Customer order # 77965L Manufacturer part # 77965LB Rev.
Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Corporation.
I have determined that the Zebra printer identified as the ™ Zebra Z4M Printer manufactured by: Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills, Illinois 60061-3109 U.S.A. has 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.
iv Zebra Z4M Printer User’s Guide
Table of Contents Welcome Hello! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Reporting Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Media and Ribbon Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 2 Printer Power . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading the Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 POWER Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Configuring the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fanfold Media Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Ribbon Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Loading the Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Ribbon Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Configuration Entering the Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Changing Password-Protected Parameters . . . . . . . . . . . . . . . . . . .
Troubleshooting LCD Error Conditions and Warnings . . . . . . . . . . . . . . . . . . . . . . 67 Print Quality Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Printer Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Additional Printer Self Tests . . . . . . . . . . . . . . . . . . . . . . . . .
Welcome Hello! n n n n This user’s guide provides all the information you will need to operate the printer. The ZPL II® Programming Guide Volume I and Volume II (part #45540L) show you how to create the perfect label format for your application. These books also explain how, through optional ZBI™, you can extend the power of ZPL II by allowing custom programs to be written that operate within the printer, directly interfacing with, for example, bar code scanners and keyboard display devices.
Reporting Damage If you discover shipping damage: n Immediately notify the shipping company and file a damage report. Zebra Technologies Corporation is not responsible for any damage incurred during the shipment of the equipment and will not repair this damage under warranty. n Keep the carton and all packing material for inspection. n Notify your local Zebra reseller. Storage If you are not placing the printer into operation immediately, repackage it using the original packing materials.
Printer Power The power supply in the printer automatically detects the applied line voltage and works in the 90 to 265 VAC range. WARNING!!! For personnel and equipment safety, always use a three-prong plug with an earth ground connection. NOTE: 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, refer to “Power Line Cord Specifications” on page 83. Refer to Figure 1.
Printer Overview Depending on the options you have selected, your printer may look slightly different.
Calibrating the Printer This chapter of the user’s guide is so important that we’ve printed it on a different color paper! That way, it will be easy for you to find when you must calibrate (set up) the printer for your particular application. Purpose n To calibrate the printer. n To verify that the printer is properly set up by printing a test label. NOTE: This procedure must be performed when the printer is first installed or when it cannot properly detect the top of the label.
Types of Media Non-Continuous Web Media Non-continuous web media (refer to Figure 3) refers to individual labels that are 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.
Non-Continuous Black Mark Media Non-continuous black mark media has black marks printed on the back that indicate the start and end of each label (refer to Figure 4). Black mark Black mark Non-continuous media for black mark sensing Figure 4 Continuous Media Continuous media (refer to Figure 5) is one uninterrupted roll of material that allows the image to be printed anywhere on the label.
Choosing the Print Mode n n n n 8 Tear-off mode allows you to tear off each label, or a strip of labels, after it is printed. In peel-off mode, backing material is peeled away from the label as it is printed. After this label is removed from the printer, the next one is printed. When in cutter mode, the printer automatically cuts the label after it is printed. In rewind mode, the media and/or backing are rewound onto a core as the labels are printed.
Loading the Media Figure 6 illustrates one method of media loading. For more detailed instructions, as well as information about how to load the different types of media and the various printing modes, refer to the instructions that begin on page 22.
Positioning the Media Sensor The correct positioning of the media sensor is important. It can make the difference between a perfect label and a call to Technical Support! 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).
Adjusting the Reflective Sensor Refer to Figure 7. 1. Open the printhead assembly by pressing the printhead open lever. 2. Locate the reflective sensor positioning lever. 3. Move the reflective sensor positioning lever across the width of the media until the reflective sensor aligns with the start-of-label indicator. The glow of the red light will assist in the proper placement of the reflective sensor. 4. Close the printhead assembly.
Transmissive Sensor The transmissive sensor is in a fixed position and enabled via the front panel (details in “SENSOR SELECT” on page 41). Loading the Ribbon Refer to Figure 8. For more detailed information, refer to the instructions that begin on page 34.
Auto Calibration When auto calibrating, the printer is determining the label length and media/ribbon 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 the PAUSE key.) The printer will begin to auto calibrate when all errors have been cleared.
