Zebra Technologies Printer Z4Mplus User Manual

Zebra^®Z4Mplus/Z6Mplus™

Industrial/Commercial Printer

User Guide

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Contents

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Proprietary Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i x

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x iii

Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv

Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv

Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv

1 • Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

LCD Display Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Print Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Contents

2 • Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Unpack and Inspect the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Report Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Select a Site for the Printe r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0

Select a Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Provide Proper Operating Condition s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0

Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Provide a Data Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Select a Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Cable Requirement s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4

Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Selecting Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Non-Continuous Medi a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6

Continuous Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

When to Use Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Ribbon Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Coated Side of Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3 • Printer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Front Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Load Roll Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

T e ar-Off Mod e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5

Cutter Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Peel-Off Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Liner T a ke-Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Rewind/Peel-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Rewind Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Adjust Media Alignment for Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Load Fanfold Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Load the Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Remove the Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Print a Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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Contents

Print a Network Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Install Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4 • Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Overvie w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0

Enter Configuration Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Exit Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Basic Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Configuration and Calibration LCD Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

ZebraNet Wired and Wireless Print Server LCD Displays . . . . . . . . . . . . . . . . . . . . 72

5 • Routine Care and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Clean the Exterio r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6

Clean the Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Clean the Printhead and Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Clean the Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Clean the Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Clean the Peel-Off Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Clean the Cutter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Position the Label Senso r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4

Adjust the Reflective Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Select the Transmissive Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

6 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

LCD Error Conditions and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Calibration Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Communication Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Power-On Self T e st. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

CANCEL Self T e st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

PAUSE Self T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7

FEED Self T e st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

FEED and PAUSE Self T e st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Communication Diagnostics T e st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Loading Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

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Contents

A • Data Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Serial Data Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Hardware Control Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

RS-232 Serial Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Parallel Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Parallel Cabling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Parallel Port Interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

B • Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

Printing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 11

Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Zebra Programming Language (ZPL II) Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

Supported Bar Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

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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

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 • ___________________________________________________________________

__________________________________________________________________________

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

www.zebra.com

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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

The Preface discusses the topics and illustrates standards that are used throughout this guide.

Contents

Contact s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x iv

Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv

Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv

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Preface

Contacts

You can contact Zebra Technologies Corporation, USA at any of the following:

Visit us at: http://www.zebra.com

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:

Web address: www.zebra.com/SS/service_support.htm

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

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

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 II™ Installation 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

This chapter shows the operational controls and location of major components needed in the

loading of media and ribbon.

Contents

Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

LCD Display Setting s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Printer Media Compartmen t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Introduction

External View

Figure 2 shows the outside of the printer.

Figure 2 • External View

Electronics cover

Front panel

Media door

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Introduction

Front Panel

The front panel keys and lights are shown in Figure 3.

Figure 3 • Front Panel Controls and LEDs

PAUSE

Power LED

Pause LED

Error LED

Data LED

LCD

PLUS (+) Key

SETUP/EXIT Key

CANCEL Key

PAUSE Key

FEED Key

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.

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

Figure 4 shows a simplified view of your printer. Depending on installed options, your

printer may look slightly different.

Figure 4 • Media Compartment

Printhead Assembly

Transmissive Sensor

Label Supply Guide

Label Supply Hanger

Dancer

Label Guide

Printhead Open Lever

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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

Before Y ou Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Report Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Select a Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Provide a Data Sourc e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0

Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Power Cord Specification s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1

Select a Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Types of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Selecting Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Non-Continuous Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Continuous Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

When to Use Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Ribbon Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Coated Side of Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Printer Setup

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

you have not, see Unpack and Inspect the Printer on page 9.

‰ Select a Site Have you selected an appropriate location for the printer? If you have not,

see Select a Site for the Printer on page 10.

‰ 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

Interface on page 13.

‰ Select Media Do you have the correct media for your application? If you are unsure,

see Types of Media on page 15.

‰ 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

•

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

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

General Specifications on page 110.

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

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

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

AC power plug for your country

3-conductor HAR cable

IEC 320 connector

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

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Printer Setup

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

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

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

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

Hole

Label Gap

Notch

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 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 • ___________________________________________________________________

__________________________________________________________________________

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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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

Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Front Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Load Roll Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

T e ar-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Cutter Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Peel-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Liner T a ke-Up Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Rewind/Peel-Off Mod e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3

Rewind Mod e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5

Adjust Media Alignment for Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Load Fanfold Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Load the Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Remove the Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Manual Calibratio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2

Print a Configuration Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Install Memory Car d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 8

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Printer Operation

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

Table 4 and Table 5.

