and User Guide
© Copyright 2003 ZIH Corp. This copyrighted guide and the label printers described herein are owned by Zebra Technologies Corporation. All rights are reserved. Unauthorized reproduction of the guide or the software 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. IBM® is a registered tradement of IBM Corporation and TrueType® is a registered trademark of Apple Computer, Inc.
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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 propriety information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Corporation.
FCC Compliance Statement Note: This equipment has been tested and found to comply with the limits for a Class B Digital Device, 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.
Copyrights The copyrights in this manual and the label printer described therein are owned by Zebra Technologies Corporation. All rights are reserved. Unauthorized reproduction of this manual or the software 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. All trademarks and registered trademarks are property of their respective owners. Copyright 2003 ZIH Corp. All rights reserved.
viii Z4Mplus and Z6Mplus User Guide
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.
x Z4Mplus and Z6Mplus User Guide
Warranty Information Effective November 1, 2001 All Zebra Technologies Corporation products are sold with warranties. Following is some general information: Printer Products Printers. All printers (excluding printheads) are warranted against defect in material or workmanship for twelve (12) months from the purchase date. Proof of purchase or shipment date is required to validate the warranty period.
Printer Products product returned for warranty service or replacement is not defective as herein defined, the customer will pay all handling and transportation costs. 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.
Printer Products 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.
Printer Software and Firmware License Agreement Zebra Link License Agreement Printer Software and Firmware License Agreement YOU SHOULD CAREFULLY READ THE FOLLOWING TERMS AND CONDITIONS OF THIS ZEBRA TECHNOLOGIES CORPORATION PRINTER SOFTWARE AND FIRMWARE LICENSE AGREEMENT (“PSFLA”) BEFORE USING THE PRINTER WHICH IS ENCLOSED OR OTHERWISE ASSOCIATED WITH THIS AGREEMENT.
Printer Software and Firmware License Agreement • Storage/Network Use. You may also store or install a copy of the SOFTWARE and FIRMWARE on a storage device, such as a network server, used only to RUN the SOFTWARE and FIRMWARE on your other PRINTERS over an internal network; however, you must acquire and dedicate a license for each separate PRINTER on which the SOFTWARE and FIRMWARE is RUN from the storage device.
Printer Software and Firmware License Agreement • Replacement, Modification and Upgrade of the SOFTWARE and/or FIRMWARE. ZEBRA reserves the right to replace, modify or upgrade the SOFTWARE and/or FIRMWARE at any time by offering you a replacement or modified version of the SOFTWARE and/or FIRMWARE or such upgrade and to charge for such replacement, modification or upgrade.
Printer Software and Firmware License Agreement 6. U.S. GOVERNMENT RESTRICTED RIGHTS. All SOFTWARE and/or FIRMWARE provided to the U.S. Government pursuant to solicitations issued on or after December 1, 1995 is provided with the commercial rights and restrictions described elsewhere herein. All SOFTWARE and/or FIRMWARE provided to the U.S. Government pursuant to solicitations issued prior to December 1, 1995 is provided with RESTRICTED RIGHTS as provided for in FAR, 48 CFR 52.
Printer Software and Firmware License Agreement 9. EXCLUSION OF ALL DAMAGES.
Printer Software and Firmware License Agreement • The SOFTWARE and FIRMWARE was provided to you at no additional charge and ZEBRA has included in this PSFLA terms that disclaim all warranties and liability for the SOFTWARE and FIRMWARE. To the full extent allowed by law, YOU HEREBY RELEASE ZEBRA AND ITS SUPPLIERS FROM ANY AND ALL LIABILITY ARISING FROM OR RELATED TO ALL CLAIMS CONCERNING THE SOFTWARE AND/OR FIRMWARE OR ITS USE.
Printer Software and Firmware License Agreement xx Z4Mplus and Z6Mplus User Guide
Table of Contents 1 • Proprietary Statement .................................v Product Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v FCC Compliance Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Canadian DOC Compliance Statement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Liability Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 3 • Introduction .........................................1 Inspect the printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Report Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z4Mplus and Z6Mplus Printer Overview . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 6 • Printer Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Printer Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Roll Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tear-Off Mode . . . . . . . . . . . . . . . . . .
Table of Contents Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Printer Self Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cancel Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pause Self Test . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface The Preface discusses the topics and illustrates standards that are used throughout this guide. Contents Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvi Support . . . . . . . . . . . . . . . . . . . . . . . . . . xxvi About this Document . . . . . . . . . . . . . . . . . . xxvii Document Conventions . . . . . . . . . . . . . . . xxviii Related Documents. . . . . . . . . . . . . . . . . . . .
Preface Contacts Contacts You can contact Zebra Technologies Corporation, USA at any of the following: Visit us at: 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.
Preface About this Document About this Document The User Guide contains these chapters: Title Content Description Introduction Provides a high level overview of the Z4Mplus and Z6Mplus printer. Printer Setup Provides instructions for loading media and ribbon. Communication Describes communications options and their connections. Printer Basics Discusses detailed functions of controls and lights. Configuration Discusses detailed configuration settings.
Preface Document Conventions Document Conventions The following conventions are used throughout this document to convey certain information: About this Chapter: This section lists and describes each main section of the chapter, including the initial page number of that section. These sections primarily serve as hyperlink components for the Adobe Acrobat.pdf version of this guide. Alternate Color: (on-line only) Cross-references contain hot links to other sections in this guide.
Preface Document Conventions Illustration Call-out Instructions: Illustration call-out instructions are used when an illustration contains either information about a dialog box, step(s) to accomplish, or numbers in a table.
Preface Related Documents Related Documents In addition to the Z4Mplus and Z6Mplus User Guide, the following documents might be helpful references: • The ZPL II Programming Guide Volume I and Volume II (Zebra part number 45540L) details how to create the perfect label format for your application.
CHAPTER 1 Introduction This chapter provides a high level overview of the Z4Mplus and Z6Mplus Printer. Contents Inspect the printer . . . . . . . . . . . . . . . . . . . . . . . 2 Report Damage . . . . . . . . . . . . . . . . . . . . . . . 2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Z4Mplus and Z6Mplus Printer Overview . . . . . . 3 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Printer Side View . . . . . . . . . . . . . . . . . . . . . .
Introduction Inspect the printer Inspect the printer • Check all exterior surfaces. • Raise the media access 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. • Depending on how your printer was ordered, a power cord may or may not be included. If one is not included, or if the one included is not suitable for your requirements, see AC Power Cord on page 122.
Introduction Z4Mplus and Z6Mplus Printer Overview Z4Mplus and Z6Mplus Printer Overview The following information is a general overview of the Z4Mplus and Z6Mplus printers operational controls and location of major components needed in the loading of media and ribbon. Front Panel The front panel keys and lights are shown below.
