ZM400™ User Guide for UPS
© 2010 ZIH Corp. The copyrights in this manual and the software and/or firmware in the label printer described therein are owned by ZIH Corp. Unauthorized reproduction of this manual or the software and/or firmware in the label printer may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability. This product may contain ZPL®, ZPL II®, and ZebraLink™ programs; Element Energy Equalizer® Circuit; E3®; and Monotype Imaging fonts.
Declaration of Conformity Declaration of Conformity I have determined that the Zebra printers identified as the ZM™ Series Z4M, Z6M, Z4Mplus, Z6Mplus, R4Mplus, ZM400, ZM600 manufactured by: Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills, Illinois 60061-3109 U.S.A.
Declaration of Conformity Compliance Information Compliance Information FCC Compliance Statement This device complies with Part 15 rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference, and 2. This device must accept any interference received, including interference that may cause undesired operation.
Contents Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Compliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Select a Data Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data Cables and Wireless Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect the Printer to the Computer or Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Cord Specifications . . . . . . . . . . . . . . . .
Contents 6 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _______________________________________________
About This Document This section provides you with contact information, document structure and organization, and additional reference documents. Contents Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Document Who Should Use This Document Who Should Use This Document This User Guide for UPS is intended for use by any person who needs to operate or to troubleshoot problems with the printer. How This Document Is Organized The User Guide for UPS is set up as follows: Section Description Introduction on page 15 This section shows the operational controls and location of major components used when loading media.
About This Document Contacts Contacts Use the following phone numbers to contact UPS technical support: • Technical Support for UPS OnLine® WorldShip: 888-553-1118 • Technical Support for UPS Internet Shipping: 877-289-6418 • General Information: 1-800-PICK-UPS® (1-800-742-5877) • International Shipping Information: 800-782-7892 Visit our web site at http://www.ups.com®. For documentation or driver updates, go to or http://www.ups.zebra.com. 2/26/10 ZM400 User Guide for UPS P1016807-001 Rev.
About This Document Document Conventions Document Conventions The following conventions are used throughout this document to convey certain information. Alternate Color (online only) Cross-references contain hot links to other sections in this guide. If you are viewing this guide online in .pdf format, you can click the cross-reference (blue text) to jump directly to its location. LCD Display Examples Text from a printer’s Liquid Crystal Display (LCD) appears in Bubbledot ICG font.
About This Document Document Conventions Illustration Callouts Callouts are used when an illustration contains information that needs to be labeled and described. A table that contains the labels and descriptions follows the graphic. Figure 1 provides an example. Figure 1 • Sample Figure with Callouts 1 2 1 2 2/26/10 FEED button CANCEL button ZM400 User Guide for UPS P1016807-001 Rev.
About This Document Document Conventions Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ______________
1 Introduction This section shows the operational controls and location of major components used when loading media. Contents External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction External View External View Figure 2 and Figure 3 show the components and connections on the outside of the printer. Figure 2 • Front of Printer 1 2 1 2 Control panel Media door Figure 3 • Rear of Printer 3 4 5 1 2 3 4 Power switch (O = off, I = on) AC power connector Wireless print server card slot (Ethernet) Wireless card ejector button P1016807-001 Rev.
Introduction Printer Media Compartment Printer Media Compartment Figure 4 shows the components inside the media compartment of your printer. Figure 4 • Printer Components 3 4 1 5 6 2 1 2 3 4 5 6 2/26/10 Peel release lever Printhead release latch Media supply guide Media hanger Dancer assembly Liner take-up spindle ZM400 User Guide for UPS P1016807-001 Rev.
Introduction Control Panel Control Panel The control panel contains the lights that indicate basic operation and the buttons that you may need to press during basic operation. The control panel buttons and lights are labeled in Figure 5. Descriptions for each are located in Table 1 and Table 2. Figure 5 • Control Panel 1 2 3 4 5 12 6 11 10 7 9 8 1 2 3 4 5 6 7 8 9 10 11 12 P1016807-001 Rev.
Introduction Control Panel Control Panel Buttons Table 1 • Control Panel Buttons Button Function FEED Forces the printer to feed one blank label each time the button is pressed. • Printer not printing: one blank label immediately feeds. • Printing: one blank label feeds after the current batch of labels is complete. PAUSE Starts and stops the printing process. • Printer not printing: no printing occurs. (Press PAUSE again to resume printing.
Introduction Control Panel Control Panel Lights Table 2 • Control Panel Lights Light Status Indication POWER Off The printer is off, or no power is applied. On The printer is on. Off Normal printer operation. On The printer has stopped all printing operations. Flashing The Pause light flashes when initializing FLASH memory and in Peel-Off Mode when the label is available. Off Normal printer operation (no errors). PAUSE ERROR On An error condition is preventing printing.