Operator Controls POWER Switch The POWER switch is located at the back of the printer above the power cord. Turn on the printer. Front Panel For a more detailed explanation of the front panel keys and lights (as shown in Figure 9), refer to the instructions that begin on page 19.
Configuring the Printer The configuration procedure in the next table contains the information you need to get your printer up and running, but it is not comprehensive. Refer to page 40 for more information. n Press the SETUP/EXIT key at the “PRINTER READY” display to enter the configuration mode. NOTE: You will need to press the INCREMENT (+) key more than once to advance to some of the displays. n n n n Press the INCREMENT (+) or DECREMENT (-) key to scroll to the setting you wish to change.
Configuring the Software of Printer Driver Many printer settings may also be controlled by your printer’s driver or label preparation software. Refer to the driver or software documentation for more information. Printing a Test Label To print a test label: 1. Turn off the printer. 2. Press and hold the CANCEL key while turning on the printer. 3. Release the key after the DATA light turns off (approximately five seconds).
Establishing Communication System Considerations Interfaces The method of interfacing this printer to a data source depends on the communication options installed in the printer. The standard interfaces are an RS-232/RS-422/RS-485 serial data port and a bi-directional parallel port. The optional ZebraNet PrintServer II enables printers to be connected to 10Base-T Ethernet networks.
When communicating via the parallel port (refer to Figure 12), the previously mentioned parameters are not considered. Refer to page 46 to configure the communication parameters for the printer. The values selected must be the same as those used by the host equipment connected to the printer. Printer 36-pin male Computer PC 25-pin female For serial and parallel pinout and technical information, refer to the Appendix on page 85.
Printer Basics Front Panel This section discusses the functions of the various controls and indicators on the printer. The operator should become familiar with each of these functions. Front Panel Display The front panel display communicates operational status and programming modes and parameters.
Front Panel Keys Key FEED Function 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 once the current batch is complete. CANCEL When in the pause mode, this key will cancel print jobs.
Front Panel Lights Light POWER PAUSE Status 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 Off ERROR DATA Indication Off In peel-off mode, the PAUSE light flashes when the label is available for removal, and when initializing FLASH or PCMCIA memory. Normal printer operation (no errors).
Roll Media Loading Tear-Off Mode Refer to Figure 14. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger. 5. Flip up the media supply guide. Slide in the media supply guide so that it just touches, but does not restrict, the edge of the roll. 6.
Media supply guide Transmissive sensor Printhead assembly Ribbon sensor Dancer Media guide Media supply hanger Printhead open lever Figure 14 Zebra Z4M Printer User’s Guide 23
Cutter Mode (Cutter option required) Refer to Figure 15. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger. 5. Flip up the media supply guide. Slide in the media supply guide so that it just touches, but does not restrict, the edge of the roll. 6.
Media supply guide Printhead assembly Cutter module Ribbon sensor Dancer Media guide Printhead open lever Transmissive sensor Media supply hanger Figure 15 Zebra Z4M Printer User’s Guide 25
Value Peel-Off Mode (Value peel option required) Refer to Figure 16. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger. 5. Flip up the media supply guide. Slide in the media supply guide so that it just touches, but does not restrict, the edge of the roll. 6.
Media supply guide Transmissive sensor Lever Printhead assembly Dancer Label Ribbon sensor Media guide Media supply hanger Printhead open lever Figure 16 Zebra Z4M Printer User’s Guide 27
Power Peel-Off Mode (Power peel-off option required) Refer to Figure 17. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger. 5. Flip up the media supply guide. Slide in the media supply guide so that it just touches, but does not restrict, the edge of the roll. 6.
Media supply guide Transmissive sensor Front housing assembly Printhead assembly Label Dancer Ribbon sensor Media guide Printhead open lever Media supply hanger Take-up spindle Rewind media guide Media alignment spindle Thumbscrew Figure 17 Backing Removal 1. Cut the backing material prior to where it winds onto the take-up spindle. 2. Rotate the take-up spindle until the rewind media guide is in the “12 o’clock” position. 3.
Power Rewind Mode (Power rewind option required) Refer to Figure 18. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger. 5. Flip up the media supply guide. Slide in the media supply guide so that it just touches, but does not restrict, the edge of the roll. 6.
