the  
changes (if the language does not change, you need to scroll to a  
different save option by pressing SELECT).  
5. Reenter configuration mode and press MINUS () to see which  
language is displayed.  
6. Repeat this process, if necessary, until you reach the desired language.  
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Troubleshooting  
Printer Diagnostics  
Printer Diagnostics  
These self tests produce sample printouts and provide specific information that help determine  
the operating conditions for the printer.  
Each self test is enabled by pressing a specific front panel key or combination of keys while  
turning the printer On (l). Press the key(s) until the DATA light turns off (approximately five  
seconds). When the Power-On Self Test is complete, the selected self test starts automatically.  
Note • Keep the following in mind while performing self tests:  
• When performing self tests, avoid sending a label format to the printer. In the case of a  
remote host, disconnect all data interface cables from the printer.  
• When cancelling a self test prior to its actual completion, always turn the printer Off (O)  
and then back On (I) to reset the printer.  
• When performing these self tests while in the Peel-Off Mode, you must remove the labels as  
they become available.  
• If your media is not wide enough or long enough, unexpected or undesired results may  
occur. Ensure that your print width is set correctly for the media you are using before you  
run any self tests, otherwise the test may print on the platen roller. See PRINT WIDTH  
on page 59 for information on setting the print width.  
Power-On Self Test  
A Power-On Self Test (POST) is performed automatically each time the printer is turned on.  
During this test sequence, the front panel lights and liquid crystal display (LCD) monitor the  
progress of the POST. If the printer fails any of these tests, the word FAILED is display. If this  
occurs, notify an authorized Zebra reseller.  
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Troubleshooting  
Printer Diagnostics  
CANCEL Self Test  
This self test prints a listing of the configuration parameters currently stored in the printer’s  
memory. See Figure 40. Depending on the options ordered, your label may look different.  
Figure 40 • Sample Configuration Labels  
The configuration shown on the label may be changed either temporarily (for specific label  
formats or ribbon and label stock) or permanently (by saving the new parameters in memory).  
See Basic Configuration on page 53 for further information about the configuration procedure.  
To perform the CANCEL Self Test, complete these steps:  
1. Turn the printer Off (O).  
2. Press and hold CANCEL while turning On (l) the printer.  
3. Release CANCEL after the DATA light turns off (approximately five seconds).  
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Printer Diagnostics  
PAUSE Self Test  
This self test can be used to provide the test labels required when making adjustments to the  
printer’s mechanical assemblies or parameter settings. See the sample printout in Figure 41.  
Figure 41 • PAUSE Test Label  
To perform the PAUSE Self Test, complete these steps:  
1. Turn the printer Off (O).  
2. Press and hold PAUSE while turning On (l) the printer.  
3. Release PAUSE after the DATA light turns off (approximately five seconds).  
The printer prints 15 labels at 2 in. (51 mm) per second, then automatically pauses. If  
PAUSE is pressed, an additional 15 labels print.  
4. Press CANCEL while the printer is paused to alter the self test, then press PAUSE.  
The printer prints 15 labels at 6 in. (152 mm) per second, then automatically pauses.  
5. Press CANCEL again while the printer is paused to alter the self test again, then press  
PAUSE.  
The printer prints 50 labels at 2 in. (51 mm) per second, then automatically pauses.  
6. Press CANCEL again while the printer is paused to alter the self test a third time, then  
press PAUSE.  
The printer prints 50 labels at 6 in. (152 mm) per second, then automatically pauses.  
7. Press CANCEL again while the printer is paused to alter the self test a fourth time, then  
press PAUSE.  
The printer prints 15 labels at the printer’s maximum speed.  
8. To exit this self test at any time, press and hold CANCEL.  
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Troubleshooting  
Printer Diagnostics  
FEED Self Test  
See Figure 42. The FEED Self Test prints labels at various darkness settings above and below  
that of the darkness value currently stored in the printer (shown on the first line of the  
configuration label). The relative darkness value printed on the best FEED Self Test label is  
added to or subtracted from the darkness value. The resulting numeric value (0 to 30) is the  
best darkness value for that specific media and ribbon combination.  
For example, if the darkness value on a printer is 10 and the best relative darkness value is  
zero, leave the darkness setting as is. If the best relative darkness value is –1, change the  
darkness setting on your printer to 9 (10 – 1). If the best relative darkness value is 2, change  
the darkness setting to 12 (10 + 2).  