2 Printer Setup This section provides the tasks that you must complete and the issues that you must consider before you load and configure your printer. Contents Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Setup Before You Begin Before You Begin Review this checklist, and resolve any issues before you set up or use your printer. Unpack and Inspect the Printer Have you unpacked the printer and inspected it for damage? If you have not, see Unpack and Inspect the Printer on page 23. Select a Site Have you selected an appropriate location for the printer? If you have not, see Select a Site for the Printer on page 24.
Printer Setup Handling the Printer Handling the Printer This section describes how to handle your printer. Unpack and Inspect the Printer When you receive the printer, immediately unpack it and inspect for shipping damage. • Save all packing materials. • Check all exterior surfaces for damage. • Raise the media door, and inspect the media compartment for damage to components. If you discover shipping damage upon inspection: • Immediately notify the shipping company and file a damage report.
Printer Setup Select a Site for the Printer Select a Site for the Printer Consider the following when selecting an appropriate location for your printer. Select a Surface Select a solid, level surface of sufficient size and strength to accommodate the printer and other equipment (such as a computer), if necessary. The choices include a table, countertop, desk, or cart. For the printer’s weight and dimensions, see General Specifications on page 106.
Printer Setup Select a Data Communication Interface Select a Data Communication Interface Table 5 provides basic information about data communication interfaces that you can use to connect your printer to a computer. You may send label formats to the printer through any data communication interface that is available. Select an interface that is supported by both your printer and your computer or your Local Area Network (LAN).
Printer Setup Select a Data Communication Interface Data Cables and Wireless Cards You must supply all data cables or wireless cards for your application. Data Cables Ethernet cables do not require shielding, but all other data cables must be fully shielded and fitted with metal or metallized connector shells. Unshielded data cables may increase radiated emissions above the regulated limits. To minimize electrical noise pickup in the cable: • Keep data cables as short as possible.
Printer Setup Select a Data Communication Interface Table 6 • Connecting the Printer to a Computer or Network (Continued) Interface Connection and Configuration IEEE 1284 Bidirectional Parallel No additional configuration is necessary. USB No additional configuration is necessary. Caution • Be careful not to plug the USB cable into the wired Ethernet print server connector on the printer because doing so will damage the connector. 2/26/10 ZM400 User Guide for UPS P1016807-001 Rev.
Printer Setup Select a Data Communication Interface Table 6 • Connecting the Printer to a Computer or Network (Continued) Interface Connection and Configuration Internal wired Ethernet print server Refer to the ZebraNet 10/100 Print Server User and Reference Guide for configuration instructions. A copy of this manual is available at http://www.zebra.com/manuals or on the user CD that came with your printer.
Printer Setup Connect the Printer to a Power Source Connect the Printer to a Power Source The AC power cord must have a three-prong female connector on one end that plugs into the mating AC power connector at the rear of the printer. If a power cable was not included with your printer, refer to Power Cord Specifications on page 30. Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation.
Printer Setup Connect the Printer to a Power Source Power Cord Specifications Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation. This cord must use an IEC 320 female connector and the appropriate region-specific, three-conductor grounded plug configuration. Depending on how your printer was ordered, a power cord may or may not be included.
Printer Setup Types of Media Types of Media Important • Zebra strongly recommends the use of Zebra-brand supplies for continuous high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the printing capabilities of the printer and to prevent premature printhead wear. To purchase supplies, go to http://www.zebra.com/howtobuy.
Printer Setup Types of Media Table 7 • Types of Media Roll and Fanfold Media (Continued) Media Type How It Looks Description Non-Continuous Fanfold Media Fanfold media is folded in a zigzag pattern. Fanfold media can have the same label separations as non-continuous roll media. The separations would fall on or near the folds. Continuous Roll Media Roll media is wound on a 3-in. (76-mm) core. Continuous roll media does not have gaps, holes, notches, or black marks to indicate label separations.
3 Operations This section provides the procedures for loading and calibrating the printer. Note • Complete the tasks and resolve the issues in Printer Setup on page 21 before operating the printer. Contents Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mode Descriptions and Printer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operations Print Modes and Printer Options Print Modes and Printer Options The printer can use different print modes and options for label removal (Table 8). Use a print mode that matches the media being used and the printer options available. For more information on the types of media, see Types of Media on page 31. To select a print mode, see Select Print Mode on page 55.
Operations Print Modes and Printer Options Media Paths Table 9 shows the media paths for print mode and printer option combinations using roll media. Fanfold media uses the same print modes and printer options as roll media.
Operations Load Media Load Media The beginning steps for loading media apply to all printers, including those that have the peel-off option. When you have completed these beginning steps, continue with the media loading instructions for the print mode and printer options that apply to you. For more information about print modes and printer options, see Print Modes and Printer Options on page 34.
Operations Load Media 3. Insert media into the printer. Follow the instructions for roll or fanfold media, as appropriate. Fanfold Media Roll Media a. Remove and discard any tags or labels that are dirty or that are held by adhesives or tape. a. Flip down the media supply guide. b. Flip down the media supply guide. b. Feed the media through the rear or bottom access slot. Rear Feed c. d. 2/26/10 Place the roll of media on the media supply hanger. Push the roll as far back as it will go.