Media supply guide Transmissive sensor Front housing assembly Printhead assembly Dancer Ribbon sensor Media guide Printhead open lever Media supply hanger Take-up spindle Rewind media guide Media alignment spindle Thumbscrew Figure 18 Media Removal 1. Cut the media prior to where it winds onto the take-up spindle. 2. Rotate the take-up spindle until the rewind media guide is in the “12 o’clock” position. 3.
Fanfold Media Loading Fanfold media feeds through either the bottom or rear access slot. Refer to Figure 19. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible. 4. Pass the fanfold media over the media supply hanger. 5. Flip up the media supply guide. Slide in the media supply guide so that it just touches, but does not restrict, the edge of the media. 6.
Media supply guide Printhead assembly Transmissive sensor Dancer Ribbon Media guide sensor Printhead open lever Media supply hanger Media supply guide Printhead assembly Transmissive sensor Dancer Ribbon Media guide sensor Printhead open lever Media supply hanger Figure 19 Zebra Z4M Printer User’s Guide 33
Ribbon Loading 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 wide ribbon is used and normal tension hampers the ribbon movement. To place this spindle in the "normal" position, firmly pull out the spindle end cap until it clicks into place as shown in Figure 20.
Ribbon take-up spindle Printhead assembly Ribbon guide plate Ribbon supply spindle Printhead open lever Printhead assembly Ribbon take-up spindle Ribbon guide plate Ribbon supply spindle Printhead open lever Ribbon sensor Figure 21 Zebra Z4M Printer User’s Guide 35
Ribbon Removal To remove the ribbon: 1. Break the ribbon between the ribbon guide plate and the ribbon take-up spindle. 2. While turning the ribbon take-up spindle release knob counterclockwise, squeeze the ribbon against the ribbon take-up spindle tension blades. 3. When the tension blades collapse into the ribbon take-up spindle, hold the release knob and rotate the spent ribbon toward the rear of the printer. Then, slide off the ribbon.
Configuration After you have installed the media and ribbon and the power-on self test (POST) is complete, the front panel display will show “PRINTER READY.” (If the printer fails its POST, refer to page 73.) You may now set printer parameters for your application using the front panel display and the four keys directly below it. NOTE: Printers that are operating on an IP network can be quickly configured via ZebraNet WebView™ (optional ZebraNet PrintServer II required).
Changing Password-Protected Parameters Certain parameters are password protected by factory default. NOTE: You have the option of making ALL parameters password protected. See “PASSWORD LEVEL” on page 52. CAUTION: Do not change password-protected parameters unless you are sure you know what you are doing! If they are set incorrectly, these parameters could cause the printer to function in an unpredictable way.
Leaving the Setup Mode You can leave the program mode at any time by pressing the SETUP/EXIT key. The “SAVE CHANGES” display will appear. There are five choices, described below. Pressing the INCREMENT (+) or DECREMENT (-) key displays other choices and pressing the SELECT key selects the displayed choice. n n n PERMANENT -- Permanently saves the changes. Values are stored in the printer even when power is turned off. TEMPORARY -- Saves the changes until changed again or until power is turned off.
Configuration and Calibration Sequence Display Shows PRINTER READY Action/Explanation Normal printer operation. Setting Print Parameters 40 DARKNESS Adjusting Print Darkness Press the INCREMENT (+) key to increase darkness. Press the DECREMENT (-) key to decrease darkness. Default: +10 Range: 0 to +30 Darkness settings are dependent upon a variety of factors, including ribbon type, media, and the condition of the printhead. You may adjust the darkness for consistent high-quality printing.
Display Shows Action/Explanation PRINT MODE Selecting Print Mode Press the INCREMENT (+) or DECREMENT (-) key to display other choices. Default: Tear-off Selections: Tear-off, peel-off, cutter, rewind Print mode settings tell the printer the method of media delivery that you wish to use. Be sure to select a print mode that your hardware configuration supports since some selections displayed are for optional printer features.
Display Shows 42 Action/Explanation PRINT METHOD Selecting Print Method Press the INCREMENT (+) key for the next value; press the DECREMENT (-) key for the previous value. Default: Thermal transfer Selections: Thermal transfer, direct thermal The print method parameter tells the printer the method of printing you wish to use: direct thermal (no ribbon) or thermal transfer (using thermal transfer media and ribbon).
Listing Printer Information Display Shows Action/Explanation LIST FONTS List Fonts Press the INCREMENT (+) key to print a label listing all of the available fonts. This selection is used to print a label that lists all of the fonts currently available in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM, FLASH memory, font EPROMs, or font cards.