Figure 42 • FEED Self Test Label, Relative Darkness Value Zero  
To perform the FEED Self Test, complete these steps:  
1. Turn the printer Off (O).  
2. Press and hold FEED while turning On (l) the printer.  
3. Release FEED after the DATA light turns off (approximately five seconds).  
4. Find the label that has the best darkness setting for your application.  
5. If the relative darkness value on this label is a number other than zero (values range from  
–3 to 3), adjust the darkness setting on your printer by adding or subtracting that relative  
darkness value from the current darkness setting. See Adjusting Print Darkness  
on page 57 for more information.  
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Troubleshooting  
Printer Diagnostics  
FEED and PAUSE Self Test  
Performing this self test temporarily resets the printer configuration to the factory default  
values. These values are active only until power is turned off unless you save them  
permanently in memory.  
To perform a FEED and PAUSE self test, complete these steps:  
1. Turn Off (O) the printer.  
2. Press and hold FEED and PAUSE while turning the power On (I). Hold FEED and  
PAUSE until the DATA light turns off.  
No labels print at the end of this test.  
Communication Diagnostics Test  
This test is controlled from the front panel display (see Setting Communication Diagnostics  
Mode on page 66). A typical printout from this test is shown in Figure 43. Turn the printer Off  
(O) to exit this self test.  
Note • This label prints upside-down.  
Figure 43 • Communication Diagnostics Test Printout  
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Troubleshooting  
Loading Factory Defaults  
Loading Factory Defaults  
Use care when loading defaults. You will need to reload all settings that you changed  
manually.  
To load the factory defaults, complete these steps:  
1. Press SETUP/EXIT two times.  
2. Use PLUS (+) or MINUS () to scroll through the SAVE CHANGESchoices.  
3. When LOAD DEFAULTSdisplays, press SETUP/EXIT.  
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Data Connections  
Serial Data Port  
Serial Data Port  
Hardware Control Signal Descriptions  
For all RS-232 input and output signals, the Z4Mplus and Z6Mplus printers follow both the  
Electronics Industries Association (EIA) RS-232 and the Consultative Committee for  
International Telegraph and Telephone (CCITT) V.24 standard signal level specifications.  
When DTR/DSR handshaking is selected, the Data Terminal Ready (DTR) control signal  
output from the printer controls when the host computer may send data. DTR ACTIVE  
(positive voltage) permits the host to send data. When the printer places DTR in the  
INACTIVE (negative voltage) state, the host must not send data.  
Note • When XON/XOFF handshaking is selected, data flow is controlled by the ASCII  
Control Codes DC1 (XON) and DC3 (XOFF). The DTR Control lead has no effect.  
Request to send (RTS) is a control signal from the printer that is connected to the clear to send  
(CTS) input at the host computer. RTS is always active (positive voltage) when the printer  
is on.  
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Data Connections  
Serial Data Port  
RS-232 Serial Data Port  
The connection for this standard interface is made through the female DB-9 connector on the  
rear panel. A DB-9 to DB-25 interface module is required for all RS-232 connections through  
For all RS-232 input and output signals, the printer follows both the Electronics Industries  
Association’s (EIA) RS-232 specifications and the Consultative Committee for International  
Telegraph and Telephone (CCITT) V.24 standard signal level specifications.  
Table 17 shows the pin configuration and function of the rear panel serial data connector on  
the printer.  
Table 17 • Serial Data Connector Pin Configuration  
Pin Number  
Name  
Description  
1
2
Not connected  
RXD  
TXD  
DTR  
SG  
Receive data—data input to printer  
Transmit data—data output from printer  
Data terminal ready—output from printer  
Signal ground  
3
4
5
6
DSR  
RTS  
Data set ready—input to printer  
Request to send—output from printer  
Clear to send—input to printer  
+5 VDC  
7
8
CTS  
*9  
+5 V DC  
* This pin is also available as a +5 VDC power source at 750 mA. To enable this capability, a  
jumper on the computer’s main logic board needs to be installed on JP1, pins 2 and 3.  
Note • An interface module is required for RS-422/RS-485 interface support  
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Data Connections  
Serial Data Port  
RS-232 Interface Connections  
The printer is configured as Data Terminal Equipment (DTE). Figure 44 shows the internal  
connections of the printer’s RS-232 connector.  
