Z4Mplus/Z6Mplus Industrial/Commercial Printer User Guide
© 2006 ZIH Corp. The copyrights in this manual and the software and/or firmware in the label printer described therein are owned by ZIH Corp. Unauthorized reproduction of this manual or the software and/or firmware in the label printer may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability. This product may contain ZPL®, ZPL II®, and ZebraLink™ programs; Element Energy Equalizer® Circuit; E3®; and Monotype Imaging fonts.
Declaration of Conformity Declaration of Conformity I have determined that the Zebra printers identified as the ZM™ Series Z4M, Z6M, Z4Mplus, Z6Mplus, R4Mplus manufactured by: Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills, Illinois 60061-3109 U.S.A.
iv Compliance Information Compliance Information Compliance Information 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.
Contents Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Compliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vi Contents Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select a Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents 4 • Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enter Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
viii Contents 7 • Data Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Parallel Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel Cabling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel Port Interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Data Port. .
About This Document This section provides you with contact information, document structure and organization, and additional reference documents. Contents Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 About This Document Who Should Use This Document Who Should Use This Document This User Guide is intended for use by any person who needs to operate or troubleshoot problems with the printer. How This Document Is Organized The User Guide is set up as follows: 13163L-001 Rev. A Section Description Introduction on page 7 This section shows the operational controls and location of major components used when loading media and ribbon.
About This Document Contacts Contacts You can contact Zebra Technologies at the following. Web Site http://www.zebra.com Technical Support via the Internet is available 24 hours per day, 365 days per year. Go to http://www.zebra.com/support. The Americas Regional Headquarters Technical Support Customer Service Dept. Zebra Technologies International, LLC 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.
4 About This Document Document Conventions Document Conventions The following conventions are used throughout this document to convey certain information. Alternate Color (online only) Cross-references contain hot links to other sections in this guide. If you are viewing this guide online in .pdf format, you can click the cross-reference (blue text) to jump directly to its location. LCD Display Examples Text from a printer’s Liquid Crystal Display (LCD) appears in Bubbledot ICG font.
About This Document Document Conventions Illustration Callouts Callouts are used when an illustration contains information that needs to be labeled and described. A table that contains the labels and descriptions follows the graphic. Figure 1 provides an example. Figure 1 • Sample Figure with Callouts 1 PAUSE 1 2 1/18/06 2 FEED button CANCEL button Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
6 About This Document Document Conventions Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _______________
1 Introduction This section shows the operational controls and location of major components used when loading media and ribbon. Contents External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Introduction External View External View Figure 2 shows the outside of the printer. Figure 2 • External View 1 2 3 1 2 3 13163L-001 Rev.
Introduction Control Panel Control Panel The control 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 control panel buttons and lights are shown in Figure 3. Descriptions for each are located in Table 1 and Table 2.
10 Introduction Control Panel Control Panel Buttons Table 1 • Control Panel Buttons Button Function FEED Forces the printer to feed one blank label each time the button 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.
Introduction Control Panel Control Panel Lights Table 2 • Control Panel Lights Light Status Indication POWER Off The printer is off, or no power is applied. On The printer is on. Off Normal printer operation. On The printer has stopped all printing operations. Flashing The Pause light flashes when initializing FLASH or PCMCIA memory and in Peel-Off Mode when the label is available. Off Normal printer operation (no errors).
12 Introduction Printer Media Compartment Printer Media Compartment Figure 4 shows a simplified view of your printer. Depending on installed options, your printer may look slightly different. Figure 4 • Media Compartment 1 9 1 2 3 4 5 6 7 8 9 13163L-001 Rev.
2 Printer Setup This section provides the tasks that you must complete and the issues that you must consider before you load and configure your printer. Contents Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 Printer Setup Before You Begin Before You Begin Review this checklist, and resolve any issues before you set up or use your printer. Unpack and Inspect the Printer Have you unpacked the printer and inspected it for damage? If you have not, see Unpack and Inspect the Printer on page 15. 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 16.
Printer Setup Handling the Printer Handling the Printer This section describes how to handle your printer. Unpack and Inspect the Printer When you receive the printer, immediately unpack it and inspect for shipping damage. • Save all packing materials. • Check all exterior surfaces for damage. • Raise the media door, and inspect the media compartment for damage to components. If you discover shipping damage upon inspection: • Immediately notify the shipping company and file a damage report.
16 Printer Setup Select a Site for the Printer Select a Site for the Printer Consider the following when selecting an appropriate location for your printer. Select a Surface Select a solid, level surface of sufficient size and strength to accommodate the printer and other equipment (such as a computer), if necessary. The choices include a table, countertop, desk, or cart.
Printer Setup Connect the Printer to a Power Source Connect the Printer to a Power Source The AC power cord must have a three-prong female connector on one end that plugs into the mating AC power connector at the rear of the printer. If a power cable was not included with your printer, refer to Power Cord Specifications on page 18. Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation.
18 Printer Setup Connect the Printer to a Power Source Power Cord Specifications 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. Depending on how your printer was ordered, a power cord may or may not be included.
Printer Setup Select a Communication Interface Select a Communication Interface The way that you connect your printer to a data source depends on the communication options installed in the printer. You may use any available connection to send commands and label formats from a host computer to the printer. Caution • Turn Off (O) the printer’s power before connecting data communications cables. Connecting a data communications cable while the power is ON may damage the printer.
20 Printer Setup Select a Communication Interface Types of Connections The method of connecting the printer to a data source depends on the communication options installed in the printer and the host. This section provides basic information about common interfaces. When communicating via the serial data port (RS-232), the baud rate, number of data and stop bits, the parity, and the XON/XOFF or DTR control should be set to match those of the host computer.
Printer Setup Select a Communication Interface IEEE 1284 Bidirectional Parallel A common communication method available on most PCs and other hosts. • Advantages: Fastest of the communication interfaces; cables and connectors are readily available from computer equipment stores and suppliers; two-way communication between the host and the printer; easy to connect. • Disadvantages: Shorter recommended cable length of 6 feet (1.
22 Printer Setup Select a Communication Interface Data 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.
Printer Setup Types of Media Types of Media The printer can use various types of media (Table 4). Zebra strongly recommends 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 prevent premature printhead wear. Table 4 • Types of Media Media Type Non-Continuous Roll Media How It Looks Description Roll media is wound on a 3-in.
24 Printer Setup Types of Media Table 4 • Types of Media (Continued) Media Type How It Looks Description Non-Continuous Fanfold Media Fanfold media is folded in a zigzag pattern. Fanfold media can have the same label divisions as noncontinuous roll media. The divisions would fall on or near the folds. Continuous Roll Media Continuous media is wound on a core and is without gaps, holes, notches, or black marks. This allows the image to be printed anywhere on the label.