Display Shows 44 Action/Explanation INITIALIZE CARD Initialize Memory Card CAUTION: Perform this operation only when it is necessary to erase all previously stored information from the optional memory card. Press the SETUP/EXIT key to bypass this function. 1. Press the INCREMENT (+) key to select “YES.” If your printer is set to require a password, you will now be prompted to enter the password. Enter the password and then press the SELECT key. 2. The display will ask “INITIALIZE CARD?”.
Media and Ribbon Sensor Calibration Performing the manual calibration procedure first resets the sensitivity of the sensors to better detect the media and ribbon you are using. 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. Display Shows Action/Explanation SENSOR PROFILE Sensor Profile Press the INCREMENT (+) key to print a media sensor profile.
Setting Communication Parameters Communication parameters must be set correctly for the printer to communicate with the host. These parameters make sure that the printer and host are “speaking the same language.” All communication parameters are password protected. Display Shows Action/Explanation PARALLEL COMM Setting Parallel Communications Press the INCREMENT (+) or DECREMENT (-) key to display other choices.
Display Shows Action/Explanation PARITY Setting Parity Press the INCREMENT (+) or DECREMENT (-) key to display other choices. Default: Even Selections: Even, odd, none The parity of the printer must match the parity of the host for accurate communications to take place. Select the parity that matches the one being used by the host. Setting Host Handshake Press the INCREMENT (+) or DECREMENT (-) key to display other choices.
Display Shows Action/Explanation NETWORK ID Setting Network ID Press the DECREMENT (-) key to move to the next digit position, press the INCREMENT (+) key to increase the value of the digit. Default: 000 Range: 000 - 999 Network ID is used to assign a unique number to a printer used in an RS-422/RS-485 network. This gives the host the means to address a specific printer. If the printer is used in a network, you must select a network ID number. This does not affect TCP/IP or IPX networks.
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. NOTE: DO NOT use the same hex value for the control, format, and delimiter character. The printer needs to see different characters to function properly.
Selecting ZPL Mode Display Shows Action/Explanation ZPL MODE Selecting ZPL Mode Press the INCREMENT (+) or DECREMENT (-) key to display other choices. Default: ZPL II Selections: ZPL II, ZPL The printer will remain in the selected mode until it is changed by this front panel instruction or by using a ZPL/ZPL II command. The printer accepts label formats written in either ZPL or ZPL II. This eliminates the need to rewrite any ZPL formats you already have.
Label Positioning Parameters Display Shows Action/Explanation BACKFEED Backfeed Sequence Press the INCREMENT (+) or DECREMENT (-) key to display other choices. Default: Default (90%) Selections: Default, after, before, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, off This parameter establishes when and how much label backfeed occurs after a label is removed or cut in the peel-off or cutter modes. It has no effect in rewind or tear-off modes.
Display Shows Action/Explanation WEB S. MEDIA S. RIBBON S. TAKE LABEL S. MEDIA LED These parameters are automatically set during the calibration procedure. They should only be changed by a qualified service technician. Refer to the maintenance manual for more information on these parameters. Press the SELECT key repeatedly to skip these parameters.
Display Shows Action/Explanation IP RESOLUTION* IP Resolution Press the INCREMENT (+) or DECREMENT (-) key to display other choices. Default: Dynamic Selections: Dynamic, permanent Depending on the selection, allows either the user (”permanent”) or the server (”dynamic”) to select the IP address. For more information, refer to ZebraNet Networking: PrintServer II Installation and User’s Guide. IP PROTOCOLS* IP Protocols Press the INCREMENT (+) or DECREMENT (-) key to display other choices.
Display Shows Action/Explanation LANGUAGE Selecting the Display Language Press the INCREMENT (+) or DECREMENT (-) key to display other choices. Default: English Selections: English, Spanish, French, German, Italian, Norwegian, Portuguese, Swedish, Danish, Spanish 2, Dutch, Finnish, Japan This parameter allows you to change the language used on the front panel display. You have now completed the entire configuration and calibration sequence. You may either press the SELECT key or the SETUP/EXIT key.