Operations Load Media Fanfold Media (Continued) Roll Media (Continued) e. Slide in the media supply guide until it touches the edge of the roll. d. Flip up the media supply guide. e. Slide in the media supply guide until it touches the edge of the media. 4. Feed the media under the dancer assembly (1), the upper media sensor (2), and the printhead-open sensor (3). Slide the media back until it touches the inside back wall of the upper media sensor. 3 P1016807-001 Rev.
Operations Load Media 5. Slide in the media guide until it touches the outer edge of the media. 6. Continue with the steps that apply to the print mode that you will use. To operate in... Then... Tear-Off mode Go to step 13 on page 42. Peel-Off mode Continue with step 7. Liner Take-Up mode Continue with step 7. 7. Push down the peel-off mechanism release lever to open the peel assembly. 2/26/10 ZM400 User Guide for UPS P1016807-001 Rev.
Operations Load Media 8. Extend the media approximately 18 in. (500 mm) out of the printer. 9. Remove the exposed labels so that only the liner remains. 10. Feed the liner over the tear-off/peel-off bar (1) and behind the peel assembly (2). Make sure that the end of the liner falls outside of the printer. 1 2 P1016807-001 Rev.
Operations Load Media 11. Continue with the steps that apply to the print mode that you will use. To operate in... Then... Peel-Off mode Continue with step 12. Liner Take-Up mode a. Slide the liner into the slot in the liner take-up spindle (1). 1 2/26/10 b. Push the liner back until it touches the back plate of the liner take-up spindle assembly. c. Wrap the liner around the liner take-up spindle and turn the spindle counterclockwise to tighten the liner. d. Continue with step 12.
Operations Load Media 12. Caution • Use the peel release lever and your right hand to close the peel assembly. Do not use your left hand to assist in closing. The top edge of the peel roller/assembly could pinch your fingers. Close the peel assembly using the peel-off mechanism release lever. 13. Set the printer to the appropriate print mode. See Select Print Mode on page 55 for instructions. 14. Close the printhead assembly. 15.
Operations Remove Used Liner Remove Used Liner When you use the liner take-up option, you will periodically need to remove used liner from the liner take-up spindle. To remove used liner from the liner take-up spindle, complete these steps: 1. If the media has not run out, tear the liner before the liner take-up spindle. 2. Pull the liner release slide toward you until it stops (about a third of the way down the liner take-up spindle). 3. Slide the used liner from the liner take-up spindle.
Operations Calibrate the Printer Calibrate the Printer Auto Calibration By default, the printer automatically calibrates on power up or when the printhead is closed. During auto calibration, the printer determines the label length and sensor settings. The results of the auto calibration are stored in the printer’s memory and are retained even if printer power is removed. These parameters remain in effect until the next calibration is performed.
Operations Adjust Printhead Pressure Adjust Printhead Pressure You may need to adjust printhead pressure if printing is too light on one side, if you use thick media, or if the media drifts from side to side during printing. See Figure 8. The pressure adjustment dials have four possible settings designated by blocks of increasing size embossed on the print mechanism. The smallest block (fully counterclockwise) is considered position 1, and the largest block (fully clockwise) is considered position 4.
Operations Adjust Printhead Pressure 2. If necessary, adjust the pressure adjustment dials as follows: P1016807-001 Rev. A If the media... Then... Requires higher pressure to print well Increase both dials one position. Shifts left while printing Increase the outside dial setting one position, or decrease the inside dial setting one position. Shifts right while printing Increase the inside dial setting one position, or decrease the outside dial setting one position.
4 Configuration This section describes the control panel parameters that are used to configure the printer for operation. Contents Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration Setup Mode Setup Mode After you have installed the media and the Power-On Self Test (POST) is complete, the control panel displays PRINTER READY. You may now set printer parameters for your application using the control panel display and the buttons directly below it. If it becomes necessary to restore the initial printer defaults, see FEED and PAUSE Self Test on page 102.
Configuration Setup Mode Exit Setup Mode To leave Setup mode, complete these steps: 1. Press SETUP/EXIT. The LCD displays SAVE CHANGES. 2. Press PLUS (+) or MINUS (-) to display the save options: LCD Description PERMANENT Stores values in the printer even when power is turned off. TEMPORARY Saves the changes until power is turned off.
Configuration Change Password-Protected Parameters Change Password-Protected Parameters Certain parameters, including the communication parameters, are password-protected by factory default. Caution • Do not change password-protected parameters unless you have a complete understanding of the parameters’ functions. If the parameters are set incorrectly, the printer may function unpredictably. The first time that you attempt to change a password-protected parameter, the printer displays ENTER PASSWORD.