Printer Setup Ribbon Overview Ribbon Overview Note • This section applies only to printers that have the Thermal Transfer option installed. Ribbon is a thin film that is coated on one side with wax, resin, 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 ribbon is used, it must be as wide as or wider than the media being used.
26 Printer Setup Ribbon Overview 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 liner. 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.
3 Operations This section provides the procedures for loading and calibrating the printer. Note • Complete the tasks and resolve the issues in Printer Setup on page 13 before operating the printer. Contents Media Loading Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start a Roll of Media. . . . . . . . . . . . . . . . .
28 Operations Media Loading Overview Media Loading Overview The printer can print on roll or fanfold media and use different print modes for label removal. Print Modes The methods for loading media for each print mode follow in this section. Use a print mode that matches the media being used and the printer options available (Table 5). For more information on the types of media, see Types of Media on page 23.
Operations Media Loading Overview Insert Media into the Printer This section shows how to insert roll or fanfold media into the printer. Fanfold media is loaded the same way as roll media, except the media is stored outside of the printer. See Figure 15 on page 31 for an illustration. Note • Depending on the media hanger that came with your printer, the size of the media core that can be used may vary. See Media Specifications on page 145 for the core sizes that your printer supports.
30 Operations Media Loading Overview Fanfold Media To insert fanfold media, complete these steps: 1. Flip down the media supply guide. 2. Thread the fanfold media through the bottom or rear access slot. 3. Drape the media over the media supply hanger. 4. Flip up the media supply guide, and then slide it in until it touches, but does not restrict, the edge of the media. 5. Continue with the media loading procedure for the desired print mode. 13163L-001 Rev.
Operations Load Media in Tear-Off Mode Load Media in Tear-Off Mode Figure 15 shows roll and fanfold media loaded in Tear-Off mode, which is the default print mode. The instructions in this section apply to all printers, including those that have the peel-off, cutter, and rewind options.
32 Operations Load Media in Tear-Off Mode To load media in Tear-Off Mode, complete these steps: 1. Set the printer to Tear-Off mode. See Select Print Mode on page 75 for instructions. 2. Insert media into the printer. See Insert Media into the Printer on page 29 for instructions. 3. Press the printhead release latch to open the printhead assembly. Lift the printhead until it latches open. 4. Slide out the media guide. 13163L-001 Rev.
Operations Load Media in Tear-Off Mode 5. Feed the media under the dancer assembly (1), through the slot in the transmissive sensor (2—standard transmissive sensor shown), and under the ribbon sensor (3). 3 2 1 6. Push the media to the back of the transmissive sensor (1). Slide in the media guide (2) until it just touches the edge of the media. 1 2 7. Close the printhead assembly. 8. If the printer is paused (the Pause light is blinking), press PAUSE to enable printing.
34 Operations Load Media in Peel-Off Mode or Liner Take-Up Mode Load Media in Peel-Off Mode or Liner Take-Up Mode This section applies only if the Peel-Off option or the Liner Take-Up option is installed (Figure 16). Note • The Liner Take-Up option is not available on the Z6Mplus printer. The peel assembly consists of several spring-loaded rollers to ensure the proper roller pressure. Use the peel release lever and your right hand to open and close the peel assembly.
Operations Load Media in Peel-Off Mode or Liner Take-Up Mode 1 2 3 4 5 6 7 8 9 10 11 12 13 Peel lever Tear-off/peel-off bar Printhead assembly Transmissive sensor Media supply guide Media supply hanger Liner take-up spindle Dancer Media guide Printhead release latch Peel assembly Label Label liner To load media in Peel-Off or in Peel-Off with Liner Take-Up mode, complete these steps: 1. Set the printer to Peel-Off mode. See Select Print Mode on page 75 for instructions. 2.
36 Operations Load Media in Peel-Off Mode or Liner Take-Up Mode 6. Feed the media under the dancer assembly (1), through the slot in the transmissive sensor (2—standard transmissive sensor shown), and under the ribbon sensor (3). 3 2 1 7. Push down the peel-off mechanism release lever to open the peel assembly. 8. Pull approximately 18 in. (500 mm) of media through the front of the printer. 13163L-001 Rev.
Operations Load Media in Peel-Off Mode or Liner Take-Up Mode 9. Remove the exposed labels so that only the liner remains. 10. Feed the liner over the tear-off/peel-off bar (1) and behind the peel assembly (2). Make sure that the end of the liner falls outside of the printer. 1 2 11. Push the media to the back of the transmissive sensor (1). Slide in the media guide (2) until it just touches the edge of the media. 1 2 1/18/06 Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
38 Operations Load Media in Peel-Off Mode or Liner Take-Up Mode 12. Close the printhead assembly. 13. Caution • Use the peel release lever and your right hand to close the peel assembly. Do not use your left hand to assist in closing. The top edge of the peel roller/assembly could pinch your fingers. Close the peel assembly using the peel-off mechanism release lever. 14. In which mode do you wish to operate? To operate in... Then...
Operations Load Media in Peel-Off Mode or Liner Take-Up Mode Remove Liner in Peel-Off with Liner Take-up Mode To remove liner when in Peel-Off with Liner Take-Up mode, complete these steps: 1. See Figure 17. Pull the liner slide tab (1) toward you until it stops about a third of the way down the liner take-up spindle (2). Figure 17 • Removing Liner from Liner Take-up Spindle 2 1 2. Slide the liner from the take-up spindle. Note • The liner slide moves back in place after the liner is removed.
40 Operations Load Media in Cutter Mode Load Media in Cutter Mode This section applies only if the Cutter Mode is installed (Figure 18). Figure 18 • Cutter Mode 3 2 1 8 9 4 7 1 2 3 4 5 6 7 8 9 6 5 Printhead assembly Transmissive sensor Media supply guide Media supply hanger Dancer Media guide Printhead release latch Cutter module Catch tray To load media in Cutter-Off Mode, complete these steps: 1. Set the printer to Cutter mode. See Select Print Mode on page 75 for instructions. 2.
Operations Load Media in Cutter Mode 3. Press the printhead release latch to open the printhead assembly. 4. Lift the printhead until it latches open. 5. Slide out the media guide. 1/18/06 Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
42 Operations Load Media in Cutter Mode 6. Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers. Feed the media under the dancer assembly (1), through the slot in the transmissive sensor (2—standard transmissive sensor shown), under the ribbon sensor (3), and through the cutter (4). 4 3 2 1 7. Push the media to the back of the transmissive sensor (1). Slide in the media guide (2) until it just touches the edge of the media. 1 2 13163L-001 Rev.