Routine Care and Adjustments Cleaning This table provides a recommended cleaning schedule. Specific cleaning procedures are provided on the following pages. Area Method Printhead Solvent* Platen roller Solvent* Media sensors Air blow Ribbon sensor Air blow Media path Solvent* Ribbon path Solvent* Pinch roller (Optional value peel-off option required. See Figure 25.) Solvent* Interval After every roll of media (or 500 feet of fanfold media) when printing in the direct thermal mode.
Cleaning 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. Cleaning the Interior Remove any accumulated dirt and lint from the interior of the printer using a soft bristle brush and/or vacuum cleaner.
NOTE: If print quality has not improved after performing this procedure, try cleaning the printhead with Save-a-Printhead cleaning film. This specially coated material removes contamination buildup without damaging the printhead. Call your authorized Zebra reseller for more information. Printhead assembly Take label sensor Transmissive sensor Ribbon sensor Reflective sensor Platen roller Figure 23 Cleaning the Sensors Brush or vacuum any accumulated paper lint and dust away from the printer sensors.
Cleaning the Power Peel-Off Module (Power peel-off option required) Perform the following procedure if adhesive buildup begins to affect peel performance. Refer to Figure 24. 1. Open the printhead assembly. 2. Open the front housing assembly by lifting the two handles; then, pivot down the front housing assembly. 3. Remove the accumulated adhesive by rolling the sticky side of a blank label against the peel rollers and lifting it away. (Do this step repeatedly until a majority of the adhesive is gone.
Cleaning the Value Peel-Off Module (Value peel-off option required) Perform the following procedure if adhesive buildup begins to affect peel-off performance. Refer to Figure 25. 1. Open the printhead assembly. 2. Open the pivot bracket assembly by pivoting the module toward you. 3. Use a swab soaked with the Zebra-recommended solvent to remove adhesive from the tear-off/peel-off bar. 4. Manually rotate the pinch roller and clean thoroughly with solvent and a swab. 5.
Cleaning the Cutter Module (Cutter option required) WARNING!!! For personnel safety, ALWAYS turn off and unplug the printer before performing this procedure. Refer to Figure 26. To clean adhesive off of the upper and lower cutter blades: 1. Use a swab moistened with the Zebra-recommended solvent to wipe along the upper cutter blade. 2. To expose the lower cutter blade, turn the cutter motor thumbnut counterclockwise until you see the “V”-shaped lower cutter blade. 3.
Upper cutter blade Lower cutter blade Cutter motor thumbnut Figure 26 Lubrication CAUTION! No lubricating agents of any kind should be used on this printer! Some commercially available lubricants will damage the finish and the mechanical parts, if used.
Printhead Pressure Adjustment This adjustment may be necessary if printing is too light on one side or if thick media is used. Refer to Figure 27. The pressure adjustment dials each have four possible settings designated by blocks of increasing size embossed on the print mechanism. The smallest block (fully counterclockwise) is considered “position 1” and the largest block (fully clockwise) is considered “position 4.” The following table will help you to select the initial dial settings for your media.
Pressure adjustment dials Figure 27 Zebra Z4M Printer User’s Guide 63
Power Rewind Media Alignment (Power rewind option required.) NOTE: Under normal operating conditions, media alignment should not be necessary if the media/backing was initially installed tightly against the backplate of the take-up spindle. Perform the following adjustment if the media does not track properly onto the take-up spindle. Refer to Figure 28. 1. With media and backing material loaded, open the printhead assembly. 2.
Printhead assembly Take-up spindle Adjustment dial Figure 28 Zebra Z4M Printer User’s Guide 65
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 3AG fast blow style rated at 5 Amp/250 VAC. Before replacing the fuse, turn off the AC power switch and unplug the AC power cord. To replace the fuse, insert the tip of a flat blade screwdriver into the slot in the end of the fuse holder end cap. Press in slightly on the end cap and turn the screwdriver slightly counterclockwise.
Troubleshooting LCD Error Conditions and Warnings Error condition RIBBON OUT Problem Solution In thermal transfer mode, the ribbon is not loaded or loaded incorrectly. Load the ribbon correctly. See “Ribbon Loading” on page 34. In thermal transfer mode, the ribbon sensor is not sensing correctly loaded ribbon. Perform the media and ribbon sensor calibration (see page 45).