Configuration Print a Configuration Label Print a Configuration Label A configuration label lists the printer settings that are stored in configuration memory. After you load the media, print a configuration label as a record of your printer’s current settings. Keep the label to use when troubleshooting printing problems. To print a configuration label, complete these steps: 1. On the control panel, press SETUP/EXIT. 2.
Configuration Print a Network Configuration Label Print a Network Configuration Label If you are using a print server, you can print a network configuration label after the printer is connected to the network. To print a network configuration label, complete these steps: 1. On the control panel, press SETUP/EXIT. 2. Press PLUS (+) or MINUS (-) to scroll through the parameters until you reach LIST NETWORK. 3. Press SELECT to select the parameter. 4. Press PLUS (+) to confirm printing.
Configuration Control Panel Parameters Control Panel Parameters Use the LCD on the control panel to view and adjust printer settings. How to View or Modify Parameters While viewing parameters, press PLUS (+) to continue to the next parameter, or press MINUS (-) to return to the previous parameter in the cycle. Press SELECT when you want to modify a parameter or view its options.
Configuration Control Panel Parameters Standard Printer Parameters Table 11 shows parameters in the order in which they are displayed when you press PLUS (+) after entering Setup mode. Table 11 • Printer Parameters (Page 1 of 20) Parameter Action/Explanation Adjust Print Darkness Darkness (burn duration) settings depend on a variety of factors, including media type and the condition of the printhead. You may adjust the darkness for consistent high-quality printing.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 2 of 20) Parameter Action/Explanation Adjust the Tear-Off Position This parameter establishes the position of the media over the tear-off/peel-off bar after printing. See Figure 11. Higher numbers move the media out (the tear line moves closer to the leading edge of the next label), and lower numbers move the media in (the tear line moves closer to the edge of the label just printed).
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 3 of 20) Parameter Action/Explanation Set Media Type This parameter tells the printer the type of media that you are using (see Types of Media on page 31 for more information). 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 Control Panel Parameters Table 11 • Printer Parameters (Page 4 of 20) Parameter Action/Explanation Set Maximum Label Length This parameter is used during the media portion of the calibration process. Always set maximum label length to a value that is at least 1.0 in. (25.4 mm) greater than the actual label length (Figure 12). If the value is set to a smaller value than the label length, the printer assumes that continuous media is loaded, and the printer cannot calibrate.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 5 of 20) Parameter Action/Explanation Set Early Warning for Maintenance When this feature is enabled, the printer provides warnings when the printhead needs to be cleaned. Default Value: MAINT. OFF Selections: MAINT. OFF, MAINTENANCE ON To change the Early Warning settings: 1. Press SELECT to select the parameter. 2. When the LCD displays EARLY WARNING MAINTENANCE, press PLUS (+) or MINUS (-) to toggle between OFF and ON.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 6 of 20) Parameter Action/Explanation Set Printhead Life for Early Warning This parameter appears only when Early Warning for Maintenance is enabled. Set this value to the number of inches of media that the printhead is expected to print. Default Value: 1,000,000 inches Range: 100 to 1,000,000 inches To change the value shown: 1. Press SELECT to select the parameter. 2. Press MINUS (-) to move the cursor. 3.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 7 of 20) Parameter Action/Explanation Print Counter Readings Prints a label that lists the odometer readings for the following: • the non-resettable counter • the two user-controlled counters • the Early Warning for Maintenance counters, which indicate when the printhead was last cleaned and the printhead life If the Early Warning for Maintenance feature is disabled, the counters related to it do not print.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 8 of 20) Parameter Action/Explanation List Formats This option prints a label that lists the available formats stored in the printer’s RAM, Flash memory, or optional memory card. To print a list of the available formats: 1. Press SELECT to select the parameter. 2. Press PLUS (+) to select PRINT. 3. Press SELECT to deselect the parameter.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 9 of 20) Parameter Action/Explanation Initialize Flash Memory This option erases all previously stored information from Flash memory. Caution • This option completely erases the Flash memory. To initialize Flash memory: 1. Press SELECT to select the parameter. 2. If prompted for a password, enter the printer password. For instructions, see Change Password-Protected Parameters on page 50. The display shows INITIALIZE FLASH? 3.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 10 of 20) Parameter Action/Explanation Calibrate Media Sensor Sensitivity Use this procedure to adjust sensitivity of media sensors. Important • Follow this procedure exactly as presented. All of the steps must be performed even if only one of the sensors requires adjustment. You may press MINUS (-) at any step in this procedure to cancel the process. To perform a media sensor calibration: 1. Press SELECT to select the parameter.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 11 of 20) Parameter Action/Explanation Set Baud This setting applies only when the serial port is used. The baud setting of the printer must match the baud setting of the host computer for accurate communications to take place. Select the value that matches the one being used by the host computer.