Introduction Z4Mplus and Z6Mplus Printer Overview Number 4 Description 1 Power LED 2 Pause LED 3 Error LED 4 Data LED 5 LCD 6 PLUS (+) Key 7 SETUP/EXIT Key 8 CANCEL Key 9 PAUSE Key 10 FEED Key 11 SELECT Key 12 MINUS (–) Key Z4Mplus and Z6Mplus User Guide
Introduction Z4Mplus and Z6Mplus Printer Overview Printer Side View The illustration below is a simplified view of your printer. Depending on installed options, your printer may look slightly different.
Introduction Z4Mplus and Z6Mplus Printer Overview 6 Z4Mplus and Z6Mplus User Guide
CHAPTER 2 Printer Setup This chapter provides instructions for loading labels and ribbon. Contents Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . 8 Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Types of Media . . . . . . . . . . . . . . . . . . . . . . 10 Print Mode . . . . . . . . . . . . . . . . . . . . . . . . . 12 Load Media and Ribbon . . . . . . . . . . . . . . . . . 13 Load the Media . . .
Printer Setup Before You Begin Before You Begin Media The Z4Mplus and Z6Mplus are capable of using various types of media. These include continuous roll and fanfold media as labels or card stock with optional perforations and registration holes. Refer to Printer Basics on page 33 for a detailed description of loading label media and ribbon.
Printer Setup Before You Begin Ribbon Ribbon is a thin film carrying wax or wax resin that is transferred to the media during the thermal transfer process. Direct thermal media does not require the use of a ribbon, but printhead life may be shortened because of the abrasion of direct contact with the media. Printhead life may be reduced by the abrasion from exposed paper fibers when using perforated media. Refer to Printer Basics on page 33 for a detailed description of loading label media and ribbon.
Printer Setup Before You Begin Types of Media The following is a description of the various types of media approved for use in the Z4Mplus and Z6Mplus printers. Non-Continuous Web Media Non-continuous web media (shown below) refers to individual labels separated by a gap, notch, or hole. When you look at the media, you can tell where one label ends and the next one begins. The illustration below shows samples of all three. The noncontinuous with gaps, is individual labels on a continuous liner.
Printer Setup Before You Begin Non-Continuous Black Mark Labels Non-continuous black mark labels have black marks printed on the back of the liner indicating the start and end of each label (shown below). 1 1 Number Description 1 Black Mark Continuous Media Continuous media (shown below) is one uninterrupted roll of material without gaps, holes, notches, or black marks that allows the image to be printed anywhere on the label.
Printer Setup Before You Begin Print Mode Print modes are displayed on the LCD on the front panel of the printer. Print modes should match the media and printer options chosen. Print mode choices are listed in the table below. Mode Printer Option Tear-Off Mode 12 Action Use for most (Default setting) applications. Each label or strip of labels can be torn off after printing. Peel-Off Mode Use only if printer has the peel option. Liner material is peeled away from the label as it is printed.
Printer Setup Load Media and Ribbon Load Media and Ribbon Load the Media One method of media loading is shown in the illustration below. For more detailed instructions, as well as information about how to load the different types of media and the various printing modes, see Printer Basics on page 33.
Printer Setup Load the Ribbon Load the Ribbon If the media is thermal transfer material, you must load a ribbon to print labels. See the illustration below. If the media is direct thermal material, do not load a ribbon.
Printer Setup Calibration Calibration 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.
Printer Setup Printhead Pressure Adjustment Printhead Pressure Adjustment Refer to the illustration below. This adjustment may be necessary if printing is too light on one side or if thick media is used. Pressure Adjustment Dials R L The pressure adjustment dials for the Z4Mplus each have four possible settings designated by blocks of increasing size embossed on the print mechanism.
Printer Setup Printhead Pressure Adjustment Set Printhead Pressure Use the tables below, depending upon which printer you have, to select the initial dial settings for your media. Z4Mplus Media Width 1 in. (25.4 mm) 2 in. (51 mm) 3 in. (76 mm) 3.5 in. and up (89 mm and up) Left Dial 3 4 3 3 Right Dial 1 1 2 3 Media Width Left Dial 2 in. (50 mm) 6 3 in. (75 mm) 6 4 in. (100 mm) 7 5 in. (125 mm) 7 5.5 in.
Printer Setup Rewind Media Alignment Rewind Media Alignment The instructions below apply if the printer has a rewind option. Refer to the illustration below. Note • The liner should be installed flush against the backplate of the take-up spindle to prevent the media/backing from winding too loosely. Do the adjustments in the order given. Do only what is needed to solve the problem. 1. Turn the adjustment dial clockwise to align the media toward the mainframe. 2.
Printer Setup Configuration Label 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. Print a Configuration Label 1. Turn the printer Off (O). 2. Press and hold CANCEL while turning the printer On (l). See the Front Panel illustration on page 3. 3. Release CANCEL after the DATA light turns off (approximately five seconds).
Printer Setup Configuration Label Z6Mplus - 300dpi Z4Mplus - 200dpi 4 4 20 Z4Mplus and Z6Mplus User Guide
Printer Setup Troubleshoot Printing Problems Troubleshoot Printing Problems If the configuration label did not print, or if the labels are aligned properly, review the items below in the order shown. Do only as many steps as needed to solve the printing problem. • Review Types of Media on page 10. • Review Load the Media on page 13. • Configure the printer according to the directions given in Basic Configuration on page 22. • Check the position of the media sensor and move if necessary.
Printer Setup Basic Configuration Basic Configuration If your labels are not printing correctly, the configuration may need to be changed because the printer defaults may not reflect the options you need. Media, ribbon, darkness, print mode, media type, sensor type, and print method all affect the way the printer is configured. Refer to Configuration on page 58 for more detailed information. Review the Front Panel illustration on page 3 to familiarize yourself with the controls.
Printer Setup Basic Configuration Basic Configuration Process See the instructions below to perform basic a configuration: 1. Enter the configuration mode by pressing SETUP/EXIT. DARKNESS displays. 2. If there is no print darkness problem, press PLUS (+) to move to the next option, Print Speed. If the labels moved forward, but the print is light or there is no print, increase the darkness. If the print is too dark, or the ribbon sticks to the media, decrease the darkness. 3. 4. 5. 6. Press SELECT.
Printer Setup Basic Configuration 15. Press PLUS (+) to move to the next option. PRINT MODE displays. When the wrong Print Mode is selected, the top of the label is not found by the printer. Some examples of common problems are gaps between noncontinuous labels not lining up on the tear bar, or continuous media not being cut at the right interval. If the labels line up correctly on the tear bar, press PLUS (+) to go to the next step, Media Type.