Operations Load Media in Cutter Mode 8. Close the printhead assembly. 9. If the printer is paused (the Pause light is on), press PAUSE to enable printing. 1/18/06 Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
44 Operations Load Media in Rewind Mode Load Media in Rewind Mode This section applies only if the Rewind option is installed (Figure 19). Follow the instructions in this section to load media in Rewind mode or in Peel-Off with Liner Take-Up mode in a printer with the rewind option. Figure 19 • Rewind Mode and Peel-Off with Liner Take-Up Mode 2 4 3 1 Rewind Mode 14 5 6 13 12 11 2 10 9 7 8 4 3 1 Peel-Off Mode (without rewind or liner take-up) 15 14 5 13 12 13163L-001 Rev.
Operations Load Media in Rewind Mode 2 4 3 1 Peel-Off with Liner Take-Up Mode 15 14 5 6 13 12 1 2 3 4 5 6 7 8 Peel lever Printhead assembly Transmissive sensor Media supply guide Media supply hanger Rewind spindle Rewind media guide Thumbscrew 11 10 8 9 9 10 11 12 13 14 15 7 Dancer Media guide Media alignment spindle Rewind base assembly Printhead release latch Peel assembly Label To load media in a printer that has the Rewind option, complete these steps: 1. Set the printer to Rewind mode.
46 Operations Load Media in Rewind Mode 4. Lift the printhead until it latches open. 5. Slide out the media guide. 6. Feed the media under the dancer assembly (1), through the slot in the transmissive sensor (2—standard transmissive sensor shown), and under the ribbon sensor (3). 3 2 1 7. Push down the peel-off mechanism release lever to open the peel assembly. 13163L-001 Rev.
Operations Load Media in Rewind Mode 8. Pull approximately 18 in. (500 mm) of media through the front of the printer. 9. Remove the exposed labels so that only the liner remains. 10. In which mode do you wish to operate? To operate in... Then... Peel-Off mode (without rewind or liner take-up) 1. Feed the liner over the tear-off/peel-off bar and behind the peel assembly. Make sure that the end of the liner falls outside of the printer. 1 2 1 2 2.
48 Operations Load Media in Rewind Mode To operate in... Then... Peel with Liner Take-Up mode 1. Feed the liner over the tear-off/peel-off bar (1) and behind the peel assembly (2). 1 2 Rewind mode 2. Continue with the next step. 1. Feed the liner over the peel assembly (1). 1 2. Continue with the next step. 11. Feed the liner under the media alignment roller. 12. Loosen the thumbscrew on the rewind media guide. 13163L-001 Rev.
Operations Load Media in Rewind Mode 13. Slide the rewind media guide all the way out, and then fold it down. 14. Slide an empty core onto the rewind spindle. 15. Wrap the liner around the core and turn the rewind spindle counterclockwise to wind up the excess liner. The liner must be attached to the rewind spindle for the printer to operate properly. Ensure that the edge of the liner is flush against the backplate of the rewind spindle. 16.
50 Operations Load Media in Rewind Mode 17. Tighten the thumbscrew on the rewind media guide. 18. Push the media to the back of the transmissive sensor (1). Slide in the media guide (2) until it just touches the edge of the media. 1 2 19. Close the printhead assembly. 20. Close the peel assembly using the peel lever. 21. If the printer is paused (the pause light is on), press PAUSE to enable printing. Peeling starts automatically.
Operations Load Media in Rewind Mode 2. Rotate the take-up spindle counterclockwise until the rewind media guide is fully upright. 3. Loosen the thumbscrew on the rewind media guide. 4. Slide the rewind media guide all the way out, and then fold it down. 5. Slide the core with the liner from the take-up spindle. 1/18/06 Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
52 Operations Load Media in Rewind Mode 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. Perform the adjustments in the order given. Do only what is needed to solve the problem. To adjust the media alignment for printers with the Rewind option, complete these steps: 1.
Operations Load Ribbon Load Ribbon Note • This section applies only to printers that have the Thermal Transfer option installed. 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 narrow ribbon is used or if normal tension hampers the ribbon movement. Note • Always use ribbon that is wider than the media to protect the printhead from wear.
54 Operations Load Ribbon To load ribbon, complete these steps: 1. Set the ribbon supply spindle for normal or low tension. • To place the ribbon supply spindle in the normal position, firmly pull out the spindle end cap until it extends and clicks in place, as shown in Figure 21. Use this setting for most applications. • To place the ribbon supply spindle in the low-tension position, firmly push in the end cap until it retracts and clicks in place, as shown in Figure 21.
Operations Load Ribbon 4. Place the ribbon roll onto the ribbon supply spindle (1) and push it all the way back. 1 5. Pull the end of the ribbon under the printhead assembly (2) and out the front of the printer. 2 6. Close the printhead assembly. 1/18/06 Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
56 Operations Load Ribbon 7. Wind the ribbon clockwise onto the ribbon take-up spindle (3). 3 Remove Used Ribbon Remove used ribbon from the printer after the ribbon runs out or when switching from thermal transfer mode to direct thermal mode. To remove used ribbon, complete these steps: 1. If the ribbon has not run out, cut or break it before the ribbon take-up spindle (1). Caution • Do not cut the ribbon directly on the ribbon take-up spindle. Doing so may damage the spindle. 1 13163L-001 Rev.
Operations Load Ribbon 2. To loosen the ribbon, squeeze the ribbon against the ribbon take-up spindle tension blades (1). At the same time, turn the ribbon take-up spindle release knob counterclockwise (2). The tension blades collapse into the ribbon take-up spindle, loosening the ribbon. 1 2 3. Slide the ribbon off of the ribbon take-up spindle. 1/18/06 Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
58 Operations Calibrate the Printer Calibrate the Printer Auto Calibration By default, the printer automatically calibrates on power up or when the printhead is closed. During auto calibration, the printer determines the label length and sensor settings. 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.
Operations Position the Media Sensors Position the Media Sensors This printer uses two types of media sensors: transmissive and reflective. Select or Position the Transmissive Sensor The standard transmissive sensor (Figure 22) is in a fixed position and enabled from the control panel. An adjustable transmissive sensor, which is available as an option for the Z4Mplus or Z6Mplus, can be adjusted for optimal print performance.
60 Operations Position the Media Sensors Figure 23 • Transmissive Sensor with Adjustment Tab Pointer 1 1 2 1 2 3 3 Positioning marks Adjustment tab pointer (outer position) Adjustment tab pointer (inner position) To adjust the transmissive sensor, complete these steps: 1. Press the printhead open lever to release the printhead assembly. 2. See Figure 22. Locate the transmissive sensor. 3. Locate the white adjustment tab pointer on the back of the transmissive sensor. 4.