Error condition HEAD OPEN Problem Solution The printhead is not fully closed. Close the printhead. The ribbon is loaded incorrectly; it is covering the head open sensor. Correctly align the ribbon with the guide mark on the ribbon guide plate before closing the printhead assembly. See “Ribbon Loading” on page 34. Error condition RIBBON IN Problem Solution Print method is incorrectly set. Via the front panel, locate the “PRINT METHOD” menu item (page 42) and select thermal transfer mode.
Warning CUTTER JAM Problem Cutter blade is in the media path. Solution 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 60. OUT OF MEMORY* Problem Solution Insufficient DRAM for the label length, downloaded fonts/graphics, and images. *There is not enough memory to perform the function shown on the second line of the error message.
Gray lines on blank labels with no consistent pattern Problem Solution Clean the printhead according to the instructions on page 56. The printhead is dirty. Light, consistent vertical lines running through all of the labels Problem The printhead or platen roller is dirty. Solution Clean the printhead, platen roller, or both according to the instructions on page 56. Intermittent creases on the left and right edges of the label Problem There is too much pressure on the printhead.
Calibration Problem Solution Adjust the reflective sensor position. See page 11. Set the printer for the correct media type. See page 41. Ensure that the media guides are properly positioned. Loss of printing registration on labels. Excessive vertical drift in top-of-form registration. Via the front panel, locate the “SENSOR SELECT” menu item (page 41) and manually select the correct sensing method. Reload the media. Check the reflective sensor position (see page 11).
A label format was sent to the printer. Several labels print, then the printer skips, misplaces, misses, or distorts the image on the label. Problem The host is set to EPP parallel communications. The serial communication settings are incorrect. Solution Change the settings on the computer host to standard parallel communications. Check the communication cable length. See page 18 for requirements. Check the printer driver or software communications settings (if applicable).
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 monitor the progress of the POST. If the printer fails any of these tests, the word “FAILED” will be added to the display. If this occurs, notify an authorized Zebra reseller.
CANCEL Key Self Test This self test prints a listing of the configuration parameters currently stored in the printer’s memory. See Figure 29. (Depending on the options ordered, your label may look different.) 1. Turn off the printer. 2. Press and hold the CANCEL key while turning on the power. 3. Release the key after the DATA light turns off (approximately five seconds).
PAUSE Key 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 in Figure 30. 1. Turn off the printer. 2. Press and hold the PAUSE key while turning on the power. 3. Release the key after the DATA light turns off (approximately five seconds). n n n n n n Figure 30 The initial self test prints 15 labels at 2"/51 mm per second, then automatically pauses the printer.
FEED Key Self Test See Figure 31. 1. Turn off the printer. 2. Press and hold the FEED key while turning on the power. 3. Release the key after the DATA light turns off (approximately five seconds). The FEED key self test prints out at various darkness settings above and below that of the darkness value shown on the configuration label. Look at these labels and determine which one has the best darkness setting for your application.
Communications Diagnostics Test This test is controlled from the front panel display. Refer to page 48. A typical printout from this test is shown in Figure 32. Turn off the power to exit this self test. NOTE: This label will be inverted when printed. Figure 32 Loading Factory Defaults 1. Press the SELECT key two times. 2. Use the INCREMENT (+) or DECREMENT (-) key to scroll through the “SAVE CHANGES” choices. 3. When “LOAD DEFAULTS” displays, press the SELECT key.
78 Zebra Z4M Printer User’s Guide
Specifications NOTE: Printer specifications are subject to change without notice. General Specifications General Specifications Z4M Height 13.3” 338 mm Width 10.9” 277 mm Depth 18.7” 475 mm Weight (without options) 32.4 lbs. 14.7 kg Electrical 90-265 VAC, 48-62 Hz, 5 Amps (fused) CISPR 22B, IEC 950, 801-2, -3, and -4 standard. Complies with FCC Class B and Canadian Doc Class A rules. Carries the CE mark of compliance.
Printing Specifications Printing Specifications Z4M 203 dots/inch Print resolution Dot size (width x length) 300 dots/inch 12 dots/mm 203 dots/inch 0.00492” x 0.00492” 0.125 mm x 0.125 mm 300 dots/inch 0.0033” x 0.0039” 0.84 mm x 0.99 mm 4.