Printer Setup Basic Configuration If the label liner has black marks, continue with Step 24. 24. Press SELECT. 25. Press PLUS (+) or MINUS (–) to scroll through the setting options. Stop at the setting that matches your printer options (Web or Mark). 26. Press SELECT to accept the change. 27. Press PLUS (+) to move to the next option. SENSOR SELECT displays. Auto Select is the default setting. Do not make any changes. 28. Press PLUS (+) to move to the next option. PRINT METHOD displays.
Printer Setup Position the Label Sensor Position the Label Sensor There are two media sensors in this printer: reflective and transmissive. Reflective Sensor The reflective sensor detects the start-of-label indicator (the notch, hole, black mark, or gap between die-cut labels).
Printer Setup Position the Label Sensor 4. Close the printhead assembly.
Printer Setup Position the Label Sensor Transmissive Sensor The standard transmissive sensor is in a fixed position and enabled from the front panel. For more detailed information, see SENSOR SELECT on page 64. Standard Transmissive Sensor Adjustable Transmissive Sensor (Optional) Configure the Software or Printer Driver 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.
CHAPTER 3 Communication This chapter describes communications options and their connections. Contents System Considerations . . . . . . . . . . . . . . . . . . 30 Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Cable Requirements . . . . . . . . . . . . . . . . . .
Communication System Considerations System Considerations Interfaces Standard interfaces: the RS-232 DB-9 serial data port, and IEEE 1284 compliant bi-directional parallel port. Note • For further information on serial and parallel, pin-out, and technical information, see Appendices A and B, starting on page 123.
Communication System Considerations communication parameters. The values selected must be the same as those used by the host equipment connected to the printer. Printer 9 Computer Male 25 9 9 Null modem adaptor (if using a standard modem cable) 50 ft. (15 mm) maximum Parallel Port Communicating using the parallel port (see the parallel illustration below), does not require special settings. The serial settings do not affect the parallel port.
Communication System Considerations Printer 36-pin male Computer PC 25-pin female 25-pin male 10 ft. (3 mm) maximum Cable Requirements Note • Zebra printers comply with FCC Rules and Regulations, Part 15 for Class B equipment using fully shielded data cables. Use of unshielded cables may increase radiation above the Class B limits. Data cables must be fully shielded and fitted with metal or metalized connector shells.
CHAPTER 4 Printer Basics This chapter provides instructions for loading media and ribbon. Contents Printer Overview . . . . . . . . . . . . . . . . . . . . . . . 34 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . 34 Load Roll Media . . . . . . . . . . . . . . . . . . . . . . . 38 Tear-Off Mode . . . . . . . . . . . . . . . . . . . . . . . 38 Cutter Mode. . . . . . . . . . . . . . . . . . . . . . . . . 40 Peel-Off Mode . . . . . . . . . . . . . . . . . . . . . . . 42 Liner Take-Up Mode . . .
Printer Basics Printer Overview Printer Overview This printer overview provides you the basics of printer controls and media loading. 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 below.
Printer Basics Printer Overview Number Description Z4Mplus and Z6Mplus User Guide 1 Power LED 2 Pause LED 3 Error LED 4 Data LED 5 LCD 6 PLUS (+) Key 7 SETUP/EXIT Key 8 CANCEL Key 9 PAUSE Key 10 FEED Key 11 SELECT Key 12 MINUS (–) Key 35
Printer Basics Printer Overview Front Panel Keys 36 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.
Printer Basics Printer Overview Front 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 Peel-Off Mode, the Pause light flashes when the label is available, and when initializing FLASH or PCMCIA memory. Off Normal printer operation (no errors). Slow flashing RIBBON IN warning, HEAD UNDER TEMP warning, or HEAD OVER TEMP error.
Printer Basics Load Roll Media Load Roll Media Tear-Off Mode See the instructions below to load media in Tear-Off Mode: This is the default mode. The printer is set to this mode in the factory. 1. Press the printhead open lever. The printhead assembly springs up. Caution • Ensure printhead is fully open and engaged in the up position. Failure to latch in the up position could result in the printhead falling on your hand during the procedure. 2. Flip down the media supply guide. 3.
Printer Basics Load Roll Media 3 2 1 5 4 6 7 Number Z4Mplus and Z6Mplus User Guide Description 1 Printhead Assembly 2 Transmissive Sensor 3 Label Supply Guide 4 Label Supply Hanger 5 Dancer 6 Label Guide 7 Printhead Open Lever 39
Printer Basics Load Roll Media Cutter Mode See the instructions below to load media in Cutter-Off Mode: Cutter Mode requires that the cutter be installed. 1. Press the printhead open lever. The printhead assembly springs up. Caution • Ensure printhead is fully open and engaged in the up position. Failure to latch in the up position could result in the printhead falling on your hand during the procedure. 2. 3. 4. 5. 6. Flip down the media supply guide.
Printer Basics Load Roll Media 3 2 1 8 9 5 6 7 Number Z4Mplus and Z6Mplus User Guide 4 Description 1 Printhead Assembly 2 Transmissive Sensor 3 Label Supply Guide 4 Label Supply Hanger 5 Dancer 6 Label Guide 7 Printhead Open Lever 8 Cutter Module 9 Catch Tray 41
Printer Basics Load Roll Media Peel-Off Mode See the instructions below to load media in Peel-Off Mode: This setting works only with the Peel-Off Option installed on the printer. An illustration of the printer with the Peel-Off Option is shown on the next page. 1. Press the printhead open lever. The printhead assembly springs up. Caution • Ensure printhead is fully open and engaged in the up position.
Printer Basics Load Roll Media 11 101 3 2 1 5 9 6 7 4 8 Number Z4Mplus and Z6Mplus User Guide Description 1 Printhead Assembly 2 Transmissive Sensor 3 Media Supply Guide 4 Media Supply Hanger 5 Dancer 6 Media Guide 7 Printhead Open Lever 8 Peel Assembly 9 Label 10 Peel Lever 11 Tear-Off/Peel/Off Bar 43
Printer Basics Load Roll Media Liner Take-Up Mode See the instructions below to load media in Liner Take-Up Mode: The Liner Take-up option must be installed to use this mode. The option is shown in the illustration on the next page. Note • This option is available on the Z4Mplus printer only 1. Press the printhead open lever. The printhead assembly springs up. Caution • Ensure printhead is fully open and engaged in the up position.
