Zebra Technologies URFIDM5E User Manual

Page 1

ZM™ Series/RZ™ Series

Industrial/Commercial Printer

therein are owned by ZIH Corp. Unauthorized reproduction of this manual or the software and/or firmware in the 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.

ZebraLink and all product names and numbers are trademarks, and Zebra, the Zebra logo, ZPL, ZPL II, Element Energy Equalizer Circuit, and E

All other brand names, product names, or trademarks belong to their respective holders. For additional trademark information, please see “Trademarks” on the product CD.

Proprietary Statement This manual contains proprietary information of Zebra Corporation and its subsidiaries

(“Zebra Technologies”). It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the express, written permission of Zebra Technologies Corporation.

Product Improvements Continuous improvement of products is a policy of Zebra Technologies Corporation.

All specifications and designs are subject to change without notice.

Liability Disclaimer Zebra Technologies Corporation takes steps to ensure that its published Engineering

specifications and manuals are correct; however, errors do occur. Zebra Technologies Corporation reserves the right to correct any such errors and disclaims liability resulting therefrom.

Limitation of Liability In no event shall Zebra Technologies Corporation or anyone else involved in the creation,

production, or delivery of the accompanying product (including hardware and software) be liable for any damages whatsoever (including, without limitation, consequential damages including loss of business profits, business interruption, or loss of business information) arising out of the use of, the results of use of, or inability to use such product, even if Zebra Technologies Corporation has been advised of the possibility of such damages. Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

, ZPL II®, and ZebraLink™ programs; Element Energy Equalizer® Circuit; E3®; and

User Guide

Part Number: 79695L-002 Rev. A

Page 2

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.

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.

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.

The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies could void the user’s authority to operate the equipment. To ensure compliance, this printer must be used with Shielded Communication Cables.

FCC Radiation Exposure Statement (for printers with RFID encoders)

This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with minimum distance 20cm between the radiator and your body.

This transmitter must not be co-located or operating in conjunction with any other antenna or transmitter.

Canadian DOC Compliance Statement

This Class B digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.

5/12/08 ZM™ Series/RZ™ Series User Guide 79695L-002 Rev. A

Page 3

Contents

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Compliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Web Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

The Americas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Europe, Africa, Middle East, and India . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Asia Pacific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1 • Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Control Panel Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Printer Language Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Firmware Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Additional Printer Language Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2 • Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Ship the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5/12/08 ZM™ Series/RZ™ Series User Guide 79695L-002 Rev. A

Contents

Select a Site for the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Select a Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Provide Proper Operating Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Provide a Data Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Provide a Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Select a Data Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Data Cables and Wireless Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Connect the Printer to the Computer or Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Ribbon Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

When to Use Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Coated Side of Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3 • Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Print Modes and Printer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Print Mode Descriptions and Printer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Media Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Load Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Beginning Steps for all Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . 41

Additional Steps for Tear-Off Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Additional Steps for Peel-Off Mode (with or without Liner Take-Up). . . . . . . . . . . . . . 45

Additional Steps for Cutter or Delayed Cut Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Additional Steps for Rewind Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Load Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Remove Used Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4 • Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Enter Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Exit Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Default Password Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Print a Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Print a Network Configuration Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

79695L-002 Rev. A ZM™ Series/RZ™ Series User Guide 5/12/08

Page 4

Contents

Control Panel Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

How to View or Modify Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Additional Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Standard Printer Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

5 • Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Replacing Printer Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Recycling Printer Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Cleaning Schedule and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Clean the Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Clean the Printhead and Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Clean the Media Compartment and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Clean the Cutter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Routine Maintenance for the Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Remove Printed Labels or Liner from the Rewind Spindle. . . . . . . . . . . . . . . . . . . . 106

Adjust Media Alignment for Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

6 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Troubleshooting Checklists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

Calibration Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

Communications Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Miscellaneous Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Power-On Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

PAUSE Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

FEED Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

FEED and PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Sensor Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

7 • Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Printing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Media Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Contents

Notes • ___________________________________________________________________

__________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________

5/12/08 ZM™ Series/RZ™ Series User Guide 79695L-002 Rev. A

79695L-002 Rev. A ZM™ Series/RZ™ Series User Guide 5/12/08

Page 5

About This Document

This section provides you with contact information, document structure and organization, and additional reference documents.

Contents

Who Should Use This Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

About This Document

Who Should Use This Document

This User Guide 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 is set up as follows:

Section Description

Introduction on page 15 This section shows the operational controls and

Printer Setup on page 23 This section provides the tasks that you must

Operations on page 37 This section provides the procedures for loading

Configuration on page 63 This section describes the control panel parameters

Routine Maintenance onpage 97 This section provides routine cleaning and

Troubleshooting onpage 109 This section provides information about errors that

Specifications on page 133 This section provides the features of and

location of major components used when loading media.

complete and the issues that you must consider before you load and configure your printer.

and calibrating the printer.

that are used to configure the printer for operation.

maintenance procedures.

you might need to troubleshoot. Assorted diagnostic tests are included.

specifications for the printer.

5/12/08 ZM™ Series/RZ™ Series User Guide 79695L-002 Rev. A

79695L-002 Rev. A ZM™ Series/RZ™ Series User Guide 5/12/08

Page 6

About This Document

Bubbl edot ICG

Contacts

About This Document

Document Conventions

Contacts

You can contact Zebra Technologies Corporation at the following:

Web Site

http://www.zebra.com

Technical Support via the Internet is available 24 hours per day, 365 days per year. Go to

http://www.zebra.com/support.

The Americas

Regional Headquarters Technical Support Customer Service Dept.

Zebra Technologies International, LLC 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.A T: +1 847 793 2600 Toll-free +1 800 423 0422 F: +1 847 913 8766

Europe, Africa, Middle East, and India

Regional Headquarters Technical Support Internal Sales Dept.