Figure 14 • Front Panel

PAUSE

Power LED

Pause LED

Error LED

Data LED

LCD

PLUS (+) Key

SETUP/EXIT Key

CANCEL Key

PAUSE Key

FEED Key

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.

PAUSE

Off

Normal printer operation.

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

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

A partial format has been received and no subsequent data activity.

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Printer Operation

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

Printhead Assembly

Transmissive Sensor

Label Supply Guide

Label Supply Hanger

Dancer

Label Guide

Printhead Open Lever

Printed Label

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

Printhead Assembly

Transmissive Sensor

Label Supply Guide

Label Supply Hanger

Dancer

Label Guide

Printhead Open Lever

Cutter Module

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

101

Printhead Assembly

Transmissive Sensor

Media Supply Guide

Media Supply Hanger

Dancer

Media Guide

Printhead Open Lever

Peel Assembly

Label

Peel Lever

Tear-Off/Peel/Off Bar

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

Printhead Assembly

Transmissive Sensor

Label Supply Guide

Label Supply Hanger

Liner Take-Up

Dancer

Label Guide

Printhead Open Lever

Peel Assembly

Label

Peel Lever

Tear-Off/Peel-Off Bar

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

Printhead Assembly

Transmissive Sensor

Label Supply Guide

Label Supply Hanger

Rewind Spindle

Rewind Label Guide

Thumbscrew

Dancer

Label Guide

Media Alignment Spindle

Printhead Open Lever

Peel Assembly

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

Printhead Assembly

Transmissive Sensor

Label Supply Guide

Label Supply Hanger

Rewind Spindle

Rewind Label Guide

Thumbscrew

Dancer

Label Guide

Media Alignment Spindle

Printhead Open Lever

Rewind Base Assembly

Peel Assembly

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

Rewind Spindle Backplate

Rewind Spindle

Adjustment Dial

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

Fanfold media feeds through either the bottom or rear access slot. See Figure 25.

Figure 25 • Loading Fanfold Media

Rear Feed

Bottom Feed

Printhead Assembly

Transmissive Sensor

Label Supply Guide

Label Supply Hanger

Dancer

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

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

Strip Plate

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

Normal Position (Spindle End Cap Extended)

Low-Tension Position (Spindle End Cap Retracted)

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

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.

For instructions, refer to Media and Ribbon Sensor Calibration (Manual Calibration)

on page 63.

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Printer Operation

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

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

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

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)

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)

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

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

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

This chapter discusses detailed configuration settings and instructs you how to view or change

parameters through the front panel.

Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Enter Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Exit Configuration Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Configuration and Calibration LCD Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

ZebraNet^®Wired and Wireless Print Server LCD Displays . . . . . . . . . . . . . . . . . . . . . 7 2

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Configuration

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

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.

Refer to Configuration and Calibration LCD Displays on page 57 for more detailed

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...

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.

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.

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.

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.

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.

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...

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

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

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

T e st on page 98.

You may want to adjust the printer’s darkness while performing the P A USE Self T e st

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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Configuration

Configuration and Calibration LCD Displays

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

Configuration and Calibration LCD Displays

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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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.

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.

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.

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

on page 62.

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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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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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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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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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 ADDRESS^2,3

ESSID^2,3

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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Table 10 • Print Server LCD Displays (Continued)

LCD

Explanation

AUTH. TYPE^2,3

Authentication Type

Default: OPEN

Selections: OPEN, SHARED

LEAP MODE^3,4

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

MODE^2,3

Selections: OFF, 40-BIT, 128-BIT

Encryption Index

Default: 1

ENCRYPTION

INDEX^2,3

Selections: 1, 2, 3, 4

RESET NETWORK^1,3

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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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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Routine Care and

Adjustments

This chapter discusses printer cleaning and minor adjustments.

Contents

Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Clean the Exterio r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6

Clean the Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Clean the Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Clean the Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Clean the Peel-Off Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Clean the Cutter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Position the Label Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Select the Transmissive Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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Routine Care and Adjustments

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*

Air blow

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

Assembly on page 81.)

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

Printhead Assembly

Platen Roller

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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

Transmissive Sensor

Reflective Sensor

Ribbon Sensor

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

Printhead Assembly

Tear-Off/Peel-Off Bar

Pinch Roller

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

Thumbscrew and Lock Washer

Cutter Shield

Upper Cutter Blade

Lower Cutter Blade

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

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

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

Transmissive Sensor on page 86.