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 12 of 20) Parameter Action/Explanation Set Host Handshake This setting applies only when the serial port is used. The handshake protocol of the printer must match the handshake protocol of the host computer for communication to take place. Select the handshake protocol that matches the one being used by the host computer. Default Value: XON/XOFF Selections: XON/XOFF, DSR/DTR, RTS/CTS To change the value shown: 1.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 13 of 20) Parameter Action/Explanation Set Communications Mode The communication diagnostics mode is a troubleshooting tool for checking the interconnection between the printer and the host computer. For more information, see Communications Diagnostics Test on page 103. Default Value: NORMAL MODE Selections: NORMAL MODE, DIAGNOSTICS To select communication diagnostics mode: 1. Press SELECT to select the parameter. 2.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 14 of 20) Parameter Action/Explanation Set Delimiter Character The delimiter character is a two-digit hex value used as a parameter place marker in ZPL/ZPL II format instructions. See the ZPL II Programming Guide for more information. Note • Do not use the same hex value for the control, format, and delimiter character. The printer must see different characters to work properly.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 15 of 20) Parameter Action/Explanation Select Media Power-Up Option This parameter sets the action of the media when you turn on the printer. Default Value: CALIBRATION Selections: CALIBRATION, SHORT CAL, LENGTH, NO MOTION, FEED • Calibration adjusts sensor levels and thresholds, determines length, and feeds the media to the next web.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 16 of 20) Parameter Action/Explanation Select Backfeed Sequence This parameter sets when or if label backfeed occurs. This setting is superseded by ~JS when received as part of a label format (see the ZPL II Programming Guide for more information). Default Value: DEFAULT (90%) Selections: DEFAULT, AFTER, OFF, BEFORE, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80% To change the value shown: 1. Press SELECT to select the parameter. 2.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 17 of 20) Parameter Action/Explanation Set Reprint Mode When reprint mode is enabled, you can reprint the last label printed either by issuing the ~PR ZPL command or by pressing MINUS (-) on the control panel. Default Value: DISABLED Selections: ENABLED, DISABLED To change the value shown: 1. Press SELECT to select the parameter. 2. Press PLUS (+) or MINUS (-) to toggle between the options. 3.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 18 of 20) Parameter Action/Explanation Select Format Convert Selects the bitmap scaling factor. The first number is the original dots per inch (dpi) value; the second, the dpi to which you would like to scale. Default Value: NONE Selections: NONE, 150 → 300, 150 → 600, 200 → 600, 300 → 600 To change the value shown: 1. Press SELECT to select the parameter. 2. Press PLUS (+) or MINUS (-) to scroll through the options. 3.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 19 of 20) Parameter Action/Explanation Set Real-Time Clock (RTC) Date This parameter allows you to set the date following the convention selected in IDLE DISPLAY. To change the value shown: 1. 2. 3. 4. Press SELECT to select the parameter. Press MINUS (-) to move to the next digit position. Press PLUS (+) to change the value of the digit. Press SELECT to accept any changes and deselect the parameter.
Configuration Control Panel Parameters Table 11 • Printer Parameters (Page 20 of 20) Parameter Action/Explanation Select the Display Language This parameter changes the language displayed on the LCD. Each language selection is displayed in the language itself. Default Value: ENGLISH Selections: ENGLISH, SPANISH, FRENCH, GERMAN, ITALIAN, NORWEGIAN, PORTUGUESE, SWEDISH, DANISH, SPANISH 2, DUTCH, FINNISH, JAPANESE, KOREAN, SIMPLIFIED CHINESE, TRADITIONAL CHINESE To change the value shown: 1.
Configuration Control Panel Parameters Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ________________
5 Routine Maintenance This section provides routine cleaning and maintenance procedures. Contents Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routine Maintenance Replacing Printer Components Replacing Printer Components Some printer components, such as the printhead and platen roller, may wear out over time and can be replaced easily. Regular cleaning may extend the life of some of these components. See Cleaning Schedule and Procedures on page 77 for the recommended cleaning intervals.
Routine Maintenance Cleaning Schedule and Procedures Cleaning Schedule and Procedures Important • Zebra is not responsible for damage caused by the use of cleaning fluids on this printer. Specific cleaning procedures are provided on the following pages. Table 12 shows the recommended cleaning schedule. These intervals are intended as guidelines only. You may have to clean more often, depending upon your application and media. .
Routine Maintenance Cleaning Procedures Clean the Printhead and Platen Roller You can minimize printhead wear and maintain print quality with regular preventive measures. Over time, the movement of media across the printhead wears through the protective ceramic coating, exposing and eventually damaging the print elements (dots). To avoid abrasion: • Clean the printhead frequently. • Minimize printhead pressure and burn temperature settings by optimizing the balance between the two.
Routine Maintenance Cleaning Procedures Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. Caution • Before touching the printhead assembly, discharge any built-up static electricity by touching the metal printer frame or by using an antistatic wriststrap and mat. To clean the printhead and platen roller, complete these steps: 1. Open the printhead assembly. 2. Remove the media. 3.