Zebra Technologies Europe Limited Zebra House The Valley Centre, Gordon Road High Wycombe Buckinghamshire, HP13 6EQ, UK

T: +44 (0)1494 472872 F: +44 (0) 1494 450103

Asia Pacific

Regional Headquarters Technical Support Customer Service

Zebra Technologies Asia Pacific, LLC 120 Robinson Road #06-01 Parakou Building Singapore 068913 T: +65 6858 0722 F: +65 6885 0838

T: +1 877 ASK ZEBRA (275 9327) F: +1 847 913 2578

Hardware: ts1@zebra.com Software: ts3@zebra.com

T: +44 (0) 1494 768298 F: +44 (0) 1494 768210 Germany: Tsgermany@zebra.com France: Tsfrance@zebra.com Spain/Portugal: Tsspain@zebra.com All other areas: Tseurope@zebra.com

T: +65 6858 0722 F: +65 6885 0838 E: China: tschina@zebra.com All other areas: tsasiapacific@zebra.com

For printers, parts, media, and ribbon, please call your distributor, or contactus.

T: +1 877 ASK ZEBRA (275 9327) E: clientcare@zebra.com

For printers, parts, media, and ribbon, please call your distributor, or contactus.

T: +44 (0) 1494 768316 F: +44 (0) 1494 768244 E: cseurope@zebra.com

For printers, parts, media, and ribbon, please call your distributor, or contactus.

T: +65 6858 0722 F: +65 6885 0836

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

Command Line Examples Command line examples appear in Courier New font. For

example, type Files and Directories File names and directories appear in Courier New font. For

example, the

Icons Used

Caution • Warns you of the potential for electrostatic discharge.

Caution • Warns you of a potential electric shock situation.

Caution • Warns you of a situation where excessive heat could cause a burn.

Caution • Advises you that failure to take or avoid a specific action could result in physical

harm to you.

Caution • (No icon) Advises you that failure to take or avoid a specific action could result in

physical harm to the hardware.

Important • Advises you of information that is essential to complete a task.

Note • Indicates neutral or positive information that emphasizes or supplements important

points of the main text.

font.

ZTools to get to the Post-Install scripts in the bin directory.

Zebra<version number>.tar file and the /root directory.

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Example • Provides an example, often a scenario, to better clarify a section of text.

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Page 7

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

FEED button

CANCEL button

About This Document

Document Conventions

Notes • ___________________________________________________________________

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Page 8

Introduction

This section shows the operational controls and location of major components used when loading media.

Contents

External View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Printer Media Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Control Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Printer Language Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

External View

Figure 2 and Figure 3 show the components and connections on the outside of the printer.

1 2

Figure 2 • Front of Printer

Control panel Media door

Figure 3 • Rear of Printer

Introduction

External View

6 7

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Power switch (O = off, I = on)

AC power connector

Wireless print server card slot (Ethernet)

Wireless card ejector button

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Serial port

Internal wired print server port (Ethernet)

USB port

Parallel port

Page 9

Printer Media Compartment

Introduction

Control Panel

Printer Media Compartment

Figure 4 shows the components inside the media compartment of your printer. Depending on

installed options, your printer may look slightly different.

Note • For optimal printing quality and proper printer performance across our product line,

Zebra strongly recommends the use of genuine Zebra™ supplies as part of the total solution. Specifically, the ZM400, ZM600, RM400, and RM600 are designed to work only with genuine Zebra™ printheads, thus maximizing safety and print quality.

Figure 4 • Printer Components

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

1 2 3 4 5 6 7 8

9 10 11 12

Power LED Pause LED Error LED Data LED LCD

CANCEL button PLUS (+) button SETUP/EXIT button MINUS (–) button SELECT button FEED button PAUSE button

Printhead assembly

Control panel

Media door

Media supply guide

Media supply hanger

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Ribbon take-up spindle

Ribbon supply spindle

Dancer assembly

Printhead release latch

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Introduction

Control Panel

Introduction

Control Panel

Control Panel Buttons

Button Function

FEED

PAUSE

CANCEL

SETUP/EXIT SELECT

PLUS (+)

(scroll mode)

PLUS (+)

(change mode)

MINUS (–)

(scroll mode)

MINUS (–)

(change mode)

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. Starts and stops the printing process.

• Printer not printing: no printing occurs. (Press

• Printing: printing stops after the current label is complete. Cancels print jobs when the printer is paused.

• Printer not printing: the next stored label format does not print.

• Printing: current label completes printing, and the next label format is cancelled. Press and hold for several seconds to cancel all print jobs in memory.

Enters and exits the configuration mode. Toggles the function of PLUS (+) and MINUS (–) between the Scroll and Change

Modes.

• Press once to use

• Press again to use Scrolls to the next selection.

• Increases the value.

• Performs the action on the bottom right of the LCD. Scrolls to the previous selection.

• Decreases the value.

• Moves to the next available digit in a number.

• Performs the action on the bottom left of the LCD.

Table 1 • Control Panel Buttons

PAUSE again to resume printing.)

PLUS (+) and MINUS (–) to change the values of the selection.

PLUS (+) and MINUS (–) to scroll through the menu items.

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.

PAUSE Off Normal printer operation.

On The printer has stopped all printing operations. Flashing The Pause light flashes when initializing FLASH memory and in

ERROR Off Normal printer operation (no errors).

On An error condition is preventing printing. This includes

Flashing An error condition exists, but printing is allowed to continue. This

DATA Off Normal printer operation (no data being received or processed).

One flash Slow flashing The printer cannot accept more data from the host. Fast flashing The printer is receiving data. On A partial format has been received and no subsequent data activity.

Peel-Off Mode when the label is available.

OUT

and RIBBON OUT errors.

RIBBON IN warning, HEAD UNDER TEMP warning,

includes and

HEAD OVER TEMP error.

CANCEL was pressed and a format is successfully cancelled.

MEDIA

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Printer Language Modes

Depending on how your printer was ordered, it came from the factory with firmware that operates in or allows you to use certain commands for one of the following printer languages:

• Zebra Programming Language (ZPL

•Eltron

Programming Language (EPL™)

Firmware Downloads

You may download firmware to the printer at any time to change from one printer langua ge to another. For the latest firmware versions and instructions for downloading them, go to

http://www.zebra.com/firmware.