Printer Basics Load Roll Media 15. Slide the liner into the slot (see inset) in the spindle of the liner take-up. Ensure the liner is resting against the back plate of the spindle assembly. 16. Turn the spindle assembly counterclockwise a few times to snug the liner. Slot 17. If the printer is paused (the pause light is on), press PAUSE to enable printing. Peeling starts automatically. Press FEED to test.
Printer Basics Load Roll Media Liner Removal Liner Slide 1. Pull the liner slide toward you (see inset) until it stops (about a third of the way down the liner take-up spindle). 2. Slide the liner from the take-up spindle. Liner Slide Tab Note • The liner slide moves back in place once the liner is removed. Rewind Peel Mode See the instructions below to load media in Rewind/Peel Mode: Refer to the illustration on the next page. 1. Press the printhead open lever. The printhead assembly springs up.
Printer Basics Load Roll 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.
Printer Basics Load Roll Media 2 15 3 1 14 4 13 5 12 11 10 Number 48 9 8 7 6 Description 1 Printhead Assembly 2 Transmissive Sensor 3 Label Supply Guide 4 Label Supply Hanger 5 Rewind Spindle 6 Rewind Label Guide 7 Thumbscrew 8 Dancer 9 Label Guide 10 Rewind Label Spindle 11 Printhead Open Lever 12 Peel Assembly 13 Label 14 Rewind Base Assembly 15 Peel Lever Z4Mplus and Z6Mplus User Guide
Printer Basics Load Roll Media Liner Removal 1. Cut the liner between the media alignment spindle and the take-up 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. Rewind Mode See the instructions below to load media in Rewind Mode: Refer to the illustration on the next page. 1.
Printer Basics Load Roll Media 13. Slide an empty core onto the take-up spindle; wrap the media 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 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.
Printer Basics Load Roll Media 2 14 3 1 4 13 5 12 11 10 9 Number Z4Mplus and Z6Mplus User Guide 8 7 6 Description 1 Printhead Assembly 2 Transmissive Sensor 3 Label Supply Guide 4 Label Supply Hanger 5 Rewind Spindle 6 Rewind Label Guide 7 Thumbscrew 8 Dancer 9 Label Guide 10 Rewind Label Spindle 11 Printhead Open Lever 12 Rewind Base Assembly 13 Peel Assembly 14 Peel Lever 51
Printer Basics Load Fanfold Media Media Removal 1. Cut the media between the media alignment spindle and the take-up 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. Load Fanfold Media Fanfold media feeds through either the bottom or rear access slot.
Printer Basics Load Fanfold Media Rear Feed 3 1 2 6 7 4 5 Bottom Feed 3 1 2 6 7 Number Z4Mplus and Z6Mplus User Guide 4 5 Description 1 Printhead Assembly 2 Transmissive Sensor 3 Label Supply Guide 4 Label Supply Hanger 5 Dancer 6 Label Guide 7 Printhead Open Lever 53
Printer Basics Load the Ribbon Load the Ribbon Note • 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 normal tension hampers the ribbon movement. See the instructions below to load the ribbon: 1. To place this spindle in the normal position, firmly pull out the spindle end cap until it clicks as shown in below. 2.
Printer Basics Load the Ribbon 4 3 2 1 5 7 6 8 Number Z4Mplus and Z6Mplus User Guide Description 1 Strip Plate 2 Printhead Assembly 3 Release Knob 4 Tension Blades 5 Ribbon Take-Up Spindle 6 Ribbon Supply Spindle 7 Ribbon Sensor 8 Printhead Open Lever 55
Printer Basics Load the Ribbon Remove the Ribbon 1. If the ribbon has not run out, break it between the strip plate and the ribbon take-up spindle. 2. While turning the ribbon take-up spindle release knob counter clockwise, 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 off the ribbon.
CHAPTER 5 Configuration This chapter discusses detailed configuration settings. Contents Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Enter Setup Mode . . . . . . . . . . . . . . . . . . . . 58 Change Password-Protected Parameters . . 59 Leave the Setup Mode . . . . . . . . . . . . . . . . 60 Configuration and Calibration Sequence. . . . .
Configuration Configuration Configuration After you have installed the media and ribbon, and the Power-On Self Test (POST) is complete, the front panel displays PRINTER READY. If the printer fails its POST, see Troubleshooting on page 97. Use the front panel display and the four keys directly below it to set printer parameters for your application. Note • Printers operating on an IP network can be quickly configured using ZebraLink WebView (optional ZebraNet PrintServer II required).
Configuration Configuration Change Password-Protected Parameters Certain parameters are password protected by factory default. Note • You have the option of making all parameters password protected. Refer to PASSWORD LEVEL on page 81 for details. 1. Enter a four-digit password at the ENTER PASSWORD display. MINUS (–) changes the selected digit position. PLUS (+) increases the selected digit value. After entering the password, press SELECT. The parameter you wish to change is displayed.
Configuration Configuration Leave the Setup Mode Note • Once the password has been entered correctly, it does not have to be entered again unless you leave and re-enter the programming mode using SETUP/EXIT. Note • You can disable the password protection feature to no longer prompt you for a password by setting the password to ØØØØ via the ^KPØ ZPL/ZPL II command.
Configuration Configuration and Calibration Sequence Configuration and Calibration Sequence Display Shows Action/Explanation PRINTER READY Normal printer operation. Set Print Parameters DARKNESS Press SELECT to make change. Adjusting Print Darkness: Press PLUS (+) to increase darkness. Press MINUS (–) to decrease darkness. Default: +10 Range: 0 to +30 Press SELECT to accept the change.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation TEAR OFF Press SELECT to make change. Adjusting the Tear-off Position: Press PLUS (+) to increase the value, press MINUS (–) to decrease the value. Each press adjusts the tear-off position by four dot rows. Default: +0 Range: –120 to +120 Press SELECT to accept the change. This parameter establishes the position of the media over the tear-off/peel-off bar after printing.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation MEDIA TYPE Press SELECT to make change. Setting Media Type: Press PLUS (+) or MINUS (–) to display other choices. Default: Non-Continuous Selections: Non-continuous, Continuous Press SELECT to accept the change. 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).