Figure 44 • RS-232 Internal Connections  
DTE  
DTE  
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
(RD)  
(TD)  
(RD)  
(TD)  
(DTR)  
(SG)  
(DTR)  
(SG)  
(DSR)  
(RTS)  
(DSR)  
(RTS)  
Note • Use a a null modem (crossover) cable to connect the printer to a computer or any other  
DTE devices.  
When the printer is connected via its RS-232 interface to Data Communication Equipment  
(DCE) such as a modem, use a standard RS-232 (straight-through) interface cable. Figure 45  
illustrates the connections required for this cable.  
Figure 45 • RS-232 to DCE Internal Connections  
DTE  
(Printer)  
DCE  
(Modem, etc.)  
RXD (receive data)  
TXD (transmit data)  
DTR (data terminal ready)  
SG (signal ground)  
2
3
4
5
6
7
2
3
4
5
6
7
DSR (data set ready)  
RTS (request to send)  
CTS (clear to send)  
+5 VDC signal source  
8
9
8
9
NOTE • Pin 1 is unused and unterminated at the printer.  
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Data Connections  
Serial Data Port  
RS-232 Interconnections Using a DB-25 Cable  
To connect the printer’s RS-232 DB-9 interface to a DB-25 connector, an interface adapter is  
required (Zebra part number 33138). A generic DB-25 adapter may also be used, however, the  
+5 VDC signal source would not be passed through. Figure 46 shows the connections required  
for the DB-9 to DB-25 interface.  
Note • Use a a null modem (crossover) cable to connect the printer to a computer or any other  
DTE devices.  
Figure 46 • DB-9 to DB-25 Internal Connections  
Male DB-9 Adapter  
Connector  
(plugs into printer)  
Female DB-25 Adapter  
Connector  
(plugs into cable)  
RXD  
2
FG  
1
TXD  
2
TXD  
3
DTR  
4
RXD  
3
RTS  
SG  
5
4
CTS  
5
DSR  
DSR  
6
6
RTS  
7
SG  
7
CTS  
8
+5 VDC  
9
SIGNAL  
+5 VDC  
SIGNAL  
9
DTR  
20  
Note • Pin 1 of DB-9 connector is unused and unterminated.  
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Data Connections  
Serial Data Port  
RS-422/RS-485 Interconnections  
Note • A jumper on the computer’s main logic board needs to be installed on JP1, Pins 2  
and 3, for the RS-422/RS-485 interface adapter to function properly.  
To connect the printer’s RS-232 DB-9 interface to a host computer through an RS-422 or an  
RS-485 interface, an interface adapter is required (Zebra part number 33130). Figure 47 shows  
the required cable wiring for interconnecting to the interface adapter’s DB-25 female  
connector.  
Figure 47 • RS-422 and RS-485 Adapter Internal Connections  
DB-25P  
Connector  
to Printer  
Shield  
1
Signal Ground  
11  
Data Input A (–)  
13  
Data Output A (–)  
14  
Data Input B (+)  
16  
Data Output B (+) 19  
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Data Connections  
Parallel Data Port  
Parallel Data Port  
The 8-bit parallel data interface supports IEEE 1284 bidirectional parallel communications in  
nibble mode. The parallel interface provides a means of communication that is typically faster  
than the previously mentioned serial interface methods. In this method, the bits of data that  
make up a character are sent all at one time over several wires in the cable, one bit per wire.  
Parallel Cabling Requirements  
An IEEE-1284 compatible bi-directional parallel data cable is required when this  
communication method is used. The required cable must have a standard 36-pin parallel  
connector on one end that is plugged into the mating connector located at the rear of the  
printer. The other end of the cable connects to the printer connector at the host computer. Port  
selection for status information is determined each time the printer is turned on.  
Parallel Port Interconnections  
Table 18 shows the pin configuration and function of a standard computer-to-printer parallel  
cable.  
Table 18 • Parallel Cable Pin Configuration  
36-Pin Connectors Description  
1
2 to 9  
10  
nStrobe/HostClk  
Data Bits 1 to 8  
nACK/PtrClk  
Busy/PtrBusy  
PError/ACKDataReq  
Select/Xflag  
11  
12  
13  
14  
nAutoFd/HostBusy  
Not used  
15  
16 and 17  
18  
Ground  
+5V @ 750 mA  
The maximum current draw may be limited by option configuration.  