Note • When the printer changes from one printer language to another, error messages may

appear on the LCD, and some control panel lights may activate in error mode. You may ignore these error messages and lights. When the firmware download is complete, reboot the printer and then load printer defaults to return the printer to Operating mode.

Additional Printer Language Information

The following manuals contain specific information about the different printer language modes. Copies of these manuals are on the CD that came with your printer and at

http://www.zebra.com/manuals.

•ZPL II

Programming Guide

• EPL2™ Programming Guide

Introduction

Printer Language Modes

)

Introduction

Printer Language Modes

Notes • ___________________________________________________________________

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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Store the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Ship the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Select a Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Provide a Data Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Provide a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Select a Data Communication Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Data Cables and Wireless Cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Connect the Printer to the Computer or Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Power Cord Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Types of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Ribbon Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

When to Use Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Coated Side of Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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 onpage 25.

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 26.

Connect to a Data Source Have you determined how the printer will connect to a data source (usually a computer)? For more information, see Select a Data

Communication Interface on page 27.

Attach a Power Cord Do you have the correct power cord for your printer? If you are unsure, see Power Cord Specifications onpage 32. To attach the power cord and connect the printer to a power source, see Connect the Printer to a Power Source onpage 31.

Select Media Do you have the correct media for your application? If you are unsure, see Types of Media onpage 33.

Select Ribbon Do you need to use ribbon, and is the appropriate ribbon available, if needed? If you are unsure, see Ribbon Overview on page 35.

Printer Setup

Before You Begin

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Page 13

Printer Setup

Handling the Printer

Select a Site for the Printer

Printer Setup

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.

• Keep all packaging material for shipping company inspection.

• Notify your authorized Zebra reseller

Important • Zebra Technologies Corporation is not responsible for any damage incurred

during the shipment of the equipment and will not repair this damage under warranty.

Store the Printer

If you are not placing the printer into immediate operation, repackage it using the original packing materials. You may store the printer under the conditions shown in Table 3.

Table 3 • Storage Temperature and Humidity

Temperature Relative Humidity

–40°F to 140°F (–40° to 60°C) 5% to 85% non-condensing

Ship the Printer

If you must ship the printer:

• Turn off (

• Remove any media, ribbon, or loose objects from the printer interior.

• Close the printhead.

• Carefully pack the printer into the original container or a suitable alternate container to

O) the printer, and disconnect all cables.

avoid damage during transit. A shipping container can be purchased from Zebra if the original packaging has been lost or destroyed.

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 onpage 134.

Provide Proper Operating Conditions

This printer is designed to function in a wide range of environmental and electrical conditions, including a warehouse or factory floor. For more information on the required conditions, see

General Specifications on page 134. Table 4 shows the temperature and relative humidity requirements for the printer when it is

operating.

Table 4 • Operating Temperature and Humidity

Mode Temperature Relative Humidity

Thermal Transfer 40° to 104°F (5° to 40°C) 20 to 85% non-condensing. Direct Thermal 32° to 104°F (0° to 40°C) 20 to 85% non-condensing

Allow Proper Space

The printer should have enough space around it for you to be able to open the media door. To allow for proper ventilation and cooling, leave open space on all sides of the printer.

Caution • Do not place any padding or cushioning material behind or under the printer

because this restricts air flow and could cause the printer to overheat.

Provide a Data Source

If the printer will be located away from the data source (such as a computer), the selected site must provide the appropriate connections to that data source. For more information on the types of communication interfaces and their limitations, see Select a Data Communication

Interface on page 27.

Provide a Power Source

Place the printer within a short distance of a power outlet that is easily accessible.

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Page 14

Select a Data Communication Interface

Printer Setup

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).

Table 5 • Characteristics of the Data Communication Interfaces

Interface

RS-232 Serial Standard • Maximum cable length of 50 ft (15.24 m).

IEEE 1284 Bidirectional Parallel

USB Standard • Maximum cable length of 16.4 ft (5 m).

Internal wired Ethernet print server

Wireless Ethernet print server

Standard or Optional on Printer

Characteristics

• You may need to change printer parameters to match the host computer.

• You need to use a null-modem adaptor to connect to the printer if using a standard modem cable.

Standard • Maximum cable length of 10 ft (3 m).

• Recommended cable length of 6 ft (1.83 m).

• No printer parameter changes required to match the host computer.

Optional • Can print to the printer from any computer on your LAN.

• Can communicate with the printer through the printer’s web pages.

• Computer must be equipped with an Ethernet board.

• The printer must be configured to use your LAN.

Optional • Can print to the printer from any computer on your Wireless

Local Area Network (WLAN).

• Can communicate with the printer through the printer’s web pages.

• Computer must be equipped with an Ethernet board.

• The printer must be configured to use your WLAN.

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.

• Do not bundle the data cables tightly with the power cords.

• Do not tie the data cables to power wire conduits.

Wireless Cards For supported wireless cards, refer to the ZebraNet Wireless Print Server and Wireless Plus Print Server User Guide. A copy of the manual is available at

http://www.zebra.com/manuals or on the userCD that came with your printer.

Connect the Printer to the Computer or Network

Table 6 shows how to connect the different types of data cables to your printer and computer.

The connectors on the back of your computer may be in different locations than on the sample computer shown in this section. For another view of the connectors on the printer, see Figure3

on page 16.

Caution • Ensure that the printer power is off (O) before connecting data communications

cables. Connecting a data communications cable while the power is on ( printer.

Table 6 • Connecting the Printer to a Computer or Network

Interface Connection and Configuration

RS-232 Serial The baud rate, number of data and stop bits, the parity, and the

XON/XOFF or DTR control must match those of the host computer. See

Control Panel Parameters onpage69 to view or change these parameters.

I) may damage the

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Page 15

Select a Data Communication Interface

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.

Table 6 • Connecting the Printer to a Computer or Network (Continued)

Interface Connection and Configuration

Internal wired Ethernet print server

Wireless 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.

Refer to the ZebraNet Wireless Print Server and Wireless Plus Print Server User 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.