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation SENSOR SELECT Press SELECT to make change. Setting the Sensor Select: Press PLUS (+) or MINUS (–) to display other choices. Default: Auto select Selections: Auto select, reflective, transmissive Press SELECT to accept the change. This parameter tells the printer the sensor you wish to use. Auto Select is compatible with most types of media.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation PRINT WIDTH Press SELECT to make change. Setting Print Width: Press PLUS (+) to increase the value, press MINUS (–) to decrease the value. 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). Default; Range: The default and range of acceptable values may vary depending on what printer you have.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation LIST IMAGES Press SELECT to select. List Images: Press PLUS (+) to print a label listing all of the available 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. LIST FORMATS Press SELECT to select. List Formats: Press PLUS (+) to print a label listing all of the available formats.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation FORMAT CARD Initialize Memory Card A Caution • Perform this operation only when it is necessary to erase all previously stored information from the optional memory card. Press PLUS (+) to bypass this function. B Press SELECT to make change. If your printer is set to require a password, you are prompted to enter the password. Enter the password and then press SELECT.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation INIT FLASH MEM Initialize Flash Memory Caution • Perform this operation only when it is necessary to erase all previously stored information from the FLASH memory. Press SELECT to make change. Press SETUP/EXIT to bypass this function. Press PLUS (+) to select YES. If your printer is set to require a password, you are prompted to enter the password. Enter the password and then press SELECT.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation Media and Ribbon Sensor 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.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation CALIBRATING PLEASE WAIT 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.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation Setting Communication 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. PARALLEL COMM Press SELECT to make change. Setting Parallel Communications: Press PLUS (+) or MINUS (–) to display other choices.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation DATA BITS Setting Data Bits: Press the INCREMENT (+) or DECREMENT (–) key to display other choices. Default: 7-bits Selections: 7-bits, 8-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 • Must be set to 8 data bits to use Code Page 850.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation PROTOCOL Press SELECT to make change. Setting Protocol: Press PLUS (+) or MINUS (–) to display other choices. Default: None Selections: None, Zebra, ACK_NACK Press SELECT to accept the change. 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.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation COMMUNICATIONS Press SELECT to make change. Setting Communications Mode: Press PLUS (+) or MINUS (–) to display other choices. Default: Normal mode Selections: Normal mode, diagnostics Press SELECT to accept the change. The communication diagnostics mode is a troubleshooting tool for checking the interconnection between the printer and the host computer.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation Selecting Prefix and Delimiter Characters 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 character.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation DELIMITER CHAR Press SELECT to make change. Delimiter Character: Press MINUS (–) to move to the next digit position, press PLUS (+) to increase the value of the digit. Default: 2C (comma) Range: 00 to FF Press SELECT to accept the change. 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.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation Power-Up and Head Close Parameters MEDIA POWER UP Press SELECT to make change. Media Power Up: Press PLUS (+) or MINUS (–) to display other choices. Default: Calibration Selections: Calibration, length, no motion, and feed Press SELECT to accept the change. This parameter establishes the action of the media when the printer is turned on. Calibration: Recalibrates the media and ribbon sensors.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation Label Positioning Parameters BACKFEED Press SELECT to make change. Backfeed Sequence: Press PLUS (+) or MINUS (–) to display other choices. Default: Default (90%) Selections: Default, after, before, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, off Press SELECT to accept the change. This parameter establishes when and how much label backfeed occurs after a label is removed or cut in the peeloff or cutter modes.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation LEFT POSITION Press SELECT to make change. Adjusting Left Position: Press MINUS (–) to move to the next position, press PLUS (+) to change between + and to increase the value of the digit. The displayed value represents dots. Default: 0000 Range: –9999 to +9999 Press SELECT to accept the change. For a negative value, enter the value before changing to the minus sign.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation FORMAT CONVERT Press SELECT to make change. Note • 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 choose150-300. Format Convert: Press PLUS (+) or MINUS (–) to display other choices.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation PASSWORD LEVEL Press SELECT to make change. Password Level: Press PLUS (+) or MINUS (–) to display other choices. Default: Selected items Selections: Selected items, all items Press SELECT to accept the change. This parameter allows you to select whether certain Zebra-selected menu items (selected items) or all menu items (all items) are password protected. IP RESOLUTION* Press SELECT to make change.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation IP ADDRESS* Press SELECT to make change. IP Address: Press MINUS (–) to move to the next digit position, press PLUS (+) to increase the value of the digit. This parameter allows you to select the IP address if permanent was chosen in IP RESOLUTION. (If dynamic was chosen, the user cannot select the address.) For more information, see ZebraNet Networking: PrintServer II Installation and Users Guide.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation LANGUAGE Press SELECT to make change. Selecting the Display Language: Press PLUS (+) or MINUS (–) to display other choices. Default: English Selections: English, Spanish, French, German, Italian, Norwegian, Portuguese, Swedish, Danish, Spanish 2, Dutch, Finnish, Japanese Press SELECT to accept the change. This parameter allows you to change the language used on the front panel display.
Configuration Configuration and Calibration Sequence Display Shows Action/Explanation SAVE SETTINGS Save Settings: Press PLUS (+) or MINUS (–) to display other choices. Default: Permanent Selections: Permanent, temporary, cancel, load defaults, load last save Press SELECT to accept the change. This display appears when you attempt to exit the configuration mode. Permanent: Permanently saves the changes, even when printer power is turned off.
CHAPTER 6 Routine Care and Adjustments This chapter discusses printer cleaning and minor adjustments. Contents Cleaning Procedures. . . . . . . . . . . . . . . . . . . . 86 Clean the Exterior . . . . . . . . . . . . . . . . . . . . 87 Clean the Interior . . . . . . . . . . . . . . . . . . . . . 87 Clean the Sensors . . . . . . . . . . . . . . . . . . . . 89 Clean the Rewind Option . . . . . . . . . . . . . . 90 Clean the Peel-Off Assembly . . . . . . . . . . . 92 Clean the Cutter Module . . . . . . . . .
Routine Care and Adjustments Cleaning Procedures Cleaning Procedures Specific cleaning procedures are provided on the following pages. Below is a recommended cleaning schedule. . Area Method Interval Printhead Solvent* Platen roller Solvent* Direct Thermal Mode: After every roll of media (or 500 feet of fanfold media). Media sensors Air blow Ribbon sensor Air blow Media path Solvent* Ribbon path Solvent* Pinch roller. (Optional peeloff option required. Refer to page 92.
Routine Care and Adjustments Cleaning Procedures 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.
Routine Care and Adjustments Cleaning Procedures 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.
Routine Care and Adjustments Cleaning Procedures 1 2 6 3 5 4 Number Description 1 Printhead Assembly 2 Transmissive Sensor 3 Reflective Sensor 4 Platen Roller 5 Ribbon Sensor 6 Take-Label Sensor Clean the Sensors Brush or vacuum any accumulated paper lint and dust away from the printer sensors. Refer to the illustration above. The reflective sensor, transmissive sensor, and ribbon sensor should be cleaned on a regular basis to ensure proper operation of the printer.