19 to 30  
Ground  
31  
32  
nInit  
nFault/NDataAvail  
Not used  
33 and 34  
35  
+5V through a 1.8KResistor  
NSelectin/1284 active  
36  
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Data Connections  
Parallel Data Port  
Notes • ___________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
To provide feedback on this document, please send your comments to [email protected], or  
write your comments on this page and fax to the following:  
Fax: 1.847.821.1795  
Attention: TechPubs — CTC  
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Specifications  
General Specifications  
General Specifications  
Table 19 • Z4Mplus and Z6Mplus General Specifications  
General Specifications  
Z4Mplus  
13.3 in.  
10.9 in.  
18.7 in.  
32.4 lbs.  
Z6Mplus  
13.3 in.  
13.4 in.  
18.7 in.  
34.7 lbs.  
Height  
338 mm  
277 mm  
475 mm  
14.7 kg  
338 mm  
341 mm  
475 mm  
16 kg  
Width  
Depth  
Weight (without options)  
Electrical  
90-265 VAC, 48-62 Hz, 5 Amps (fused) 90-265 VAC, 48-62 Hz, 5 Amps  
(fused)  
Agency Approvals  
UL 1950, CISPR 22 (class B), CSA 22.2 No. 950-95, IEC60950, EN60950,  
EN500824, EN55022 (class B), EN55024, EN61000-3-2, -3-3. Complies with  
FCC Class B and Canadian Doc Class A rules. Carries the CE mark of  
compliance. Product markings: cULus, CE Marking, FCC-B, ICES-003, VCCI,  
C-Tick, NOM, IRAM, CCC, GOST-R, BSMI.  
Temperature  
Operating  
Storage  
40° to 104°F  
–40° to 140°F  
5° to 40°C  
40° to 104°F  
5° to 40° C  
–40° to 60°C  
–40° to 140°F –40° to 60°C  
20% to 85%, non-condensing  
5% to 85%, non-condensing  
Relative  
Humidity  
Operating  
Storage  
20% to 85%, non-condensing  
5% to 85%, non-condensing  
Communication Interface  
RS-232/CCITT V.24 serial data interface; 110 to115000 baud, parity,  
bits/character, 7 or 8 data bit, and XON-XOFF, RTS/CTS or DTR/DSR  
handshake protocol required. 750mA at 5V from pin 9.  
8-bit parallel data interface; supports IEEE 1284 bi-directional parallel, ECP  
and nibble mode compliant. Error detection CRC protocol.  
Memory  
8 MB DRAM memory (3.5 MB user available)  
2 MB flash memory  
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Specifications  
Printing Specifications  
Printing Specifications  
Table 20 • Z4Mplus and Z6Mplus Printing Specifications  
Printing Specifications  
Z4Mplus  
Z6Mplus  
Print resolution  
203 dots/inch  
300 dots/inch  
8 dots/mm  
203 dots/inch  
300 dots/inch  
8 dots/mm  
12 dots/mm  
12 dots/mm  
Dot size  
203 dpi  
300 dpi  
0.00492 in. x  
0.00492 in.  
0.125 mm x  
0.125 mm  
0.00492 in. x  
0.00492 in.  
0.125 mm x  
0.125 mm  
(width x length)  
0.0033 in. x  
0.0039 in.  
0.084 mm x  
0.099 mm  
0.0033 in. x  
0.0039 in.  
0.084 mm x  
0.099 mm  
Maximum print 203 dpi  
4.09 in.  
4.1 in.  
104 mm  
106 mm  
6.6 in.  
168 mm  
width  
300 dpi  
Minimum print length  
1 dot row  
1 dot row  
65 in.  
Maximum print 203 dots/inch 105 in.  
2667 mm  
1143 mm  
1651 mm  
737 mm  
length  
300 dots/inch 45 in.  
29 in.  
Bar code  
modulus  
203 dots/inch 5 mil to 50 mil  
5 mil to 50 mil  
3.3 mil to 33 mil  
300 dots/inch 3.3 mil to 33 mil  
(X) dimension  
Programmable  
constant print  
speeds  
203 dots/inch Per second:  
Per second:  
Per second: 7 in. Per second:  
7 in.  
8 in.  
9 in.  
10 in.  
178 mm 203 mm 8 in.  
229 mm 254 mm 9 in.  
10 in.  
178 mm  
203 mm  
229 mm  
254 mm  
300 dots/inch Per second:  
Per second:  
51 mm  
76 mm  
102 mm  
127 mm  
152 mm  
Per second: 2 in. Per second:  
2 in.  