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Page 16

Connect the Printer to a Power Source

Printer Setup

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 onpage32.

Caution • For personnel and equipment safety, always use an approved three-conductor

power cord specific to the region or country intended for installation. This cord must use an IEC 320 female connector and the appropriate region-specific three-conductor grounded plug configuration.

To connect the printer to a power source, complete these steps:

1. Toggle the printer power switch to the off (O) position.

2. Plug the power cord into the AC power connector (1) on the rear of the printer.

3. Plug the other end of the power cord into a power outlet near the printer.

4. Turn on (I) the printer.

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. If one is not included or if the one included is not suitable for your requirements, see Figure6 and refer to the following guidelines:

• The overall cord length must be less than 9.8 ft. (3 m).

• The cord must be rated for at least 10 A, 250 V.

• The chassis ground (earth) must be connected to ensure safety and reduce electromagnetic interference.

Figure 6 • Power Cord Specifications

AC power plug for your country—This should bear

the certification mark of at least one of the known international safety organizations (Figure 7). 3-conductor HAR cable or other cable approved for

your country. IEC 320 connector—This should bear the

certification mark of at least one of the known international safety organizations (Figure 7). Length d 9.8 ft. (3 m). Rating 10 Amp, 250 VAC.

The control panel LCD and lights activate, indicating that the printer is booting up.

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Figure 7 • International Safety Organization Certifications

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Page 17

Printer Setup

Types of Media

Printer Setup

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.

Your printer can use various types of media:

• Standard media—Most standard media uses an adhesive backing that sticks individual labels or a continuous length of labels to a liner.

• Tag stock—Tags are usually made from a heavy paper. Tag stock does not have adhesive or a liner, and it is typically perforated between tags.

• Radio frequency identification (RFID) “smart” media—RFID media can be used in a printer that is equipped with an RFID reader/encoder. RFID labels are made from the same materials and adhesives as non-RFID labels. Each label has an RFID transponder (sometimes called an “inlay”), made of a chip and an antenna, embedded between the label and the liner. The shape of the transponder varies by manufacturer and is visible through the label. All “smart” labels have memory that can be read, and many have memory that can be encoded.

Important • Transponder placement within a label depends on the transponder type and

the printer model. Make sure that you are using the correct “smart” media for your printer.

Table 7 describes roll and fanfold media. Roll media is loaded into the printer while fanfold

media may be located inside or outside of the printer.

Table 7 • Roll and Fanfold Media

Media Type How It Looks Description

Non-Continuous Roll Media

Roll media is wound on a 3-in. (76-mm) core. Individual labels are separated by one or more of the following methods:

• Web media separates labels by gaps, holes, or notches.

• Black mark media uses pre-printed black marks on the back side of the media to indicate label separations.

• Perforated media has perforations that allow the labels or tags to be separated from each other easily. The media may also have black marks or other separations between labels or tags.

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.

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Continuous Roll Media

79695L-002 Rev. A ZM™ Series/RZ™ Series User Guide 5/12/08

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. This allows the image to be printed anywhere on the label. Sometimes a cutter is used to cut apart individual labels.

Page 18

Printer Setup

Ribbon Overview

Printer Setup

Ribbon Overview

Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is transferred to the media during the thermal transfer process. The media determines whether you need to use ribbon and how wide the ribbon must be.

When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is narrower than the media, areas of the printhead are unprotected and subject to premature wear.

When to Use Ribbon

Thermal transfer media requires ribbon for printing while direct thermal media does not. Todetermine if ribbon must be used with a particular media, perform a media scratch test.

To perform a media scratch test, complete these steps:

1. Scratch the print surface of the media rapidly with your fingernail.

2. Did a black mark appear on the media?

If a black mark... Then the media is...

Does not appear on the media Thermal transfer. A ribbon is required. Appears on the media Direct thermal. No ribbon is required.

Coated Side of Ribbon

Ribbon can be wound with the coated side on the inside or outside. The ribbon used must match the Thermal Transfer option installed. The standard Thermal Transfer option (black ribbon spindle) uses ribbon coated on the outside, and the alternate Thermal Transfer option (gray ribbon spindle) uses ribbon coated on the inside. If you are unsure which side of a particular roll of ribbon is coated, perform an adhesive test or a ribbon scratch test to determine which side is coated.

Adhesive Test

If you have labels available, perform the adhesive test to determine which side of a ribbon is coated. This method works well for ribbon that is already installed.

To perform an adhesive test, complete these steps:

1. Peel a label from its liner.

2. Press a corner of the sticky side of the label to the outer surface of the roll of ribbon.

3. Peel the label off of the ribbon.

4. Observe the results. Did flakes or particles of ink from the ribbon adhere to the label?

If ink from the ribbon... Then...

Adhered to the label The ribbon is coated on the outside and can be

Did not adhere to the label The ribbon is coated on the inside and can be

used with the standard Thermal Transfer option (black ribbon spindle). In the ribbon loading procedure, instructions are marked with this symbol.

used with the alternate Thermal Transfer option (gray ribbon spindle). In the ribbon loading procedure, instructions are marked with this symbol.

Ribbon Scratch Test

Perform the ribbon scratch test when labels are unavailable.

To perform a ribbon scratch test, complete these steps:

1. Unroll a short length of ribbon.

2. Place the unrolled section of ribbon on a piece of paper with the outer surface of the

ribbon in contact with the paper.

3. Scratch the inner surface of the unrolled ribbon with your fingernail.

4. Lift the ribbon from the paper.

5. Observe the results. Did the ribbon leave a mark on the paper?

If the ribbon... Then...

Left a mark on the paper The ribbon is coated on the outside and can be used with

Did not leave a mark on the paper

the standard Thermal Transfer option (black ribbon spindle).

The ribbon is coated on the inside and can be used with the alternate Thermal Transfer option (gray ribbon spindle). In the ribbon loading procedure, instructions are marked with this symbol.

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Page 19

Operations

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 onpage 33. To select a print mode, see

Select Print Mode on page 73.