Operations Position the Media Sensors Adjust the Reflective Sensor The reflective sensor is compatible with most types of media. With non-continuous media, the reflective sensor detects the start-of-label indicator (the notch, hole, black mark, or gap between die-cut labels). With both continuous media and non-continuous media, the sensor detects an out-of-paper condition.
62 Operations Position the Media Sensors To adjust the reflective sensor, complete these steps: 1. See Figure 24. Press the printhead release latch. 2. Lift the printhead until it latches open. 3. Locate the reflective sensor positioning lever. 4. Move the reflective sensor positioning lever across the width of the media until the reflective sensor aligns with the gap or notch. 5. Close the printhead assembly. 13163L-001 Rev.
Operations Adjust Printhead Pressure Adjust Printhead Pressure You may need to adjust printhead pressure if printing is too light on one side or if you use thick media. See Figure 25. The Z4Mplus pressure adjustment dials 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.
64 Operations Adjust Printhead Pressure Table 7 • Z6Mplus Printhead Pressure Media Width Inside Dial Outside Dial 2 in. (50 mm) 6 1 3 in. (75 mm) 6 2 4 in. (100 mm) 7 3 5 in. (125 mm) 7 4 5.5 in. and up (140 mm and up) 6 6 2. If necessary, adjust the pressure adjustment dials as follows: 13163L-001 Rev. A If the media... Then... Requires higher pressure to print well Increase both dials one position.
Operations Install Memory Card Install Memory Card The printer can use Type I or Type II compliant Personal Computer Memory Card International Association (PCMCIA) cards. 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.
66 Operations Install Memory Card Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ________________________
4 Configuration This section describes the control panel parameters that are used to configure the printer for operation. Contents Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68 Configuration Setup Mode Setup Mode After you have installed the media and ribbon and the Power-On Self Test (POST) is complete, the control panel displays PRINTER READY. You may now set printer parameters for your application using the control panel display and the buttons directly below it. If it becomes necessary to restore the initial printer defaults, see FEED and PAUSE Self Test on page 132.
Configuration Setup Mode Exit Setup Mode To leave Setup mode, complete these steps: 1. Press SETUP/EXIT. The LCD displays SAVE CHANGES. 2. Press PLUS (+) or MINUS (-) to display the save options (Table 8). Table 8 • Save Options When Leaving Setup Mode LCD Description PERMANENT Stores values in the printer even when power is turned off. TEMPORARY Saves the changes until power is turned off.
70 Configuration Change Password-Protected Parameters Change Password-Protected Parameters Certain parameters, including the communication parameters, are password-protected by factory default. Caution • Do not change password-protected parameters unless you have a complete understanding of the parameters’ functions. If the parameters are set incorrectly, the printer may function unpredictably. The first time that you attempt to change a password-protected parameter, the printer displays ENTER PASSWORD.
Configuration Print a Configuration Label Print a Configuration Label A configuration label lists the printer settings that are stored in configuration memory. After you load the media and ribbon (if necessary), print a configuration label as a record of your printer’s current settings. Keep the label to use when troubleshooting printing problems. To print a configuration label, complete these steps: 1. On the control panel, press SETUP/EXIT. 2.
72 Configuration Print a Network Configuration Label Print a Network Configuration Label If you are using a print server, you can print a network configuration label after the printer is connected to the network. To print a network configuration label, complete these steps: 1. On the control panel, press SETUP/EXIT. 2. Press NEXT or PREVIOUS to scroll through the parameters until you reach LIST NETWORK. 3. Press the right oval to confirm printing. A network configuration label prints (Figure 28).
Configuration Control Panel LCD Displays Control Panel LCD Displays Use the LCD display on the control panel to adjust printer settings. Table 9 shows parameters in the order in which they are displayed when you press PLUS (+) after entering Setup mode. Table 10 on page 96 shows the additional parameters that appear when a wired or wireless print server is installed in the printer.
74 Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 2 of 23) Parameter PRINT SPEED 2 IPS Action/Explanation + Adjust Print Speed Adjusts the speed for printing a label (given in inches per second). Slower print speeds typically yield better print quality. Print speed changes take effect upon exiting Setup mode. Default: 2 IPS Range: 2 to 10 IPS To change the value shown: 1. 2. 3. 4. TEAR OFF - +000 + Press SELECT to select the parameter.
Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 3 of 23) Parameter PRINT MODE -TEAR-OFF Action/Explanation + Select Print Mode Print mode settings tell the printer the method of media delivery that you wish to use. Make sure that your printer can support the selected option. Default: TEAR-OFF Selections: TEAR-OFF, PEEL-OFF, CUTTER, REWIND To change the value shown: 1. Press SELECT to select the parameter. 2. Press PLUS (+) or MINUS (-) to scroll through the options. 3.
76 Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 4 of 23) Parameter SENSOR SELECT -AUTO SELECT Action/Explanation + Select a Sensor This parameter tells the printer the sensor that you wish to use. AUTO SELECT is compatible with most types of media. Select the reflective sensor with continuous media or with non-continuous black mark media; select the transmissive sensor if you are using non-continuous web media.
Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 5 of 23) Parameter PRINT WIDTH - 104 0/8 MM Action/Explanation + Set Print Width Determines the printable area across the width of the label given the resolution of the printer. Default: 104 0/8 MM Note • Setting the width too narrow can result in portions of the label not being printed on the media. Setting the width too wide wastes formatting memory and can cause printing off the label and on the platen roller.
78 Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 6 of 23) Parameter MAXIMUM LENGTH -39.0 IN 988 MM Action/Explanation Set Maximum Label Length This parameter is used during the media portion of the calibration process. Always set maximum label length to a value that is at least 1.0 in. (25.4 mm) greater than the actual label length (Figure 30).
Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 7 of 23) Parameter LIST FONTS PRINT Action/Explanation List Fonts This option prints a label that lists the available fonts in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM, Flash memory, optional PCMCIA font cards, or Compact Flash cards. To print a list of the available fonts: 1. Press SELECT to select the parameter. 2. Press PLUS (+) to select PRINT. 3.
80 Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 8 of 23) Parameter LIST SETUP PRINT Action/Explanation List Setup This option prints a configuration label (see Figure 27 on page 71), which lists the current printer configuration. To print a configuration label: 1. Press SELECT to select the parameter. 2. Press PLUS (+) to select PRINT. 3. Press SELECT to accept any changes and deselect the parameter.
Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 9 of 23) Parameter FORMAT CARD: A: Action/Explanation B: Format Memory Card This option erases all previously stored information from the optional PCMCIA card or Compact Flash card. Caution • This option completely erases the selected card. To format a memory card: 1. Press SELECT to select the parameter. 2. Press MINUS (-) to select A: or PLUS (+) to select B:.