Routine Maintenance Cleaning Procedures 4. While manually rotating the platen roller, clean it thoroughly with the swab. Allow the solvent to evaporate. Important • Do not use anything but the isopropyl alcohol solution to clean the platen roller. Use of other cleaning agents or solvents may damage the platen roller and affect platen life. 5. Reload the media, and close the printhead assembly.
Routine Maintenance Cleaning Procedures Clean the Media Compartment and Sensors To clean the media compartment and sensors, complete these steps: 1. Brush or vacuum any accumulated paper lint and dust away from the media path. 2. Brush or vacuum any paper lint and dust away from the sensors (Figure 14). Figure 14 • Cleaning the Sensors 1 2 1 2 2/26/10 Take-label sensor Media sensor ZM400 User Guide for UPS P1016807-001 Rev.
Routine Maintenance Cleaning Procedures Clean the Peel Assembly The peel assembly, which is part of the Peel-Off option, consists of several spring-loaded rollers to ensure the proper roller pressure. Clean the pinch roller and tear-off/peel-off bar if adhesive buildup begins to affect peel performance. Caution • Do not use your left hand to assist in closing the Peel assembly. The top edge of the Peel roller/assembly could pinch your fingers.
Routine Maintenance Cleaning Procedures 2. Push down the peel-off mechanism release lever to open the peel assembly. 3. Remove any media backing to expose the pinch roller. 4. While manually rotating the pinch roller, clean it thoroughly with the swab from the Preventive Maintenance Kit (part number 47362). In place of the Preventive Maintenance Kit, you may use a clean swab dipped in a solution of isopropyl alcohol (minimum 90%) and deionized water (maximum 10%). Allow the solvent to evaporate. 5.
Routine Maintenance Cleaning Procedures 6. Close the printhead assembly. 7. Caution • Use the peel release lever and your right hand to close the peel assembly. Do not use your left hand to assist in closing. The top edge of the peel roller/assembly could pinch your fingers. Close the peel assembly using the peel-off mechanism release lever. 8. Close the media door. The printer is ready to operate. P1016807-001 Rev.
6 Troubleshooting This section provides information about errors that you might need to troubleshoot. Assorted diagnostic tests are included. Contents Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Troubleshooting Checklists Troubleshooting Checklists If an error condition exists with the printer, review this checklist: Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media Sensor Sensitivity on page 63. Are you experiencing problems with print quality? If yes, see Print Quality Problems on page 90. Are you experiencing communications problems? If yes, see Communications Problems on page 93.
Troubleshooting LCD Error Messages LCD Error Messages The LCD displays messages when there is an error. See Table 13 for LCD errors, the possible causes, and the recommended solutions. Table 13 • LCD Error Messages LCD Display/ Printer Condition ERROR CONDITION INVALID HEAD Possible Cause Recommended Solution The printhead was replaced with one that is not a genuine Zebra™ printhead. Install a genuine Zebra™ printhead. The media is not loaded or is loaded incorrectly. Load media correctly.
Troubleshooting LCD Error Messages Table 13 • LCD Error Messages (Continued) LCD Display/ Printer Condition THERMISTOR FAULT ERROR CONDITION HEAD ELEMENT BAD Possible Cause Caution • An improperly connected printhead data or power cable can cause these error messages. The printhead may be hot enough to cause severe burns. Allow the printhead to cool. The printhead data cable is not properly connected. The printer stops; the ERROR light is on; the printer cycles through these messages.
Troubleshooting LCD Error Messages Table 13 • LCD Error Messages (Continued) LCD Display/ Printer Condition OUT OF MEMORY (function) Possible Cause Recommended Solution There is not enough memory to perform the function specified on the second line of the error message. Free up some of the printer’s memory by adjusting the label format or printer parameters. One way to free up memory is to adjust the print width to the actual width of the label instead of leaving the print width set to the default.
Troubleshooting Print Quality Problems Print Quality Problems Table 14 identifies problems with print quality, the possible causes, and the recommended solutions. Table 14 • Print Quality Problems Problem Possible Cause Recommended Solution General print quality issues The printer is set at the incorrect print speed. For optimal print quality, set the print speed to the lowest possible setting for your application via control panel, the driver, or the software. See Adjust Print Speed on page 54.
Troubleshooting Print Quality Problems Table 14 • Print Quality Problems (Continued) Problem Possible Cause Vertical drift in top-of-form position The printer is out of calibration. Recalibrate the printer. Vertical image or label drift The bar code printed on a label does not scan. 2/26/10 Recommended Solution Vertical drift occurs during normal printer operation. Note • A vertical drift of ± 4 to 6 dot rows (approximately 0.5 mm) is within normal tolerances. Calibrate the printer.
Troubleshooting Calibration Problems Calibration Problems Table 15 identifies problems with calibration, the possible causes, and the recommended solutions. Table 15 • Calibration Problems Problem Possible Cause Recommended Solution Loss of printing registration on labels. Excessive vertical drift in top-of-form registration. The platen roller is dirty. Clean the platen roller according to the instructions in Clean the Printhead and Platen Roller on page 78.