Routine Care and Adjustments Cleaning Procedures Clean the Rewind Option The Rewind option is required. Refer to the illustration on next page and perform the following procedure if adhesive buildup begins to affect peel performance. 1. Open the printhead assembly. Caution • Ensure printhead is fully open and engaged in the up position. Failure to latch in the up position could result in the printhead falling on your hand during the procedure. 2.
Routine Care and Adjustments Cleaning Procedures 1 2 3 4 Number Description 91 1 Printhead Assembly 2 Tear-Off/Peel-Off Bar 3 Pinch Roller 4 Peel Assembly Z4Mplus and Z6Mplus User Guide
Routine Care and Adjustments Cleaning Procedures Clean the Peel-Off Assembly The Peel-Off option is required. Refer to the illustration on the previous page and perform the following procedure if adhesive buildup begins to affect peeloff performance. 1. Open the printhead assembly. Caution • Ensure printhead is fully open and engaged in the up position. Failure to latch in the up position could result in the printhead falling on your hand during the procedure. 2.
Routine Care and Adjustments Cleaning Procedures Clean the Cutter Module Cutter option required. Caution • For personnel safety, always turn off and unplug the printer before performing this procedure. Refer to the illustration on the next page and the procedures below to clean adhesive off of the upper and lower cutter blades: 1. Remove the cutter shield by removing the thumbscrew and lock washer. Caution • Cutter blade is sharp. Use caution when cleaning. Do not rub the blade with your fingers. 2.
Routine Care and Adjustments Cleaning Procedures 1 2 3 4 5 Number Description 1 Thumbscrew and Lock Washer 2 Cutter Shield 3 Upper Cutter Blade 4 Lower Cutter Blade Lubrication No lubrication is needed for this printer.
Routine Care and Adjustments Cleaning Procedures Fuse Replacement Caution • Some commercially available lubricants will damage the finish and the mechanical parts if used. 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 • Before replacing the fuse, turn off the AC power switch and unplug the AC power cord. Perform the following procedure to replace the fuse: 1.
Routine Care and Adjustments Cleaning Procedures 96 Z4Mplus and Z6Mplus User Guide
CHAPTER 7 Troubleshooting This chapter discusses typical problems and their probable solutions. Content LCD Error Conditions and Warnings . . . . . . . . 98 Error Conditions . . . . . . . . . . . . . . . . . . . . . 98 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Print Quality Problems. . . . . . . . . . . . . . . . . . 103 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . 105 Communication Problems . . . . . . . . . . . . . 106 Printer Diagnostics . . . . . . . . . . . .
Troubleshooting LCD Error Conditions and Warnings LCD Error Conditions and Warnings The LCD displays error condition messages and warnings if the printer detects a problem. The messages, along with their causes and solutions, are listed below. Error Conditions Error condition — RIBBON OUT Problem Solution In thermal transfer mode, the ribbon is not loaded or loaded incorrectly. Load the ribbon correctly. See Load the Ribbon on page 54.
Troubleshooting LCD Error Conditions and Warnings Error condition — PAPER OUT Problem Solution The media is not loaded or loaded incorrectly. Reload the media. See Load Roll Media beginning on page 38. The media sensor is not positioned properly. Check the position of the reflective sensor. See Position the Label Sensor on page 26. The printer is set for noncontinuous media, but continuous media is loaded.
Troubleshooting LCD Error Conditions and Warnings Error condition — HEAD OPEN Problem Solution 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 mark on the strip plate before closing the sensor. printhead assembly. See Position the Label Sensor on page 26. Print method is incorrectly set. Via the front panel, locate the PRINT METHOD menu item (page 64) and select thermal transfer mode.
Troubleshooting LCD Error Conditions and Warnings Warnings Warning — HEAD OVER TEMP Caution • The printhead is hot and can cause severe burns. Allow the printhead to cool. Problem Solution The printhead is over temperature. Allow the printer to cool. Printing automatically resumes when the printhead elements cool to an acceptable operating temperature. Warning — HEAD UNDER TEMP Caution • The printhead is hot and can cause severe burns. Allow the printhead to cool.
Troubleshooting LCD Error Conditions and Warnings Warning — CUTTER JAM Caution • Cutter blade is sharp. Use caution when cleaning. Do not rub the blade with your fingers. Problem Solution 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 on page 93.
Troubleshooting Print Quality Problems Print Quality Problems General print quality issues Problem Solution You are using an incorrect media and ribbon combination for your application. Consult your authorized Zebra reseller/ distributor for information and advice. The printer is set at an excessive For optimal print quality, set the print print speed to achieve optimal speed to a lower setting via ZPL II, the quality. driver, software, or front panel.
Troubleshooting Print Quality Problems Intermittent creases on the left and right edges of the label Problem Solution There is too much pressure on the printhead. Reduce the printhead pressure. See Set Printhead Pressure on page 17. Wrinkled ribbon Problem Solution The ribbon is not loaded correctly. Load the ribbon correctly. See Load the Ribbon on page 54. The darkness setting is incorrect. Set the darkness to the lowest possible setting for good print quality. See DARKNESS on page 61.
Troubleshooting Print Quality Problems Calibration Problem Solution Loss of printing registration on labels. Excessive vertical drift in top-of-form registration. Adjust the reflective sensor position. See page 26. Set the printer for the correct media type. See page 63. Ensure that the media guides are properly positioned. Via the front panel, locate the SENSOR SELECT menu item (page 64) and manually select the correct sensing method. Reload the media.
Troubleshooting Print Quality Problems Communication Problems Data light does not flash when a label format is sent. Problem Solution The printer does not respond to label requests. Check the printer driver or software communications settings. Confirm you are using the correct communication cable. See Cable Requirements on page 32. Via the front panel, check the protocol setting. It should be set to the default none. See page 73. Ensure that the correct driver is being used.
Troubleshooting Print Quality Problems Problem Solution The prefix and delimiter characters set in the printer do not match the ones in the label format. Verify the prefix and delimiter characters. See page 75. Incorrect data is being sent to the printer. Check the communication settings on the computer. Ensure they match the printer settings.
Troubleshooting Printer Diagnostics Printer Diagnostics 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.
Troubleshooting Printer Diagnostics Cancel Self Test This self test prints a listing of the configuration parameters currently stored in the printer’s memory. See the labels below. Depending on the options ordered, your label may look different. Perform the following procedure to complete the Cancel Self Test: 1. Turn the printer Off (O). 2. Press and hold CANCEL while turning the printer On (l). 3. Release CANCEL after the DATA light turns off (approximately five seconds).