Print Modes and Printer Options

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 23 before

operating the printer.

Contents

Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Print Mode Descriptions and Printer Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Media Paths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Beginning Steps for all Print Modes and Printer Options. . . . . . . . . . . . . . . . . . . . . . . 41

Additional Steps for Tear-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Additional Steps for Peel-Off Mode (with or without Liner Take-Up) . . . . . . . . . . . . . . 45

Additional Steps for Cutter or Delayed Cut Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Additional Steps for Rewind Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Load Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Remove Used Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Calibrate the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Manual Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Print Mode Descriptions and Printer Requirements

Table 8 • Print Modes and Printer Options

Print Mode When to Use/Printer Options Required Printer Actions

Tear-Off (default setting)

Peel-Off Use only if the printer has the Peel-Off,

Cutter Use if the printer has a cutter option when

Delayed Cut Use if the printer has a cutter option when

Rewind Use if the printer has the Rewind option and

Linerless Peel Reserved for future options. Reserved for future options. Linerless

Rewind

Use for most applications. This mode can be used with any printer options and most media types.

Liner Take-Up, or Rewind option.

you want the labels to be cut apart.

you want the printer to cut the labels apart at a signal.

you want the labels to rewind on a core.

Reserved for future options. Reserved for future options.

The printer prints label formats as it receives them. The printer operator can tear off the printed labels any time after they print.

The printer peels the label from the liner during printing and then pauses until the label is removed.

In Peel-Off mode, the liner exits the front of the printer. In Peel-Off mode with Liner Take-Up, the liner winds onto the liner take-up spindle or the rewind spindle.

The printer prints a label and then cuts it free.

The printer prints a label, pauses, and cuts the label when it receives the ~JK (delayed cut) ZPL command.

The printer prints without pausing between labels. The media or liner is wound onto a core after printing.

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Operations

Print Modes and Printer Options

Operations

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.

Table 9 • Media Paths for Print Modes with Various Printer Options

Print Mode Printer Option Media Path

Tear-Off Printers with any

Peel-Off Peel, Liner take-up,

Peel-Off (with Liner Take-Up)

printer options can use Tear-Off mode

or Rewind

Liner take-up

Table 9 • Media Paths for Print Modes with Various Printer Options (Continued)

Print Mode Printer Option

Cutter or Delayed Cut

Cutter (shown with an optional catch tray)

Media Path

Rewind Rewind

Red solid lines = media, Blue dotted lines = backing only

Rewind

Red solid lines = media, Blue dotted lines = backing only

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Operations

Load Media

Operations

Load Media

The beginning steps for loading media apply to all printers, including those that have the peel-off, liner take-up, cutter, or rewind 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 onpage 38.

Caution • While performing any tasks near an open printhead, remove all rings, watches,

hanging necklaces, identification badges, or other metallic objects that could touch the printhead. You are not required to turn off the printer power when working near an open printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose all temporary settings, such as label formats, and you must reload them before you resume printing.

Beginning Steps for all Print Modes and Printer Options

To begin loading media for all print modes and printer options, complete these steps:

1. Press the printhead release latch to open the printhead assembly. Lift the printhead until it

latches open.

3. Insert media into the printer. Follow the instructions for roll or fanfold media, as

appropriate.

Roll Media

a. Remove and discard any tags or

labels that are dirty or that are held by adhesives or tape.

b. Flip down the media supply guide. b. Feed the media through the rear or

c. Place the roll of media on the media

supply hanger. Push the roll as far back as it will go.

Fanfold Media

a. Flip down the media supply guide.

bottom access slot.

Rear Feed

Bottom Feed

2. Slide out the media guide.

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d. Flip up the media supply guide. c. Drape the media over the media

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Operations

Load Media

Operations

Load Media

Roll Media (Continued)

e. Slide in the media supply guide until

it touches the edge of the roll.

4. Feed the media under the dancer assembly (1), the upper media sensor (2), and the ribbon

sensor (3). Slide the media back until it touches the inside back wall of the upper media sensor.

Fanfold Media (Continued)

d. Flip up the media supply guide.

e. Slide in the media supply guide until

it touches the edge of the media.

13 2

Additional Steps for Tear-Off Mode

After completing Beginning Steps for all Print Modes and Printer Options onpage 41, continue with this section to operate the printer in Tear-Off mode.

To operate the printer in Tear-Off mode, complete these steps:

1. Slide in the media guide until it touches the outer edge of the media.

2. Set the printer to Tear-Off mode. See Select Print Mode on page 73 for instructions.

3. Close the printhead assembly.

5. Continue with the final instructions for the desired print mode. The print mode must be

compatible with the media being used and the printer options installed. See Print Mode

Descriptions and Printer Requirements onpage 38 for more information.

• Additional Steps for Tear-Off Mode on page 44

• Additional Steps for Peel-Off Mode (with or without Liner Take-Up) on page 45

• Additional Steps for Cutter or Delayed Cut Mode onpage 50

• Additional Steps for Rewind Mode onpage 51

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4. If the printer is paused (the Pause light is on), press PAUSE to enable printing.

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Operations

Load Media

Operations

Load Media

Additional Steps for Peel-Off Mode (with or without Liner Take-Up)

After completing Beginning Steps for all Print Modes and Printer Options onpage 41, continue with this section to operate the printer in Peel-Off mode with or without liner take-up. Your printer must have the Peel option, the Liner Take-Up option, or the Rewind option installed. See Print Modes and Printer Options on page 38 for more information.

For additional procedures related to the rewind option, see Routine Maintenance for the

Rewind Option on page 106.

To operate the printer in Peel-Off mode, complete these steps:

1. Extend the media approximately 18 in. (500 mm) out of the printer.

2. Remove the exposed labels so that only the liner remains.

3. Push down the peel-off mechanism release lever to open the peel assembly.

4. 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.

5. Complete this step only if you want to use Peel-Off mode with liner take-up. Your printer

must have the Liner Take-Up option or the Rewind option installed. Follow the instructions for your printer option.