Media Specifications Media Specifications Label length Minimum 0.5” 13 mm Peel-off 1” 25.4 mm Rewind 0.5” 13 mm Cutter 1” 25.4 mm 39” 991 mm 4.5” 114 mm Minimum 0.0023” 0.058 mm Maximum Maximum Label width (maximum) Total thickness (includes liner, if any) Z4M Tear-off 0.010” 0.25 mm Core size 3” 76 mm Maximum roll diameter 8” 203 mm Minimum 0.079” 2 mm Preferred 0.118” 3 mm Maximum 0.157” 4 mm 0.236” x 0.
Zebra Programming Language (ZPL II) n n Downloadable graphics (with data compression) Bit image data transfer and printing, mixed text/graphics n Format inversion n Mirror image printing n Slew command n Serialized fields n n Four-position field rotation (0°, 90°, 180°, 270°) n n n n Programmable quantity with print pause Communicates in printable ASCII characters Controlled via mainframe, mini, PC, portable data terminal In-Spec OCR-A and OCR-B UPC/EAN (nominal 100% magnification [6 dots/m
AC Power Cord 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. WARNING!!! 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 n The overall length must be less than 9.8” (3.0 m). n It must be rated for at least 5A, 250 VAC.
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Appendix Printer Interface Technical Information Serial Data Communications The following table illustrates the pin connections on the DB-25 connector at the rear of the printer. Pin No.
RS-232 Interface This printer is configured as Data Terminal Equipment (DTE). The serial data cable used to connect the printer to the host computer will be one of two styles: n 9-pin to 25-pin cable – (null modem cable) must have a 9-pin “D” type (DB-9S) connector on the end that is plugged into the serial port at the computer and a 25-pin “D” type (DB-25P) connector on the other end that is plugged into the connector at the rear of the printer. Figure 35 shows the required cable connections.
Hardware Control Signal Descriptions For all RS-232 input and output signals, this printer follows both the Electronics Industries Association (EIA) RS-232 and the Consultative Committee for International Telegraph and Telephone (CCITT) V.24 standard signal level specifications. When DTR/DSR handshaking is selected, the Data Terminal Ready (DTR) control signal output from the printer controls when the host computer may send data. DTR ACTIVE (positive voltage) permits the host to send data.
RS-485 Interface Figure 37 illustrates the pin connections on the DB-25 connector at the rear of the printer that are used for the RS-485 communication protocol. NOTE: XON/XOFF handshaking must be used for RS-485 communications.
Parallel Data Communications The following table illustrates the pin connections on the bi-directional parallel connector at the rear of the printer. Pin No. 1 Description nStrobe/HostClk 2-9 Data Bits 1-8 10 nAck/PtrClk 11 Busy/PtrBusy 12 PError/AckDataReq 13 Select/Xflag 14 nAutoFd/HostBusy 15 Not Used 16 and 17 18 19-30 Ground +5V @ 1A Ground 31 ninit 32 nFault/nDataAvail 33 and 34 Not Used 35 +5V through a 3.
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Index A Adjustments Printhead pressure . . . . . . . . . . 62 Reflective sensor . . . . . . . . . . . 11 Auto calibration . . . . . . . . . . . . . 13 C Leaving the setup mode . . . . . . . 39 Configuring the printer Basic . . . . . . . . . . . . . . . . . 15 Complete . . . . . . . . . . . . . . . 40 Continuous media . . . . . . . . . . . . . 7 D Cabling requirements . . . . . . . . . . . 18 Calibrating the printer . . . . . . . . . . . 5 Calibration, auto . . . . . . . . . . . . .
M Maintenance manual . . . . . . . . . . . . 1 Media loading Cutter . . . . . . . . . . . . . . . . . 24 Fanfold . . . . . . . . . . . . . . . . 32 Power peel-off . . . . . . . . . . . . 28 Power rewind . . . . . . . . . . . . . 30 Roll . . . . . . . . . . . . . . . . . . 22 Tear-off . . . . . . . . . . . . . . . . 22 Value peel-off. . . . . . . . . . . . . 26 Media requirements . . . . . . . . . . . . 2 Media sensors Reflective . . . . . . . . . . . . . . . 10 Transmissive . . . . . . . . . . . . .
U Unpacking . . . . . . . . . . . . . . . . . 1 Z ZebraNet Networking: PrintServer II Installation and User's Guide . . . . . . 1 ZPL II Programming Guide Volume I and Volume II . . . . . . . . .
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