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. See the sample printout at right. Perform the following procedure to complete the Pause Self Test: 1. Turn the printer Off (O). 2. Press and hold PAUSE while turning the printer On (l). 3. Release PAUSE after the DATA light turns off (approximately five seconds). • The initial self test prints 15 labels at 2 in.
Troubleshooting Printer Diagnostics Feed Self Test See the illustration at right. Perform the following procedure to complete the Feed Self Test: 1. Turn the printer Off (O). 2. Press and hold FEED while turning the printer On (l). 3. Release FEED after the DATA light turns off (approximately five seconds). Feed Self Test prints out at various darkness settings above and below that of the darkness value shown on the configuration label.
Troubleshooting Printer Diagnostics Communications Diagnostics Test This test is controlled from the front panel display. See page 75. A typical printout from this test is shown in below. Turn the printer Off (O) to exit this self test. Note • This label is inverted when printed (prints upside down). Loading Factory Defaults Perform the following procedure to load the factory defaults: 1. Press SETUP/EXIT two times. 2. Use PLUS (+) or MINUS (–) to scroll through the SAVE CHANGES choices. 3.
CHAPTER 8 Specifications This chapter contains all needed specifications on the Z4Mplus and Z6Mplus printers. Contents General Specifications. . . . . . . . . . . . . . . . . . 114 Printing Specifications . . . . . . . . . . . . . . . . . . 115 Media Specifications . . . . . . . . . . . . . . . . . . . 116 Ribbon Specifications . . . . . . . . . . . . . . . . . . 118 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Zebra Programming Language (ZPL II) . . . . 120 Bar codes . . . . . .
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. 16 kg Electrical 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.
Specifications Printing Specifications Printing Specifications Printing Specifications Z4Mplus Print resolution Z6Mplus 203 dots/inch 8 dots/mm 203 dots/inch 8 dots/mm 300 dots/inch 12 dots/mm 300 dots/inch 12 dots/mm Dot size 203 dpi (width x length) 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 300 dpi 4.1 in.
Specifications Media Specifications Media Specifications Media Specifications Label length 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 Maximum 39 in. 991 mm 39 in. 991 mm Minimum 1 in. 25.4 mm 2 in. 51 mm Tear/Cutter 4.5 in. 114 mm 7.0 in. 178 mm Peel/ Rewind 4.25 in. 108 mm 6.75 in. 171 mm Minimum 0.0023 in. 0.058 mm 0.0023 in. 0.058 mm Maximum 0.
Specifications Media Specifications Media Specifications Z4Mplus 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 in. to 2.25 in. from the media inner edge Z6Mplus May also be centered from 5.84 mm to 57 mm from the media inner edge May also be centered from 0.23 in. to 3.5 in.
Specifications Ribbon Specifications Ribbon Specifications Ribbon Specifications Z4Mplus Z6Mplus Ribbon must be wound with the coated side out Ribbon width Minimum >1 in. 25.4 mm >2 in. 60 mm (Zebra recommends using ribbon at least as wide as the media to protect the printhead from wear.) Maximum 4.3 in. 109 mm 6.9 in. 174 mm Standard lengths 2:1 media to ribbon roll ratio 984 ft. 300 m 984 ft. 300 m 3:1 media to ribbon roll ratio 1476 ft. 450 m 1476 ft. 450 m 1 in. 25.4 mm 1 in.
Specifications Options Options Z4Mplus Z6Mplus • Cutter • Cutter • Peel-off • Peel-off • Liner take-up • Not Available • PCMCIA card socket (supports Zebra • PCMCIA card socket (supports Zebra Rapid Flash and ATA formats) Rapid Flash and ATA formats) • Linear Memory Card (Zebra Rapid Flash) 8MB and 32MB • Linear Memory Card (Zebra Rapid Flash) 8MB and 32MB • Compact Flash 32MB, 64MB, 128MB, and 256MB • Compact Flash 32MB, 64MB, 128MB, and 256MB • 300 dpi printhead • 300 dpi printhead • Rewind
Specifications Zebra Programming Language (ZPL II) Zebra Programming Language (ZPL II) Z4M/Z6Mplus ZPL II Features • Downloadable graphics (with data • Programmable quantity with print compression) pause 120 • Bit image data transfer and printing, mixed text/graphics • Communicates in printable ASCII characters • Format inversion • Controlled via mainframe, mini, PC, portable data terminal • Mirror image printing • In-Spec OCR-A and OCR-B • Four-position field rotation (0°, 90°, 180°, 270°) • UPC/
Specifications Bar codes Bar codes Z4M/Z6Mplus Bar Code Features Code 11 LOGMARS Code 39 (supports ratios of 2:1 to 3:1) Plessey Code 49 (2-dimensional bar code) EAN-8, EAN-13, EAN EXTENSIONS Code 93 UPC-A, UPC-E, UPC EXTENSIONS Code 128 (supports serialization in all subsets and UCC case codes) MSI Codabar (supports ratios of 2:1 to 3:1) PDF-417 (2-dimensional bar code) Codablock Micro-PDF-417 Interleaved 2 of 5 (supports ratios of 2:1 to 3:1; modulus 10 check digit) POSTNET Industrial 2 o
Specifications AC Power Cord AC Power Cord Caution • For personnel and equipment safety, always use a three-prong plug with an earth ground connection to the AC power source. Power Line Cord Specifications Note • Since many areas of the world have specific power requirements, an AC power cord may not be included with your printer. The power cord must meet your local electrical requirements. • The overall length must be less than 9.8 ft. (3.0 m). • It must be rated for at least 5A, 250 VAC.
APPENDIX A DB-9 Connectors This appendix discusses the Serial Port connections and adaptors. Content Printer Interface Technical Information . . . . . 124 Serial Data Communications . . . . . . . . . . . 124 Cable Specifications . . . . . . . . . . . . . . . . .
DB-9 Connectors Printer Interface Technical Information Printer Interface Technical Information Serial Data Communications 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.
DB-9 Connectors Printer Interface Technical Information The Table below shows the pin configuration and function of the rear panel serial data connector on the printer.
DB-9 Connectors Printer Interface Technical Information RS-232 Interface Connections The printer is configured as Data Terminal Equipment (DTE). The illustration below shows the internal connections of the printer’s RS-232 connector. DTE DTE 1 1 2 3 4 5 6 7 (RD) (RD) (TD) (TD) (DTR) (SG) (DTR) (SG) (DSR) (DSR) (RTS) (RTS) 2 3 4 5 6 7 8 8 9 9 Note • The cable used to connect the printer to a computer must be a null modem (crossover) cable.
DB-9 Connectors Printer Interface Technical Information 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. DTE (Printer) 2 3 4 5 DCE (Modem, etc.