82 Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 10 of 23) Parameter INIT FLASH MEM. YES Action/Explanation Initialize Flash Memory This option erases all previously stored information from Flash memory. Caution • This option completely erases the Flash memory. To initialize Flash memory: 1. Press SELECT to select the parameter. 2. Press PLUS (+) to select YES. If your printer is set to require a password, you are prompted to enter the password. 3. Enter the password.
Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 11 of 23) Parameter SENSOR PROFILE PRINT Action/Explanation Print Sensor Profile The sensor profile may be used to troubleshoot registration problems that may be caused when the media sensor detects preprinted areas on the media or if it experiences difficulty in determining web location. Figure 31 shows a sensor profile.
84 Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 12 of 23) Parameter MEDIA AND RIBBON CALIBRATE Action/Explanation Calibrate Media and Ribbon Sensor Sensitivity Use this procedure to adjust sensitivity of media and ribbon sensors. Important • Follow this procedure exactly as presented. All of the steps must be performed even if only one of the sensors requires adjustment. You may press MINUS (-) at any step in this procedure to cancel the process.
Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 13 of 23) Parameter PARALLEL COMM. -BIDIRECTIONAL Action/Explanation + Set Parallel Communications Select the communications port that matches the one being used by the host computer. Default: BIDIRECTIONAL Selections: BIDIRECTIONAL, UNIDIRECTIONAL To change the value shown: 1. Press SELECT to select the parameter. 2. Press PLUS (+) or MINUS (-) to scroll through the options. 3.
86 Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 14 of 23) Parameter Action/Explanation Set 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 • Code Page 850 requires the data bits to be set to 8 bits. See the ZPL II Programming Guide for more information.
Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 15 of 23) Parameter PROTOCOL NONE Action/Explanation + Set 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.
88 Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 16 of 23) Parameter COMMUNICATIONS - NORMAL MODE Action/Explanation + Set Communications Mode 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 prints as straight ASCII characters, with the hex value below the ASCII text.
Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 17 of 23) Parameter FORMAT PREFIX <^>5EH Action/Explanation + Set Format Prefix Character The format prefix is a two-digit hex value used as a parameter place marker in ZPL/ZPL II format instructions. The “H” that is displayed indicates Hexadecimal and is not part of the value. The printer looks for this hex character to indicate the start of a ZPL/ZPL II format instruction.
90 Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 18 of 23) Parameter ZPL MODE ZPL II Action/Explanation + Select ZPL Mode The printer remains in the selected mode until it is changed by this parameter or by using a ZPL/ZPL II command. The printer accepts label formats written in either ZPL or ZPL II, eliminating the need to rewrite any ZPL formats that already exist. See the ZPL II Programming Guide for more information on the differences between ZPL and ZPL II.
Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 19 of 23) Parameter HEAD CLOSE - CALIBRATION Action/Explanation + Select Head Close Option This parameter sets the action of the media when you close the printhead. Default: CALIBRATION Selections: FEED, CALIBRATION, LENGTH, and NO MOTION • Feed—feeds the labels to the first registration point. • Calibration—determines the length of the label and adjusts the sensor settings.
92 Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 20 of 23) Parameter LABEL TOP +000 - Action/Explanation + Adjust Label Top Position This parameter adjusts the print position vertically on the label. Positive numbers adjust the label top position farther down the label (away from the printhead); negative numbers adjust the position up the label (toward the printhead). The displayed value represents dots.
Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 21 of 23) Parameter Action/Explanation WEB S. - 073 MEDIA S. - 075 RIBBON S. - 071 To skip these parameters: + - 1. Press PLUS (+) repeatedly. + + MEDIA LED - 082 RIBBON LED - 008 LCD ADJUST - + These parameters are automatically set during the calibration procedure and should be changed only by a qualified service technician. Refer to the ZPL II Programming Guide for information on these parameters.
94 Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 22 of 23) Parameter IDLE DISPLAY - FW VERSION Action/Explanation + Select Idle Display This parameter selects the LCD options for the real-time clock. Note • If the default value is not selected, pressing PLUS (+) or MINUS (-) briefly displays the firmware version of the printer.
Configuration Control Panel LCD Displays Table 9 • Printer Parameters (Page 23 of 23) Parameter LANGUAGE ENGLISH Action/Explanation Select the Display Language This parameter changes the language displayed on the LCD. Default: ENGLISH Selections: ENGLISH, SPANISH, FRENCH, GERMAN, ITALIAN, NORWEGIAN, PORTUGUESE, SWEDISH, DANISH, SPANISH 2, DUTCH, FINNISH, JAPAN To change the value shown: 1. Press SELECT to select the parameter. 2. Press PLUS (+) or MINUS (-) to scroll through the options. 3.
96 Configuration Control Panel LCD Displays Print Server LCD Displays The menu options shown in Table 10 display only if you have a print server installed. Table 10 • Print Server Parameters (Page 1 of 5) Parameter LOAD LAN FROM? PRINTER Action/Explanation Load LAN Source1 This parameter, which serves the same function as the ^NP ZPL command, specifies whether to use the printer’s or the print server’s IP settings at bootup.
Configuration Control Panel LCD Displays Table 10 • Print Server Parameters (Page 2 of 5) Parameter IP PROTOCOL ALL Action/Explanation Specify IP Protocol2 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.
98 Configuration Control Panel LCD Displays Table 10 • Print Server Parameters (Page 3 of 5) Parameter DEFAULT GATEWAY 000.000.000.000 Action/Explanation Specify Default Gateway2 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. To change the value shown: 1. 2. 3. 4. Press SELECT to select the parameter. Press MINUS (–) to move the cursor. Press PLUS (+) to increase the value of the digit.
Configuration Control Panel LCD Displays Table 10 • Print Server Parameters (Page 4 of 5) Parameter ENCRYPTION MODE OFF Action/Explanation Select Encryption Mode1,3 Select whether to use 40-bit encryption, 128-bit encryption, or no encryption. Important • If using encryption, use the ^WE ZPL command to set the value for the active encryption key. Failure to do so can disable the wireless system. For more information, see the Wireless Print Server User Guide.
100 Configuration Control Panel LCD Displays Table 10 • Print Server Parameters (Page 5 of 5) Parameter RESET NETWORK YES Action/Explanation Reset Network2,3 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 SELECT to select the parameter. 2.
5 Routine Maintenance This section provides routine cleaning and maintenance procedures. Contents Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Printhead and Platen Roller.
102 Routine Maintenance Lubrication Lubrication No lubrication is needed for this printer. Caution • Some commercially available lubricants will damage the finish and the mechanical parts if used on this printer. Cleaning Procedures Important • Zebra is not responsible for damage caused by the use of cleaning fluids on this printer. Specific cleaning procedures are provided on the following pages. Table 11 shows the recommended cleaning schedule. .