Rewind Option Liner Take-Up Option

a. Feed the liner under the media

alignment roller (

1).

a. Slide the liner into the slot in the

liner take-up spindle (

1).

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Operations

Load Media

Operations

Load Media

Rewind Option (Continued) Liner Take-Up Option (Continued)

b. Loosen the thumbscrew on the

rewind media guide.

c. Slide the rewind media guide all the

way out, and then fold it down.

d. Slide an empty core onto the rewind

spindle.

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.

Rewind Option (Continued) Liner Take-Up Option (Continued)

e. Wrap the liner around the core and

turn the rewind spindle counterclockwise to tighten the liner.

f. Fold up the rewind media guide, and

then slide it in until it touches the liner.

g. Tighten the thumbscrew on the

rewind media guide.

(No additional steps for the liner take-up option.)

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Operations

Load Media

Operations

Load Media

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.

Slide in the media guide until it touches the outer edge of the media.

8. Set the printer to Peel-Off mode. See Select Print Mode on page 73 for instructions.

9. Close the printhead assembly.

Additional Steps for Cutter or Delayed Cut Mode

After completing Beginning Steps for all Print Modes and Printer Options onpage 41, continue with this section to operate the printer in Cutter or Delayed Cut mode.

To operate the printer in Cutter or Delayed Cut mode, complete these steps:

Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers.

Feed the media through the cutter (1).

Slide in the media guide until it touches the outer edge of the media.

10. If the printer is paused (the Pause light is on), press PAUSE to enable printing. Peeling and

liner take-up (if used) begin automatically.

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3. Set the printer to Cutter or Delayed Cut mode. See Select Print Mode on page 73 for

instructions.

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Operations

Load Media

Operations

Load Media

4. Close the printhead assembly.

5. If the printer is paused (the Pause light is on), press PAUSE to enable printing. Cutting

begins automatically.

Additional Steps for Rewind Mode

After completing Beginning Steps for all Print Modes and Printer Options onpage 41, continue with this section to operate the printer in Rewind mode. For additional procedures related to the rewind option, see Routine Maintenance for the Rewind Option on page 106.

To operate the printer in Rewind mode, complete these steps:

1. Pull approximately 18 in. (500 mm) of media through the front of the printer.

2. Feed the media over the peel assembly (1).

3. Feed the media under the media alignment roller (1).

4. Loosen the thumbscrew on the rewind media guide.

5. Slide the rewind media guide all the way out, and then fold it down.

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Operations

Load Media

Operations

Load Media

6. Slide an empty core onto the rewind spindle.

7. Wrap the media around the core and turn the rewind spindle counterclockwise to tighten

the media. Ensure that the edge of the media is flush against the backplate of the rewind spindle.

8. Fold up the rewind media guide, and then slide it in until it touches the media.

9. Tighten the thumbscrew on the rewind media guide.

10. Slide in the media guide until it touches the outer edge of the media.

11. Set the printer to Rewind mode. See Select Print Mode on page 73 for instructions.

12. Close the printhead assembly.

13. If the printer is paused (the Pause light is on), press PAUSE to enable printing. Rewinding

begins automatically.

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Operations

Load Ribbon

Operations

Load Ribbon

Always use ribbon that is wider than the media to protect the printhead from wear. For direct thermal printing, do not load ribbon in the printer.

The standard Thermal Transfer option (black ribbon spindle) uses ribbon coated on the outside, and the alternate Thermal Transfer option (gray ribbon spindle) uses ribbon coated on the inside. To avoid damaging your printer, follow the directions for the Thermal Transfer option installed in your printer.

Figure 8 shows the ribbon paths for ribbon coated on the outside and ribbon coated on the

inside. The coated surfaces of the ribbon are shown in gray when they are visible. To determine which side of a ribbon is printed, see Coated Side of Ribbon onpage 35.

Figure 8 • Ribbon Path

Ribbon Coated Outside (black ribbon spindle)

Caution • While performing any tasks near an open printhead, remove all rings, watches,

To load ribbon, complete these steps:

1. Set the ribbon supply spindle for normal or low tension.

• To place the ribbon supply spindle in the normal position, firmly pull out the spindle end cap until it extends and clicks in place, as shown in Figure 9. Use this setting for most applications.

• To place the ribbon supply spindle in the low-tension position, firmly push in the end

Ribbon Coated Inside (gray ribbon spindle)

cap until it retracts and clicks in place, as shown in Figure9. Use this setting when using a narrow ribbon or if normal tension hampers ribbon movement.

Figure 9 • Ribbon Spindle—Normal and Low Tension

1 2

Normal Position (Spindle End Cap Extended)

2. Press the printhead release latch to open the printhead assembly. Lift the printhead until it

latches open.

Low-Tension Position (Spindle End Cap Retracted)

Tension blade

Ribbon take-up spindle

Ribbon supply spindle

Printhead assembly

Printhead release latch

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Operations

Load Ribbon

Operations

Load Ribbon

3. Insert the ribbon into the printer. In this step, follow the instructions for the Thermal

Transfer option installed in your printer.

Ribbon Coated Outside (black ribbon spindle)

a. Hold the ribbon with the loose end unrolling

clockwise.

b. Place the roll of ribbon on the ribbon supply

spindle (

1) and push it all the way back.

1 1

c. Pull the end of the ribbon under the printhead

1) and out the front of the printer.

assembly ( Extend the ribbon approximately 24 in. (610 mm) out of the printer.

Ribbon Coated Inside (gray ribbon spindle)

a. Hold the ribbon with the loose end unrolling

counterclockwise.

b. Place the roll of ribbon on the ribbon supply

spindle (

1) and push it all the way back.

c. Pull the end of the ribbon under the printhead

1) and out the front of the printer.

assembly ( Extend the ribbon approximately 24 in. (610 mm) out of the printer.