DB-9 Connectors Printer Interface Technical Information 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. The illustration below shows the connections required for the DB-9 to DB-25 interface.
DB-9 Connectors Printer Interface Technical Information 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).
DB-9 Connectors Printer Interface Technical Information 130 Z4Mplus and Z6Mplus User Guide
APPENDIX B Parallel Data Port This appendix discusses the parallel data port and connections. Contents Parallel Data Port . . . . . . . . . . . . . . . . . . . . . 132 Parallel Interface . . . . . . . . . . . . . . . . . . . . 132 Parallel Port Interconnections . . . . . . . . . .
Parallel Data Port Parallel Data Port Parallel Data Port Parallel Interface The 8-bit parallel data interface supports IEEE 1284 bi-directional 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 Data Port Parallel Data Port 36-Pin Connectors Description 1 nStrobe/HostClk 2 to 9 Data Bits 1 to 8 10 nACK/PtrClk 11 Busy/PtrBusy 12 PError/ACKDataReq 13 Select/Xflag 14 nAutoFd/HostBusy 15 Not used 16 and 17 Ground 18 +5V @ 750 mA The maximum current draw may be limited by option configuration. 19 to 30 Ground 31 nInit 32 nFault/NDataAvail 33 and 34 Not used 35 +5V through a 1.
Parallel Data Port Parallel Data Port 134 Z4Mplus and Z6Mplus User Guide
APPENDIX C Memory Cards This appendix discusses the field available memory cards and their installation. Contents Memory Cards. . . . . . . . . . . . . . . . . . . . . . . . 136 PCMCIA Card . . . . . . . . . . . . . . . . . . . . . .
Memory Cards Memory Cards Memory Cards PCMCIA Card See the instructions below to install the Type I or Type II compliant PCMCIA card: Caution • The printer electronics are susceptible to static discharge. Use a properly grounded wrist strap while working on the printer. Note • The PCMCIA card is hot-swappable, it can be installed while the printer is On (l). Install the PCMCIA Card Refer to illustration on next page. 1. Remove the PCMCIA card shield from the rear of the printer. 2.
Memory Cards Memory Cards 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.
Memory Cards Memory Cards 138 Z4Mplus and Z6Mplus User Guide
APPENDIX D Extend Printhead Life This appendix discusses the processes needed to extend the life of the printhead. Content Extend the Life of Your Printhead with Save-a-Printhead Cleaning Film . . . . . . . . . . 140 Recommended for all Zebra printers . . . . . 140 Use Save-a-Printhead Cleaning Film . . . . 143 How to Order Cleaning Film Kits . . . . . . . .
Extend Printhead Life Extend the Life of Your Printhead with Save-a-Printhead Cleaning Film Extend the Life of Your Printhead with Save-a-Printhead Cleaning Film Recommended for all Zebra printers Challenge The printhead is the most critical component in your printer, and possibly the most delicate. It is a consumable item, just like the brakes on your car, that eventually wears over time. However, with ongoing careful attention and maintenance, you can extend the life of the printhead.
Extend Printhead Life Extend the Life of Your Printhead with Save-a-Printhead Cleaning Film Preventive Maintenance For optimum performance, clean the printhead regularly. Take care when handling or cleaning the printhead by removing any jewelry that may scratch it, and use a grounding strap or anti-static mat to discharge static electricity that could damage the printhead.
Extend Printhead Life Extend the Life of Your Printhead with Save-a-Printhead Cleaning Film Ribbon Backcoating and Buildup: Printhead contamination from direct thermal labels or thermal transfer ribbon may occur in applications requiring high burn settings, high head pressure, high speed, or high volume. This contamination builds up on the printhead elements, creating a barrier to the heat transformation required to produce high-quality images.
Extend Printhead Life Extend the Life of Your Printhead with Save-a-Printhead Cleaning Film Use Save-a-Printhead Cleaning Film Caution • An improperly seated printhead data cable or power cable could result in the printhead generating excessive heat that could cause harm if it is touched. 1. 2. 3. 4. 5. 6. 7. 8. 9. Open the media cover. Open the printhead, remove labels and ribbon from the print mechanism. Clean the printhead per recommended preventive maintenance procedures.
Extend Printhead Life Extend the Life of Your Printhead with Save-a-Printhead Cleaning Film How to Order Cleaning Film Kits There are five kits to accommodate printers with different print widths. Each kit contains three 10 in. (254 mm) long strips of film. Reference the following table to order the appropriate kit for your printer: Order kit number: 144 For Printers with Print Widths of: 46902 3.0–4.0 in. (76–102 mm) 44902 4.0–5.0 in. (102–127 mm) 48902 5.0–6.0 in. (127–152 mm) 38902 6.0–7.0 in.
Index A About this Document xxvii AC Power Cord Specifications, Adjustments Printhead Pressure, 16 Reflective Sensor, 26 Auto Calibration, 28 Printer Driver Software, Printer, 28 Contacts xxvi Continuous Media, 11 Cutter Mode, 40 122 D Damage, 2 Data Communications Parallel, 132 Serial, 124 Data Ports Parallel, 132 Serial, 124–129 Document Conventions B Bar Codes, 121 C Cabling Requirements, 32 Calibrating the Printer, 7 Cleaning Cutter Module, 93 Power Peel/Rewind Module, 90 Printhead and Platen Rol
Index G General Specifications, N Non-Continuous Black Mark Media, 114 H P Hardware Control Signal Descriptions, 124 I Interconnections Parallel Port, 132 RS-232, 125–128 RS-422, 129 RS-485, 129 Interfaces Parallel, 132 Printer, 124–132 System, 30 L LCD Error Conditions and Warnings, Liner Removal, 46, 49 Liner Take-up Mode, 44 Lubrication, 94 98 M Media Loading Cutter Mode, 40 Fanfold, 52 Liner Take-up Mode, 44 Tear-off Mode, 38 Value Peel-off Mode, 42 Media Removal, 52 Media Specifications, 116
Index S Save-a-Printhead Cleaning Film 142–144 Self Tests CANCEL Key, 109 Communications Diagnostics, 112 FEED Key, 111 PAUSE Key, 110 Serial Data Communications, 124 Serial Data Port, 124–129 Specifications AC Power Cord, 122 Bar Codes, 121 General, 114 Media, 116 Options, 118 Printing, 115 Zebra Programming Language (ZPL II), Storage, 2 Support xxvi System Considerations Interfaces, 30 120 T Tear-off Mode, 38 Technical 124 Transmissive Sensor Positioning, 28 Types of Media Continuous Media, 11 Non-cont
Index Index-4 Z4Mplus and Z6Mplus User Guide