Figure 38 • Adjusting the Reflective Sensor

Printhead Assembly

Reflective Sensor

Adjustment Lever

Printhead Open Lever

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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

Standard Transmissive Sensor

Adjustable Transmissive Sensor (optional)

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Troubleshooting

This chapter discusses typical problems and their probable solutions.

Content

LCD Error Conditions and Warnings. . . . . . . . . . . . . . . . . . . . . . . . 88

Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Communication Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Power-On Self T e st. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

CANCEL Self T e st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

PAUSE Self T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7

FEED Self T e st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Communication Diagnostics T e st . . . . . . . . . . . . . . . . . . . . . . . . 99

Loading Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

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Troubleshooting

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

Ribbon on page 40.

In thermal transfer mode, the

ribbon sensor is not sensing

correctly loaded ribbon.

Perform the media and ribbon sensor

calibration (see Media and Ribbon Sensor

Calibration (Manual Calibration)

on page 63).

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

Method on page 59.

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

on page 25.

The media sensor is not

positioned properly.

Check the position of the reflective sensor.

See Position the Label Sensor on page 84.

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

Sensor Calibration (Manual Calibration)

on page 63).

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

Sensor on page 84.

Print method is incorrectly set. Via the front panel, locate the PRINT

METHOD menu item and select thermal

transfer mode. See Selecting Print Method

on page 59.

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

Method on page 59.

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

instructions in Clean the Cutter Module

on page 82.

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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

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

instructions in Clean the Printhead and

Platen Roller on page 77.

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.

Pressure on page 46.

Gray lines on blank labels

with no consistent pattern

The printhead is dirty.

Clean the printhead according to the

instructions in Clean the Printhead and

Platen Roller on page 77.

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

Printhead and Platen Roller on page 77.

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.

Printhead Pressure on page 46.

Wrinkled ribbon

The ribbon is not loaded

correctly.

Load the ribbon correctly. See Load the

Ribbon on page 40.

The darkness setting is incorrect. Set the darkness to the lowest possible

setting for good print quality. See

DARKNESS on page 57.

Incorrect printhead pressure or

balance.

Set the pressure to the minimum required for

good print quality. See Set Printhead

Pressure on page 46.

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

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

on page 58.

Adjust the reflective sensor position. See Adjust the Reflective

Sensor on page 84.

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

Adjust the Reflective Sensor on page 84).

Clean the platen roller according to the instructions in Clean

the Printhead and Platen Roller on page 77.

Auto Calibrate failed.

Perform a manual calibration (see Media and Ribbon Sensor

Calibration (Manual Calibration) on page 63).

Reload the media and ensure that the reflective sensor is

properly positioned (see Adjust the Reflective Sensor

on page 84).

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Troubleshooting

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

Requirements on page 14.

Via the front panel, check the protocol

setting. It should be set to the default

None. See Setting Protocol on page 65.

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.

on page 67.

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

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

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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Troubleshooting

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

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

This appendix provides details about the serial port and parallel port data connections.

Content

Serial Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Hardware Control Signal Descriptions . . . . . . . . . . . . . . . . . . . 102

RS-232 Serial Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Parallel Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Parallel Cabling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 107

Parallel Port Interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . 107

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Data Connections

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

a DB-25 cable (see RS-232 Interconnections Using a DB-25 Cable on page 105 for details).

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

Not connected

RXD

TXD

DTR

Receive data—data input to printer

Transmit data—data output from printer

Data terminal ready—output from printer

Signal ground

DSR

RTS

Data set ready—input to printer

Request to send—output from printer

Clear to send—input to printer

+5 VDC

CTS

+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

(see RS-422/RS-485 Interconnections on page 106).

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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

(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)

DSR (data set ready)

RTS (request to send)

CTS (clear to send)

+5 VDC signal source

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

TXD

DTR

RXD

RTS

CTS

DSR

RTS

CTS

+5 VDC

SIGNAL

+5 VDC

SIGNAL

DTR

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

Signal Ground

Data Input A (–)

Data Output A (–)

Data Input B (+)

Data Output B (+) 19

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Data Connections

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

2 to 9

nStrobe/HostClk

Data Bits 1 to 8

nACK/PtrClk

Busy/PtrBusy

PError/ACKDataReq

Select/Xflag

nAutoFd/HostBusy

Not used

16 and 17

Ground

+5V @ 750 mA

The maximum current draw may be limited by option configuration.