Troubleshooting Communications Problems Communications Problems Table 16 identifies problems with communications, the possible causes, and the recommended solutions. Table 16 • Communications Problems Problem Possible Cause Recommended Solution A label format was sent to the printer but was not recognized. The DATA light does not flash. The communication parameters are incorrect. Check the printer driver or software communications settings (if applicable).
Troubleshooting Miscellaneous Printer Problems Miscellaneous Printer Problems Table 17 identifies miscellaneous problems with the printer, the possible causes, and the recommended solutions. Table 17 • Miscellaneous Printer Problems Problem Possible Cause Recommended Solution The LCD displays a language that I cannot read The language parameter was changed through the control panel or a firmware command. 1. Press SETUP/EXIT to enter configuration mode. 2. Press MINUS (-).
Troubleshooting Miscellaneous Printer Problems Table 17 • Miscellaneous Printer Problems (Continued) Problem Possible Cause Recommended Solution While in Peel-Off mode, media liner wraps around the platen roller. You are using perforated media, which is not recommended for Peel-Off mode. While operating in Peel-Off mode, use media that is not perforated. The printer fails to calibrate or detect the top of the label. The printer was not calibrated for the label being used.
Troubleshooting Printer Diagnostics Printer Diagnostics Self tests and other diagnostics provide specific information about the condition of the printer. The self tests produce sample printouts and provide specific information that helps determine the operating conditions for the printer. The most commonly used are the Power-On and the CANCEL self tests. Each self test is enabled by pressing a specific control panel key or combination of keys while turning on (I) the printer power.
Troubleshooting Printer Diagnostics CANCEL Self Test The CANCEL self test prints a configuration label (Figure 15). To perform the CANCEL Self Test, complete these steps: 1. Turn off (O) the printer. 2. Press and hold CANCEL while turning on (I) the printer. Hold CANCEL until the first control panel light turns off. A printer configuration label prints (Figure 15). Figure 15 • Sample Configuration Label 2/26/10 ZM400 User Guide for UPS P1016807-001 Rev.
Troubleshooting Printer Diagnostics PAUSE Self Test This self test can be used to provide the test labels required when making adjustments to the printer’s mechanical assemblies or to determine if any printhead elements are not working. Figure 16 shows a sample printout. To perform a PAUSE self test, complete these steps: 1. Turn off (O) the printer. 2. Press and hold PAUSE while turning on (I) the printer. Hold PAUSE until the first control panel light turns off.
Troubleshooting Printer Diagnostics FEED Self Test Different types of media may require different darkness settings. This section contains a simple but effective method for determining the ideal darkness for printing bar codes that are within specifications. During the FEED self test, labels are printed at different darkness settings at two different print speeds. The relative darkness and the print speed are printed on each label. The bar codes on these labels may be ANSI-graded to check print quality.
Troubleshooting Printer Diagnostics Figure 18 • Bar Code Darkness Comparison Table 18 • Judging Bar Code Quality P1016807-001 Rev. A Print Quality Description Too dark Labels that are too dark are fairly obvious. They may be readable but not “in-spec.” • The normal bar code bars increase in size. • The openings in small alphanumeric characters may fill in with ink. • Rotated bar code bars and spaces run together. Slightly dark Slightly dark labels are not as obvious.
Troubleshooting Printer Diagnostics Table 18 • Judging Bar Code Quality (Continued) Print Quality Description “In-spec” The “in-spec” bar code can only be confirmed by a verifier, but it should exhibit some visible characteristics. • The normal bar code will have complete, even bars and clear, distinct spaces. • The rotated bar code will have complete, even bars and clear, distinct spaces. Although it may not look as good as a slightly dark bar code, the bar code will be “in-spec.
Troubleshooting Printer Diagnostics FEED and PAUSE Self Test Performing this self test temporarily resets the printer configuration to the factory default values. These values are active only until power is turned off unless you save them permanently in memory. If the factory default values are permanently saved, a media calibration procedure must be performed. To perform a FEED and PAUSE self test, complete these steps: 1. Turn off (O) the printer. 2.
Troubleshooting Printer Diagnostics Communications Diagnostics Test The communication diagnostics test is a troubleshooting tool for checking the interconnection between the printer and the host computer. When the printer is in diagnostics mode, it prints all data received from the host computer as straight ASCII characters with the hex values below the ASCII text. The printer prints all characters received, including control codes such as CR (carriage return).
Troubleshooting Printer Diagnostics Sensor Profile Use the sensor profile label to troubleshoot the following types of problems: • If the media sensor experiences difficulty in determining gaps (web) between labels. • If the media sensor incorrectly identifies preprinted areas on a label as gaps (web). For instructions on printing a sensor profile, see Print Sensor Profile on page 62. If the sensitivity of the sensors must be adjusted, perform Calibrate Media Sensor Sensitivity on page 63.