3 in.  
4 in.  
5 in.  
6 in.  
3 in.  
4 in.  
5 in.  
6 in.  
51 mm 76 mm  
102 mm  
127 mm  
152 mm  
Thin film printhead with energy control  
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Specifications  
Media Specifications  
Media Specifications  
Table 21 • Z4Mplus and Z6Mplus Media Specifications  
Media Specifications  
Z4Mplus  
0.5 in.  
1 in.  
Z6Mplus  
0.5 in.  
1 in.  
Label length  
Minimum Tear-off  
13 mm  
13 mm  
Peel-off  
Rewind  
Cutter  
25.4 mm  
13 mm  
25.4 mm  
13 mm  
0.5 in.  
1 in.  
0.5 in.  
25.4 mm  
991 mm  
25.4 mm  
114 mm  
108 mm  
0.058 mm  
0.25 mm  
76 mm  
1.5 in.  
38.1 mm  
991 mm  
51 mm  
Maximum  
Minimum  
39 in.  
39 in.  
Label width  
1 in.  
2 in.  
Maximum Tear/Cutter  
Peel/Rewind  
4.5 in.  
4.25 in.  
0.0023 in.  
0.010 in.  
3 in.  
7.0 in.  
6.75 in.  
0.0023 in.  
0.010 in.  
3 in.  
178 mm  
171 mm  
0.058 mm  
0.25 mm  
76 mm  
Total thickness  
(includes liner, if any)  
Minimum  
Maximum  
Core size  
Maximum roll diameter  
Inter-label gap  
8 in.  
203 mm  
2 mm  
8 in.  
203 mm  
2 mm  
Minimum  
Preferred  
Maximum  
0.079 in.  
0.118 in.  
0.157 in.  
0.079 in.  
0.118 in.  
0.157 in.  
3 mm  
3 mm  
4 mm  
4 mm  
Ticket/tag notch size (width x length)  
0.236 in. ×  
0.12 in.  
6 mm ×  
3 mm  
0.236 in. ×  
0.12 in.  
6 mm × 3 mm  
Hole diameter  
0.125 in.  
0.15 in.  
2.25 in.  
3 mm  
0.125 in.  
0.15 in.  
3.5 in.  
3 mm  
3.8  
Notch or hole position  
(Centered from inner  
media edge)  
Minimum  
Maximum  
3.8 mm  
57 mm  
90 mm  
Black mark  
dimensions  
Vertical length  
0.98 in. to  
0.453 in.  
2.5 to  
11.5 mm  
0.98 in. to  
0.453 in.  
2.5 to  
11.5 mm  
Horizontal width  
Location  
> 0.37 in.  
> 9.5 mm  
> 0.37 in.  
> 9.5 mm  
Within 0.40 in. (1 mm) of inside media edge  
May also be centered  
from 0.23 to 2.25 in.  
(5.84 to 57 mm)  
May also be centered  
from 0.23 to 3.5 in.  
(5.84 to 90 mm)  
from the media inner edge  
from the media inner edge  
Density, in Optical Density Units (UDO)  
Maximum media density  
> 1.0 ODU  
< 0.5 ODU  
Transmissive Sensor  
Fixed  
7/16 in. (11 mm) from inside edge  
112  
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Specifications  
Ribbon Specifications  
Ribbon Specifications  
Table 22 • Z4Mplus and Z6Mplus Ribbon Specifications  
Ribbon Specifications  
Z4Mplus  
Z6Mplus  
Ribbon must be wound with the coated side out  
Ribbon width  
Minimum  
Maximum  
>2 in.*  
4.3 in.  
51 mm*  
109 mm  
>2 in.  
6.9 in.  
51 mm  
(Zebra recommends using ribbon  
at least as wide as the media to  
protect the printhead from wear.)  
174 mm  
Standard lengths  
2:1 media to  
ribbon roll ratio  
984 ft.  
1476 ft.  
1 in.  
300 m  
984 ft.  
1476 ft.  
1 in.  
300 m  
3:1 media to  
ribbon roll ratio  
450 m  
450 m  
Ribbon core inside diameter  
25.4 mm  
25.4 mm  
* The narrowest width tested and approved for this printer is 2 in. (51 mm). You may be able to use narrower ribbon, as  
long as the ribbon is wider than the media being used. To use a ribbon narrower than 2 in. (51 mm), test the ribbon’s  
performance with your media to assure that you get the desired results.  