4. Close the printhead assembly.

5. Wind the ribbon clockwise onto the ribbon take-up spindle (1).

Ribbon Coated Outside (black ribbon spindle)

Ribbon Coated Inside (gray ribbon spindle)

1 1

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Operations

MEDIA POW ER UP

HEAD CLOS E

Load Ribbon

Operations

Calibrate the Printer

Remove Used Ribbon

To remove used ribbon, complete these steps:

Caution • Do not cut the ribbon directly on the ribbon take-up spindle. Doing so may

damage the spindle.

If the ribbon has not run out, cut or break it before the ribbon take-up spindle (1).

To loosen the ribbon, squeeze it against the ribbon take-up spindle tension blades(1). At

the same time, turn the ribbon take-up spindle release knob counterclockwise (2). The tension blades collapse into the ribbon take-up spindle, loosening the ribbon.

3. Slide the used ribbon off of the ribbon take-up spindle and discard.

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.

Note • If the control panel settings for

LENGTH, NO MOTION, or FEED, the printer starts printing without auto calibrating. See

Select Media Power-Up Option on page 90 or Select Head Close Option on page 90.

Manual Calibration

Perform a media and ribbon sensor calibration to reset the sensitivity of the sensors so the media and ribbon are detected more accurately. If you change the type of ribbon or media, your printer may operate better if you perform this calibration.

For instructions, refer to Calibrate Media and Ribbon Sensor Sensitivity on page 84.

are set to

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Adjust Printhead Pressure

Operations

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 10. The ZM400 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. The ZM600 dials have seven settings instead of four.

Figure 10 • Printhead Pressure Adjustment Dials

1 2

To set printhead pressure, complete these steps:

1. Use Table 10 or Table 11 to select the initial dial settings for your media, depending on

which printer you have.

Table 10 • ZM400 Printhead Pressure

Media Width

1 in. (25.4 mm) 2 in. (51 mm) 3 in. (76 mm)

3.5 in. and up (89 mm and up)

Outside dial Inside dial

Inside Dial Outside Dial

31 41 32 33

Table 11 • ZM600 Printhead Pressure

Media Width

Inside Dial Outside Dial

2 in. (50 mm) 6 1 3 in. (75 mm) 6 2 4 in. (100 mm) 7 3 5 in. (125 mm) 7 4

5.5 in. and up (140 mm and up) 6 6

2. If necessary, adjust the pressure adjustment dials as follows:

If the media... Then...

Requires higher pressure to print well

Shifts left while printing Increase the outside dial setting one position, or

Shifts right while printing Increase the inside dial setting one position, or

Prints too lightly on the left side of the label.

Prints too lightly on the right side of the label.

Increase both dials one position.

decrease the inside dial setting one position.

decrease the outside dial setting one position. Increase the inside dial setting one position.

Increase the outside dial setting one position.

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Configuration

PRINT ER R EADY

This section describes the control panel parameters that are used to configure the printer for operation.

Contents

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Enter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Default Password Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Print a Configuration Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Print a Network Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

How to View or Modify Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Additional Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Standard Printer Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Setup Mode

After you have installed the media and ribbon and the Power-On Self Test (POST) is complete, the control panel displays 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 onpage129.

Important • Certain printing conditions may require that you adjust printing parameters,

such as print speed, darkness, or print mode. These conditions include (but are not limited to):

• printing at high speeds

• peeling the media

• the use of extremely thin, small, synthetic, or coated labels

Because these and other factors affect print quality, run tests todetermine the best combination of printer settings and media for your application. A poor match may limit print quality or print rate, or the printer may not function properly in the desired print mode.

Enter Setup Mode

To enter Setup Mode, complete these steps:

1. Press SETUP/EXIT.

2. Press PLUS (+) or MINUS (–) to scroll through the parameters.

3. Press SELECT to select and deselect the parameters.

Configuration

Setup Mode

. You may now set printer parameters for your

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SAVE CHA NGES

PRINT ER R EADY

PERMA NENT

TEMPO RARY

CANCE L

LOAD DEFA ULTS

LOAD LAST SAVE

DEFAU LT N ET

ENTER PAS SWORD

Configuration

Setup Mode

Change Password-Protected Parameters

Configuration

Exit Setup Mode

To leave Setup mode, complete these steps:

1. Press SETUP/EXIT.

The LCD displays

2. Press PLUS (+) or MINUS (-) to display the save options:

LCD Description

Stores values in the printer even when power is turned off.

3. Press SETUP/EXIT to select the displayed choice.

When the configuration and calibration sequence is done,

Saves the changes until power is turned off. Cancels all changes made since you entered Setup mode,

except for changes made to the darkness and tear-off settings, which go into effect as soon as they are made.

Restores all parameters other than the network settings back to the factory defaults. Use care when loading defaults because you will need to reload all settings that you changed manually.

Loads values from the last permanent save. Restores the wired and wireless network settings back to

factory defaults.

Note • Loading factory defaults causes the printer to

auto-calibrate.

displays.

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 numeric password. After you have entered the password correctly, you do not have to enter it

again unless you leave Setup mode by pressing

To enter a password for a password-protected parameter, complete these steps:

1. At the password prompt, use MINUS (-) to change the selected digit position.

2. When you have selected the digit that you wish to change, use PLUS (+) to increase the

selected digit value. Repeat these two steps for each digit of the password.

3. After entering the password, press SELECT.

The parameter you selected to change is displayed. If the password was entered correctly, you can change the value.

Default Password Value

The default password value is 1234. The password can be changed using the Zebra Programming Language (ZPL) command pages (ZebraNet

Disable the Password Protection Feature

You can disable the password protection feature so that it no longer prompts you for a password by setting the password to 0000 via the password-protection feature, send the ZPL command 1 to 9999.

. Before you can change the parameter, you must enter the four-digit

SETUP/EXIT or by turning off (O) the printer.

10/100 Print Server, or Wireless Plus Print Server required).

^KP (Define Password) or using the printer’s web

^KP ZPL command. To re-enable the

^KPx, where x can be any number from

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Configuration

LIST SET UP

LIST NET WORK

Print a Configuration Label

Print a Network Configuration Label

Configuration

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. Press PLUS (+) or MINUS (-) to scroll through the parameters until you reach

3. Press SELECT to select the parameter.

4. Press PLUS (+) to confirm printing.

A configuration label prints (Figure 11).