7 Specifications This section provides the features of and specifications for the printer. Contents General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications General Specifications General Specifications General Specifications Height 13.3 in. 338 mm Width 10.9 in. 278 mm Depth 18.7 in. 475 mm Weight (without options) 32.4 lbs. 15 kg Electrical 90-265 VAC, 48-62 Hz, 5 Amps (fused) Temperature Relative Humidity Operating 40° to 104°F 5° to 40°C Storage –40° to 140°F –40° to 60°C Operating 20% to 85%, non-condensing Storage 5% to 85%, non-condensing Communication Interfaces • USB 2.
Specifications Printing Specifications Printing Specifications Printing Specifications Print resolution 203 dots/in. 8 dots/mm Dot size (width x length) 0.0049 in. x 0.0049 in. 0.125 mm x 0.125 mm First dot location measured from inside media backing edge 0.10 in. ± 0.04 in. (2.5 mm ± 1 mm) Maximum print width 4.09 in. 104 mm Minimum print length 1 dot row Maximum continuous print length 157 in. Bar code modulus (X) dimension 3988 mm Picket fence (non-rotated) orientation 4.
Specifications Media Specifications Media Specifications Media Specifications Label length Minimum 0.5 in. 13 mm Maximum 12 in. 305 mm Minimum 1 in. 25.4 mm Maximum 4.25 in. 108 mm Minimum 0.0023 in. 0.058 mm Maximum 0.010 in. 0.25 mm Core size 3 in. 76 mm Maximum roll diameter 8 in. 203 mm Maximum fanfold pack size (length x width x height) 8.0 in. × 4.5 in. × 6.2 in. 203 mm × 114 mm × 157 mm Minimum 0.079 in. 2 mm Preferred 0.118 in. 3 mm Maximum 0.157 in.
Index A adjustments left position, 69 print darkness, 54 printhead pressure, 45 tear-off position, 55 auto calibration, 44 B backfeed setting, 69 bar codes available, 60 battery disposal, 76 baud setting, 64 before you begin setup, 22 bitmap scaling factor, 71 black mark media described, 31 C calibration media sensor, 63 setting for head close, 68 setting for media power up, 68 troubleshooting problems, 92 Canadian DOC compliance, 4 CANCEL button CANCEL self test, 97 description, 19 2/26/10 checklist b
Index F control panel buttons described, 19 enter Setup mode, 48 exit Setup mode, 49 LCD error messages, 87 lights described, 20 location, 16 overview and illustration, 18 parameters, 53 control prefix setting, 66 counters, 60 customer service, 11 factory defaults reload parameters, 49 restore network settings, 49 fanfold media described, 32 loading, 37 FCC compliance, 4 FEED button description, 19 FEED and PAUSE self test, 102 FEED self test, 99 Flash memory, 62 font list, 60 format convert setting
Index Liner Take-Up mode description, 34 loading media, 36 media path, 35 remove used liner, 43 list settings all settings, 61 bar codes, 60 fonts, 60 formats, 61 images, 60 network, 61 setup, 61 load factory defaults, 49 loading media, 36 lubrication, 76 N M P manual calibration, 44 mark LED setting, 70 Mark Med S.
Index print modes described, 34 load media for different print modes and options, 36 media paths, 35 selecting, 55 print network configuration label, 61 instructions and sample label, 52 print quality troubleshooting, 90 print server characteristics of internal wired connection, 25 characteristics of wireless connection, 25 print width setting, 56 printer components, 17 printer diagnostics, 96 printer options described, 34 load media for different print modes and options, 36 media paths, 35 printer se
Index setup checklist, 22 unpack the printer, 23 Setup mode enter Setup mode, 48 exit Setup mode, 49 LCD messages, 53 passwords, 50 shipping report damage, 23 reshipping the printer, 23 spacing requirements, 24 specifications general, 106 media, 108 power cord, 30 printing, 107 storing the printer, 23 surface for the printer, 24 T tag stock described, 31 Tear-Off mode loading media, 36 media path, 35 print mode use described, 34 tear-off position adjustment, 55 technical support, 11 temperature requiremen
Index Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ________________________________________________
Zebra Technologies Corporation Zebra Technologies Corporation 475 Half Day Road, Suite 500 Lincolnshire, IL 60069 USA T: +1 847 634 6700 Toll-free +1 866 230 9494 F: +1 847 913 8766 Zebra Technologies Europe Limited Dukes Meadow Millboard Road Bourne End Buckinghamshire, SL8 5XF, UK T: +44 (0)1628 556000 F: +44 (0)1628 556001 Zebra Technologies Asia Pacific, LLC 120 Robinson Road #06-01 Parakou Building Singapore 068913 T: +65 6858 0722 F: +65 6885 0838 http://www.ups.zebra.