Routine Maintenance 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 or ribbon across the printhead wears through the protective ceramic coating, exposing and eventually damaging the print elements (dots). To avoid abrasion: • Clean the printhead frequently, and use well-lubricated thermal transfer ribbons with backings optimized to reduce friction.
104 Routine Maintenance Cleaning Procedures Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. To clean the printhead and platen roller, complete these steps: 1. Open the printhead assembly. 2. Remove the media and ribbon. 3. Using the swab from the Preventive Maintenance Kit (part number 47362) or a solution of 90% Isopropyl alcohol and 10% deionized water and a cotton swab, wipe along the brown strip on the printhead assembly from end to end.
Routine Maintenance Cleaning Procedures Clean the Media Compartment and Sensors To clean the media compartment and sensors, complete these steps: 1. Brush or vacuum any accumulated paper lint and dust away from the media and ribbon paths. 2. Brush or vacuum any paper lint and dust away from the sensors (see Figure 33). Figure 33 • Cleaning the Sensors 2 3 1 4 1 2 3 4 1/18/06 Take-label sensor Ribbon sensor Transmissive sensor Reflective sensor Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
106 Routine Maintenance Cleaning Procedures Clean the Rewind Option The Rewind option is required. Refer to Figure 34 and perform the following procedure if adhesive buildup begins to affect peel performance. Figure 34 • Cleaning the Rewind Option 1 2 3 4 1 2 3 4 Printhead Assembly Tear-Off/Peel-Off Bar Pinch Roller Peel Assembly To clean the Rewind option, complete these steps: 1. Open the printhead assembly. 2. Close the peel assembly to prevent bending the tear-off/peel-off bar during cleaning.
Routine Maintenance Cleaning Procedures Clean the Peel-Off Assembly The Peel-Off option is required. The Peel assembly consists of several spring-loaded rollers to ensure the proper roller pressure. Use the peel release lever and your right hand to open and close the Peel assembly. Doing this will keep your fingers away from the rollers. Caution • Do not use your left hand to assist in closing the Peel assembly. The top edge of the Peel roller/assembly could pinch your fingers.
108 Routine Maintenance Cleaning Procedures 5. While manually rotating the pinch roller, clean it thoroughly with the swab from the Preventive Maintenance Kit (part number 47362) or a solution of 90% Isopropyl alcohol and 10% deionized water and a cotton swab. Allow the solvent to evaporate. 6. Use the swab to remove excess adhesive from the tear-off/peel-off bar. Allow the solvent to evaporate. Important • Apply minimum force when cleaning the tear-off/peel-off bar.
Routine Maintenance Cleaning Procedures 8. Caution • Use the peel release lever and your right hand to close the peel assembly. Do not use your left hand to assist in closing. The top edge of the peel roller/assembly could pinch your fingers. Close the peel assembly using the peel-off mechanism release lever. 9. Close the media door. The printer is ready to operate. 1/18/06 Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
110 Routine Maintenance Cleaning Procedures Clean the Cutter Module If the cutter is not cutting the labels cleanly or if it jams with labels, clean the cutter. Caution • For personnel safety, always power off and unplug the printer before performing this procedure. To clean the cutter module, complete these steps: 1. Turn the printer Off (O), and unplug the printer from its power source. 2. Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers.
Routine Maintenance Cleaning Procedures 6. Replace the cutter shield. 7. Plug the printer into its power source, and then turn On (I) the printer. The lower cutter blade returns to its correct operating position. 8. If the cutter continues to perform unsatisfactorily, contact an authorized service technician. 1/18/06 Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
112 Routine Maintenance Fuse Replacement 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. Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following maintenance. Figure 36 • Replacing the Fuse 4 3 2 1 1 2 3 4 Slot Fuse holder Fuse Fuse socket To replace the fuse, complete these steps: 1. See Figure 36.
6 Troubleshooting This section provides information about errors that you might need to troubleshoot. Assorted diagnostic tests are included. Contents Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114 Troubleshooting Troubleshooting Checklists Troubleshooting Checklists If an error condition exists with the printer, review this checklist: Is there an error message on the LCD? If yes, see LCD Error Messages on page 115. Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media and Ribbon Sensor Sensitivity on page 84.
Troubleshooting LCD Error Messages LCD Error Messages The LCD displays messages when there is an error. See Table 12 for LCD errors, the possible causes, and the recommended solutions. Table 12 • LCD Error Messages LCD Display/ Printer Condition ERROR CONDITION RIBBON OUT The printer stops; RIBBON light ON, ERROR light flashes. Possible Cause Recommended Solution In thermal transfer mode, ribbon is not loaded or incorrectly loaded. Load ribbon correctly. See Load Ribbon on page 53.
116 Troubleshooting LCD Error Messages Table 12 • LCD Error Messages (Continued) LCD Display/ Printer Condition WARNING RIBBON IN Possible Cause Recommended Solution Ribbon is loaded, but the printer is set for direct thermal mode. Ribbon is not required with direct thermal media. If you are using direct thermal media, remove ribbon unless you are using it to protect the printhead. This error message will not affect printing. RIBBON light ON, ERROR light flashes.
Troubleshooting LCD Error Messages Table 12 • LCD Error Messages (Continued) LCD Display/ Printer Condition WARNING HEAD COLD The printer stops and the ERROR light flashes. Possible Cause Recommended Solution Caution • An improperly connected printhead data or power cable can cause this error message. The printhead may be hot enough to cause severe burns. Allow the printhead to cool. The printhead is under temperature. The printhead data cable is not properly connected.
118 Troubleshooting Print Quality Problems Print Quality Problems Table 13 identifies problems with print quality, the possible causes, and the recommended solutions. Table 13 • Print Quality Problems Problem Possible Cause Recommended Solution General print quality issues The printer is set at the incorrect print speed. For optimal print quality, set the print speed to the lowest possible setting for your application via control panel, the driver, or the software. See Adjust Print Speed on page 74.
Troubleshooting Print Quality Problems Table 13 • Print Quality Problems (Continued) Problem Possible Cause Recommended Solution Fine, angular gray lines on blank labels Wrinkled ribbon. See wrinkled ribbon causes and solutions in this table. Printing too light or too dark over the entire label Media or ribbon is not designed for high-speed operation. Replace supplies with those recommended for high-speed operation. You are using an incorrect combination of labels and ribbon for your application.
120 Troubleshooting Print Quality Problems Table 13 • Print Quality Problems (Continued) Problem Possible Cause Recommended Solution Vertical drift in top-of-form position Normal tolerances of mechanical parts and printer modes. Note • A vertical drift of ± 4 to 6 dot rows (approximately 0.5 mm) is within normal tolerances. 1. Calibrate the printer. 2. Adjust the label top position setting. See Adjust Label Top Position on page 92. The printer is out of calibration. Recalibrate the printer.