19 to 30

Ground

nInit

nFault/NDataAvail

Not used

33 and 34

+5V through a 1.8KΩ Resistor

NSelectin/1284 active

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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

This appendix contains specifications for the Z4Mplus and Z6Mplus printers.

Contents

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Printing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Media Specification s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 12

Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Zebra Programming Language (ZPL II) Features. . . . . . . . . . . . . 115

Supported Bar Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

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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

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

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

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

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

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.

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

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

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

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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

Ribbon core inside diameter

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

Table 23 • Z4Mplus and Z6Mplus Options

Option

Z4Mplus

Z6Mplus

Cutter

Peel-off

Liner take-up

Not available

PCMCIA card socket

(supports Zebra Rapid Flash and ATA formats)

Linear Memory Card (Zebra Rapid Flash)

8MB and 32MB

Compact Flash

32MB, 64MB, 128MB, and 256MB

300 dpi printhead

Rewind

Adjustable transmissive sensor

External PrintServer

Internal PrintServer

Not available

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Specifications

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

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

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Index

AC power cord specifications, 11

addresses, xiv

cabling requirements, 14

calibration

adhesive test for ribbon coating, 18

adjustments

auto versus manual, 42

head close action, 68

darkness, 57

manual calibration procedure, 63

media power up action, 68

troubleshooting problems, 92

Canadian DOC compliance, vi

CANCEL self test, 96

checklist for printer setup, 8

cleaning

cutter module, 82

peel-off assembly, 81

printhead and platen roller, 77

rewind option, 80

label left position, 69

label top position, 69

LCD display, 70

media alignment for rewind, 37

print speed, 57

printhead pressure, 46

reflective sensor, 84

tear-off position, 58

authentication type, 73

auto calibration, 42

communication diagnostics

setting, 66

test and sample label, 99

communication interfaces, 13

communication problems, 93

configuration

basic configuration, 53

changing password-protected parameters, 52

enter configuration mode, 50

exit configuration mode, 51

LCD displays, 57

backfeed sequence, 69

bar codes

list available, 60

supported by this printer, 116

basic configuration, 53

baud rate

setting through front panel, 64

before you begin setup, 8

black mark media, 16

configuration label

printing and example, 43

connect printer to data source, 13

contacts, xiv

continuous media, 16

control prefix character, 67

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Index

customer support, xiv

Cutter Jam message, 89

cutter mode

backfeed sequence setting, 69

media loading, 26

font list, 60

format convert setting, 70

format prefix character, 67

formats list, 60

front panel

adjusting LCD display, 70

keys described, 23

LCD display settings, 4

lights described, 24

location, 2

darkness adjustment

FEED key self test, 98

procedure, 57

location of keys and lights, 3

overview and illustration, 22

data bits, 64

data cable requirements, 14

data communications

parallel ports, 107

serial port, 102

data ports

general specifications, 110

gleaning, 72

parallel, 107

serial, 103

data source connections, 10

date change for RTC, 70

default gateway, 72

delimiter character, 67

diagnostic tests, 95

direct thermal mode

media scratch test, 17

selecting through front panel, 59

display language

handshake protocol, 65

hardware control signal descriptions, 102

head close action, 68

Head Open message, 89

Head Over Temp message, 89

Head Under Temp message, 89

host handshake, 65

humidity requirements, 10

changing from unreadable language, 94

parameter description, 71

document conventions, xv

illustration callouts, xvi

dpi conversion, 70

idle display for RTC, 70

images list, 60

initialize flash memory, 62

initialize memory card, 61

inspect printer, 9

install memory card, 48

interconnections

electronics cover, 2

encryption settings, 73

enter configuration mode, 50

ESSID setting, 72

exit configuration mode, 51

external view of printer, 2

parallel port, 107

RS-232, 104

RS-422/RS-485, 106

interfaces

data connections, 101

system connections, 13

international safety organization marks, 12

IP settings