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Specifications  
Printer Options  
Printer Options  
Table 23 • Z4Mplus and Z6Mplus Options  
Option  
Z4Mplus  
Z6Mplus  
Cutter  
X
X
X
X
X
Peel-off  
X
Liner take-up  
Not available  
X
PCMCIA card socket  
(supports Zebra Rapid Flash and ATA formats)  
Linear Memory Card (Zebra Rapid Flash)  
8MB and 32MB  
X
X
X
X
Compact Flash  
32MB, 64MB, 128MB, and 256MB  
300 dpi printhead  
Rewind  
X
X
X
X
X
X
X
Adjustable transmissive sensor  
External PrintServer  
Internal PrintServer  
Not available  
X
X
114  
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Specifications  
Zebra Programming Language (ZPL II) Features  
Zebra Programming Language (ZPL II) Features  
Downloadable graphics (with data compression)  
Bit image data transfer and printing, mixed text/graphics  
Format inversion  
Mirror image printing  
Four-position field rotation  
(0°, 90°, 180°, 270°)  
Slew command  
Programmable quantity with print pause  
Communicates in printable ASCII characters  
Controlled via mainframe, mini, PC, portable data terminal  
In-Spec OCR-A and OCR-B  
UPC/EAN  
(nominal 100% magnification 6 dots/mm printheads only)  
Serialized fields  
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Specifications  
Supported Bar Codes  
Supported Bar Codes  
Table 24 • Supported Bar Codes  
Z4M/Z6Mplus Bar Code Features  
Code 11  
LOGMARS  
Code 39 (supports ratios of 2:1 to 3:1)  
Code 49 (2-dimensional bar code)  
Code 93  
Plessey  
EAN-8, EAN-13, EAN EXTENSIONS  
UPC-A, UPC-E, UPC EXTENSIONS  
MSI  
Code 128 (supports serialization in all  
subsets and UCC case codes)  
Codabar (supports ratios of 2:1 to 3:1)  
Codablock  
PDF-417 (2-dimensional bar code)  
Micro-PDF-417  
Interleaved 2 of 5 (supports ratios of 2:1 to POSTNET  
3:1; modulus 10 check digit)  
Industrial 2 of 5  
Standard 2 of 5  
QR Code  
MaxiCode  
Datamatrix  
Check digit calculation where applicable  
116  
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13163L Rev. 3 5/20/2004  
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Index  
A
C
calibration  
adjustments  
cleaning  
communication diagnostics  
configuration  
B
bar codes  
baud rate  
configuration label  
13163L Rev. 3 5/20/2004  
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117  
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Index  
cutter mode  
front panel  
D
darkness adjustment  
data communications  
data ports  
G
H
direct thermal mode  
display language  
I
interconnections  
E
interfaces  
IP settings  
F
118  
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13163L Rev. 3 5/20/2004  
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Index  
media types  
L
memory card  
language displayed  
N
network configuration label  
liner removal  
liner take-up mode  
O
list  
P
parallel communications  
peel-off mode  
pinouts  
print modes  
M
media  
media loading  
media removal  
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Index  
print server settings  
rewind mode  
printer parameters  
ribbon  
printer settings  
printhead  
PrintServer II (PSII)  
S
scratch test  
self tests  
R
real-time clock (RTC)  
reflective sensor  
sensors  
serial communications  
removing  
120  
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Index  
Note • ____________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
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__________________________________________________________________________  
__________________________________________________________________________  
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__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
__________________________________________________________________________  
To provide feedback on this document, please send your comments to [email protected], or  
write your comments on this page and fax to the following:  
Fax: 1.847.821.1795  
Attention: TechPubs — CTC  
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Zebra Technologies Corporation  
333 Corporate Woods Parkway  
Vernon Hills, Illinois 60061.3109 U.S.A.  
Telephone: +1 847.634.6700  
Facsimile: +1 847.913.8766  
Zebra Technologies Europe Limited  
Zebra House  
The Valley Centre, Gordon Road  
High Wycombe  
Buckinghamshire HP13 6EQ, UK  
Telephone: +44 (0) 1494 472872  
Facsimile: +44 (0) 1494 450103  
Customer Order # 13163LB  
Manufacturer Part # 13163LB Rev. 3  
© 2004 ZIH Corp.  
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