Troubleshooting Calibration Problems Calibration Problems Table 14 identifies problems with calibration, the possible causes, and the recommended solutions. Table 14 • Calibration Problems Problem Possible Cause Recommended Solution Loss of printing registration on labels. Excessive vertical drift in top-of-form registration. Improperly positioned media guides. Ensure that the media guides are properly positioned. Media type set incorrectly.
122 Troubleshooting Communications Problems Communications Problems Table 15 identifies problems with communications, the possible causes, and the recommended solutions. Table 15 • Communications Problems Problem Possible Cause Recommended Solution A label format was sent to the printer but was not recognized. The DATA light does not flash. The communication parameters are incorrect. Check the printer driver or software communications settings (if applicable).
Troubleshooting Miscellaneous Printer Problems Miscellaneous Printer Problems Table 16 identifies miscellaneous problems with the printer, the possible causes, and the recommended solutions. Table 16 • Miscellaneous Printer Problems Problem Possible Cause Recommended Solution The LCD displays a language that I cannot read The language parameter was changed through the control panel or a ZPL command. 1. Press SETUP/EXIT to enter configuration mode. 2. Press MINUS (-).
124 Troubleshooting Miscellaneous Printer Problems Table 16 • Miscellaneous Printer Problems (Continued) Problem Possible Cause Recommended Solution The printer fails to calibrate or detect the top of the label. The printer was not calibrated for the label being used. Perform the calibration procedure in Calibrate Media and Ribbon Sensor Sensitivity on page 84. The printer is configured for continuous media. Set the media type to noncontinuous media. See Set Media Type on page 75.
Troubleshooting Printer Diagnostics Printer Diagnostics Self tests and other diagnostics provide specific information about the condition of the printer. The self tests produce sample printouts and provide specific information that helps determine the operating conditions for the printer. The most commonly used are the Power-On and the CANCEL self tests. Important • Use full-width media when performing self tests. If your media is not wide enough, the test labels may print on the platen roller.
126 Troubleshooting Printer Diagnostics CANCEL Self Test The CANCEL self test prints a configuration label (Figure 37). To perform the CANCEL Self Test, complete these steps: 1. Turn Off (O) the printer. 2. Press and hold CANCEL while turning the printer On (I). Hold CANCEL until the first control panel light turns off. A printer configuration label prints (Figure 37). Figure 37 • Configuration Label 13163L-001 Rev.
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 to determine if any printhead elements are not working. Figure 38 shows a sample printout. To perform a PAUSE self test, complete these steps: 1. Turn Off (O) the printer. 2. Press and hold PAUSE while turning the power On (I). Hold PAUSE until the first control panel light turns off.
128 Troubleshooting Printer Diagnostics FEED Self Test Different types of media may require different darkness settings. This section contains a simple but effective method for determining the ideal darkness for printing bar codes that are within specifications. During the FEED self test, labels are printed at different darkness settings at two different print speeds. The relative darkness and the print speed are printed on each label.
Troubleshooting Printer Diagnostics Figure 39 • FEED Test Label 4. See Figure 40 and Table 17. Inspect the test labels and determine which one has the best print quality for your application. If you have a bar code verifier, use it to measure bars/spaces and calculate the print contrast. If you do not have a bar code verifier, use your eyes or the system scanner to choose the optimal darkness setting based on the labels printed in this self test. 1/18/06 Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
130 Troubleshooting Printer Diagnostics Figure 40 • Bar Code Darkness Comparison Table 17 • Judging Bar Code Quality 13163L-001 Rev. A Print Quality Description Too dark Labels that are too dark are fairly obvious. They may be readable but not “in-spec.” • The normal bar code bars increase in size. • The openings in small alphanumeric characters may fill in with ink. • Rotated bar code bars and spaces run together. Slightly dark Slightly dark labels are not as obvious.
Troubleshooting Printer Diagnostics Table 17 • Judging Bar Code Quality (Continued) Print Quality Description “In-spec” The “in-spec” bar code can only be confirmed by a verifier, but it should exhibit some visible characteristics. • The normal bar code will have complete, even bars and clear, distinct spaces. • The rotated bar code will have complete, even bars and clear, distinct spaces. Although it may not look as good as a slightly dark bar code, the bar code will be “in-spec.
132 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. If the factory default values are permanently saved, a media calibration procedure must be performed. To perform a FEED and PAUSE self test, complete these steps: 1. Turn Off (O) the printer. 2.
7 Data Ports This section describes the standard communication ports available to connect the printer to your computer or network. Contents Parallel Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel Cabling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel Port Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 Data Ports Parallel Data Port Parallel Data Port The parallel data interface supports IEEE 1284 bidirectional parallel communications in nibble mode. The parallel interface provides a means of communication that typically is faster than the 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.
Data Ports Parallel Data Port Table 18 • Parallel Cable Pin Configuration (Continued) 36-Pin Connectors 31 nInit 32 nFault/NDataAvail 33, 34 1/18/06 Description Not used 35 +5 V through a 1.8 KΩ Resistor 36 NSelectin/1284 active Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
136 Data Ports Serial Data Port Serial Data Port See RS-232 Serial on page 20 for basic cabling information. To communicate using the serial data port of the printer, you must choose the number of data bits, parity, and handshaking. Parity applies only to data transmitted by the printer because the parity of received data is ignored. The values selected must be the same as those used by the host equipment connected to the printer.
Data Ports Serial Data Port Pin Configuration Connect the serial data cable to the female DB-9 connector on the back of the printer. For all RS-232 connections through a DB-25 cable, use a DB-9 to DB-25 interface module (see DB-9 to DB-25 Connections on page 139). Note • Adapters are available from Zebra Technologies LLC. • RS-422/RS-485 adapter, Zebra part number 33114M • RS-232 DB-9 to DB-25 adapter, Zebra part number 33109M Table 19 shows the pin configuration of the serial data connector.
138 Data Ports Serial Data Port RS-232 Interface Connections The printer is configured as Data Terminal Equipment (DTE). Figure 42 shows the internal connections of the printer’s RS-232 connector. Note • Use a null modem (crossover) cable to connect the printer to a computer or any other DTE device.
Data Ports Serial Data Port DB-9 to DB-25 Connections To connect the printer’s RS-232 DB-9 interface to a DB-25 connector, an interface adapter is required (Zebra part number 33109M). A generic DB-25 adapter can be used, although the +5 VDC signal source would not be passed through the adapter. Figure 44 shows the connections required for the DB-9 to DB-25 interface.
140 Data Ports Serial Data Port Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________
8 Specifications This section provides the features of and specifications for the printer. Contents General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Specifications . . . . . . . . . .