factory defaults, 100

fanfold media loading, 38

FCC compliance, v

default gateway, 72

IP address, 72

FEED and PAUSE self test, 99

FEED key self test, 98

flash memory initialization, 62

protocol, 72

subnet mask, 72

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Index

media types

continuous media, 16

setting through front panel, 58

memory card

initialize through front panel, 61

installation, 48

label left position adjustment, 69

label sensor positioning, 84

label top position adjustment, 69

language displayed

changing from unreadable language, 94

parameter description, 71

LCD display adjustment, 70

LCD error conditions and warnings, 88

left edge of label adjustment, 69

liability, vi

network configuration label

printing as baseline, 45

printing through front panel, 61

network ID setting, 65

liner removal

liner take-up mode, 32

rewind/peel-off mode, 34

liner take-up mode

liner removal, 32

operating conditions, 10

Out of Memory message, 90

loading media, 30

list

all information, 61

bar codes, 60

Paper Out message, 88

parallel cabling requirements, 107

parallel communications

parallel data port, 107

setting through front panel, 64

load factory defaults, 100

loading ribbon, 40

lubrication, 83

password level, 71

password-protected parameters, 52

PAUSE key self test, 97

PCMCIA card installation, 48

peel-off mode

backfeed sequence setting, 69

cleaning peel-off assembly, 81

pinouts

position label sensor, 84

power cord specifications, 11

Power-On Self Test (POST), 95

power-up media action, 68

print configuration label, 43

print darkness adjustment, 57

print method selection, 59

print modes

described, 5

selection, 58

tear-off mode, 25

print network configuration label, 45

print quality problems, 91

MAC address, 72

manual calibration, 42

maximum label length setting, 60

media

black mark media, 16

non-continuous media, 16

media loading

liner take-up mode, 30

peel-off mode, 28

rewind/peel-off mode, 33

tear-off mode, 25

media power up action, 68

media removal

rewind mode, 36

media scratch test, 17

media sensor calibration, 63

media sensor profile, 62

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Index

print server settings

resolution effects on formats, 70

rewind mode

adjust media alignment, 37

cleaning rewind option, 80

liner removal, 34

print speed adjustment, 57

print width setting, 59

printer calibration, 42

printer diagnostics, 95

printer parameters

loading media, 33

removing printed media, 36

ribbon

adhesive test, 18

determining coated side, 17

loading, 40

basic configuration, 53

LCD displays, 57

removing, 41

password protection, 52

printer settings

IP settings, 72

Ribbon In message, 88

Ribbon Out message, 88

scratch test, 18

network configuration label as baseline, 45

print server settings, 72

printer setup checklist, 8

printer storage requirements, 9

printhead

specifications, 113

troubleshooting wrinkles, 91

when to use, 17

ribbon sensor calibration, 63

roll media loading, 25

RS-232 serial data port, 102

ruse replacement, 83

cleaning, 77

head close action, 68

pressure adjustment, 46

printing specifications, 111

PrintServer II (PSII)

password level, 71

product improvements, v

proprietary statement, v

protocol setting, 65

scratch test

media type, 17

ribbon coated side, 18

select a printer site, 10

self tests

CANCEL key, 96

communication diagnostics, 99

FEED and PAUSE , 99

FEED key, 98

real-time clock (RTC)

reflective sensor

sensors

adjustments, 84

sensor selection, 59

setting sensor type, 58

transmissive sensor locations, 86

serial communications

setting through front panel, 64

serial data port, 102

setup checklist, 8

sensor selection, 59

registration problems, 92

relative humidity requirements, 10

removing

printed media from rewind spindle, 36

ribbon, 41

replacing fuse, 83

reporting shipping damage, 9

reset network option, 73

shipping damage, 9

site requirements, 10

spacing requirements, 10

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Index

specifications

types of media

non-continuous media, 16

power cord, 11

printing, 111

ribbon, 113

supported bar codes, 116

Zebra Programming Language (ZPL II), 115

storage requirements, 9

subnet mask, 72

support, xiv

surface for the printer, 10

system interfaces, 13

unpack printer, 9

web media, 16

Wireless Print Server

list network settings, 61

password level, 71

Wireless Print Server settings

authentication type, 73

tear-off mode

tear-off position adjustment, 58

temperature requirements, 10

thermal transfer mode

media scratch test, 17

selecting through front panel, 59

time change for RTC, 71

top of label adjustment, 69

transmissive sensor

Zebra Programming Language (ZPL II)

features, 115

prefix and delimiter characters, 67

selecting ZPL mode, 68

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Index

Note • ____________________________________________________________________

__________________________________________________________________________

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

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