142 Specifications General Specifications General Specifications General Specifications Z4Mplus Height 13.3 in. 338 mm 13.3 in. 338 mm Width 10.9 in. 277 mm 13.4 in. 341 mm Depth 18.7 in. 475 mm 18.7 in. 475 mm Weight (without options) 32.4 lbs. 14.7 kg 34.7 lbs.
Specifications Agency Approvals Agency Approvals 1/18/06 Agency Approvals • • • • IEC 60950-1 EN55022 Class B EN55024 EN61000-3-2,3 Product Markings • • • • • • • • • • • • • cULus CE Marking FCC-B ICES-003 VCCI C-Tick NOM CCC GOST-R BSMI S-Mark (Argentina) MIC ZIK Z4Mplus/Z6Mplus User Guide 13163L-001 Rev.
144 Specifications Printing Specifications Printing Specifications Printing Specifications Z4Mplus Print resolution 203 dots/inch 8 dots/mm 203 dots/inch 8 dots/mm 300 dots/inch 12 dots/mm 300 dots/inch 12 dots/mm 203 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 300 dpi 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 203 dpi 4.09 in. 104 mm 6.6 in. 168 mm 300 dpi 4.1 in.
Specifications Media Specifications Media Specifications Media Specifications Label length Minimum Z4Mplus Z6Mplus Tear-off 0.5 in.* 13 mm* 0.5 in. 13 mm Peel-off 1 in.* 25.4 mm* 1 in. 25.4 mm Rewind 0.5 in.* 13 mm* 0.5 in. 13 mm Cutter 1 in.* 25.4 mm* 1.5 in. 38.1 mm RFID “smart” labels Varies for each transponder type N/A. RFID is not available for the Z6Mplus. Tear/Cutter/ Peel/Rewind 39 in. 39 in. RFID “smart” labels Varies for each transponder type N/A.
146 Specifications Media Specifications Media Specifications Z4Mplus Z6Mplus 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 > 0.37 in. > 9.5 mm > 0.37 in. > 9.5 mm Location 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) from the media inner edge Density, in Optical Density Units (ODU) > 1.0 ODU Maximum media density < 0.
Specifications Ribbon Specifications Ribbon Specifications Note • This section applies only to printers that have the Thermal Transfer option installed. Ribbon must be wound with the coated side out. Ribbon Specifications Z4Mplus Z6Mplus Ribbon width (Zebra recommends using ribbon at least as wide as the media to protect the printhead from wear.) Minimum >2 in.* 51 mm* >2 in. 51 mm Maximum 4.3 in. 109 mm 6.9 in. 174 mm Standard lengths 2:1 media to ribbon roll ratio 984 ft.
148 Specifications Printer Options Printer Options Option Z4Mplus Z6Mplus Cutter X X Peel-off X X Liner take-up X Not available PCMCIA card socket (supports linear Flash memory and ATA formats) X X Linear Flash memory card 8 MB, 16 MB, and 32 MB X X Compact Flash 32 MB, 64 MB, 128 MB, and 256 MB X X 300 dpi printhead X X Rewind X X Adjustable transmissive sensor X X External print server (10/100 or 10base-T) X X Internal print server (10base-T) X X Wireless print server
Specifications ZPL II Features ZPL II Features ZPL II Features • Bit image data transfer and printing, mixed text/graphics • Mirror-image printing • Communicates in printable ASCII characters • Object copying between memory areas (RAM, memory card, and internal Flash) • Controlled via mainframe, mini-computer, PC, portable data terminal • Programmable quantity with print, pause, and cut control • Data compression • Serialized fields • Downloadable graphics, scalable and bitmap fonts, and label for
150 Specifications Supported Bar Codes Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ___________________
Index A C adhesive test for ribbon coating, 26 adjustments LCD, 93 left position, 92 media alignment for rewind, 52 print darkness, 73 printhead pressure, 63 reflective sensor, 61 tear-off position, 74 agency approvals, 143 authentication type, 98 auto calibration, 58 cable requirements, 22 calibration media and ribbon sensor, 84 setting for head close, 91 setting for media power up, 90 troubleshooting problems, 121 Canadian DOC compliance, iv CANCEL button CANCEL self test, 126 description, 10 checklis
152 Index configuration changing parameters, 73 enter Setup mode, 68 exit Setup mode, 69 configuration label printing using CANCEL self test, 126 printing using List Setup command, 80 connect to power source, 17 contacts, 3 continuous media described, 24 setting media type, 75 control panel buttons described, 10 enter Setup mode, 68 exit Setup mode, 69 LCD error messages, 115 LCD parameters, 73 lights described, 11 location, 8 overview and illustration, 9 control prefix setting, 88 customer service, 3 cut
Index I idle display setting, 94 images list, 79 initialize Flash memory, 82 initialize memory card, 81 inspect for shipping damage, 15 install memory card, 65 interfaces IEEE 1284 bidirectional parallel, 21 print servers, 21 RS-232 serial, 20 international safety organization marks, 18 IP settings default gateway, 98 IP address, 97 protocol, 97 subnet mask, 97 L label length maximum setting, 78 label sensor positioning, 59 label top printer cannot detect, 124 setting, 92 labels did not print, 122 languag
154 Index N network configuration label printing, 72 printing using List Network command, 80 network ID setting, 87 non-continuous media described, 23 setting media type, 75 O operating conditions, 16 optional print servers, 21 options, 148, 149 ordering ribbon and media, 3 OUT OF MEMORY message, 117 P PAPER OUT message, 116 parallel port cabling requirements, 134 overview, 21 pin configuration, 134 setting parallel communications, 85 settings, 134 parity setting, 86 passwords default, 70 disable, 70 en
Index printer settings backfeed, 91 baud, 85 control prefix, 88 data bits, 86 date, 94 delimiter character, 89 format convert, 93 format prefix, 89 host handshake, 86 idle display, 94 IP settings, 96 label top, 92 language, 95 LCD, 93 left position, 92 maximum label length, 78 media type, 75 network configuration label as baseline, 72 network ID, 87 parallel communications, 85 parity, 86 print darkness, 73 print method, 76 print server settings, 96 print width, 77 protocol, 87 saving, 69 serial communicati
156 Index sensors reflective, 61 sensor profile, 83 sensor selection, 76 transmissive sensor location, 59 serial port pin configuration, 137 setting serial communications, 85 settings, 136 setup checklist, 14 unpack the printer, 15 Setup mode enter Setup mode, 68 exit Setup mode, 69 LCD messages, 73 passwords, 70 shipping report damage, 15 reshipping the printer, 15 “smart” labels, 24 spacing requirements, 16 specifications agency approvals and markings, 143 general, 142 media, 145 power cord, 18 printing
Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.A. Telephone: +1 847.793.2600 Facsimile: +1 847.913.