Figure 11 • 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

3. Press SELECT to select the parameter.

4. Press PLUS (+) to confirm printing.

A network configuration label prints (Figure 12). An asterisk designates whether the wired or wireless print server is active. If no wireless print server is installed, the wireless portion of the label does not print.

Figure 12 • Network Configuration Label (With a Wireless Print Server Installed)

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Configuration

Control Panel Parameters

Configuration

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. When a parameter is changed, an asterisk (*) appears in the upper left corner of the display to indicate that the value is different from the one currently active in the printer.

Note • Your label preparation software or the printer driver may override adjustments made

through the control panel. Refer to the software or driver documentation for more information.

Additional Parameters

Additional parameters appear in the following situations.

• When a wired print server is installed in the printer. For more information, refer to the

ZebraNet 10/100 Print Server User and Reference Guide

• When a wireless print server is installed in the printer. Refer to the ZebraNet Wireless Print Server and Wireless Plus Print Server User Guide.

• When a Radio Frequency Identification (RFID) reader is installed. Refer to the RFID Programming Guide for more information.

Copies of these manuals are available at http://www.zebra.com/manuals or on the userCD that came with your printer.

Standard Printer Parameters

Table 12 shows parameters in the order in which they are displayed when you press PLUS (+)

after entering Setup mode.

Table 12 • Printer Parameters (Page 1 of 26)

Parameter Action/Explanation

ZPL, XML, APL-D, APL-I

EPL only

Adjust Print Darkness/Density

Darkness (burn duration) settings depend on a variety of factors, including ribbon type, media type, and the condition of the printhead. Yo u may adjust the darkness for consistent high-quality printing.

If printing is too light or if there are voids in printed areas, increase the darkness. If printing is too dark or if there is spreading or bleeding of printed areas, decrease the darkness.

The FEED Self T est onpage 126 can be used to determine the best darkness setting. Y ou may want to adjust darkness while performing the PAUSE Se lf

Test on page 125. Because the darkness setting takes effect immediately,

you can see the results on labels that are currently printing. Darkness settings also may be changed by the driver or software settings.

Default Value (ZPL, XML, APL-D, APL-I): +10 Range (ZPL, XML, APL-D, APL-I): 00 to +30

Default Value (EPL): +7 Range (EPL): 00 to +15

To change the value shown:

1. Press SELECT to select the parameter.

2. Press

3. Press

4. Press

Important • Set the darkness to the lowest setting that provides

good print quality. If the darkness is set too high, the ink may smear, the ribbon may burn through, or the printhead may wear prematurely.

PLUS (+) to increase darkness. MINUS (-) to decrease darkness. SELECT to accept any changes and deselect the parameter.

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Control Panel Parameters

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Parameter

Table 12 • Printer Parameters (Page 2 of 26)

Action/Explanation

Adjust Print Speed

Adjusts the speed for printing a label (given in inches per second). Slower print speeds typically yield better print quality. Print speed changes take effect upon exiting Setup mode.

Default Value (ZPL, XML, APL-I, EPL): 2 IPS Default Value (APL-D): 6 IPS Range:

• 200 dpi: 2 to 10 IPS

• 300 dpi: 2 to 8 IPS

• 600 dpi: 1 to 4 IPS

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) to increase the value.

2. Press

3. Press

MINUS (-) to decrease the value. SELECT to accept any changes and deselect the parameter.

4. Press

Parameter

Table 12 • Printer Parameters (Page 3 of 26)

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 13. 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).

Figure 13 • Tear-Off Position Adjustment

Media direction

Factory-set tear line location at position 00

Default Value (ZPL, EPL, APL-I): 0 Range (ZPL, EPL, APL-I): -120 to +120

Default Value (APL-D): +128i Range (APL-D): +00i to +999i (inches), 0m to 2537m (metric)

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) to increase the value. Each press adjusts the tear-off

2. Press position by four dot rows.

MINUS (-) to decrease the value. Each press adjusts the tear-off

3. Press position by four dot rows.

SELECT to accept any changes and deselect the parameter.

4. Press

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Configuration

Control Panel Parameters

Configuration

Control Panel Parameters

Parameter

APL-D only

Table 12 • Printer Parameters (Page 4 of 26)

Action/Explanation

Select Print Mode

This parameter tells the printer how printed labels will be removed. Make sure that you select a print mode that is compatible with your printer and printer options. For information about how the print modes work with different printer options, see Print Modes and Printer Options on page 38.

Default Value: TEAR-OFF Selections: TEAR-OFF, PEEL-OFF, CUTTER, DELAYED CUT,

LINERLESS-P, LINERLESS-R, LINERLESS-T, REWIND

Note • The linerless selections apply only to printers that have the

Linerless option.

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

Set APL-D Compatibility Mode

Sets compatibility with DPL printers.

Default Value: OFF Selections: ON, OFF

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

Set APL-D Control Codes

Default Value: STANDARD Selections: STANDARD, MAINFRAME

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

Set Module A Storage Device for APL-D

Default Value: NONE Selections: NONE, RAM 1, RAM 2, FLASH 1, FLASH 2

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

Parameter

APL-D only

APL-I only

Table 12 • Printer Parameters (Page 5 of 26)

Action/Explanation

Set Module B Storage Device for APL-D

Default Value: NONE Selections: NONE, RAM 1, RAM 2, FLASH 1, FLASH 2

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

Set Printer Resolution for APL-I

Sets the dot size for backward compatibility with some older APL-I printers.

Default Value: 5 MIL Selections: 5 MIL, 10 MIL, 15 MIL

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

Set Media Type

This parameter tells the printer the type of media that you are using (see

Types of Media onpage 33 for more information). Selecting continuous

media requires that you include a label length instruction in your label

^LLxxxx if you are using ZPL or ZPL II).

format ( When non-continuous media is selected, the printer feeds media to

calculate label length (the distance between two recognized registration points of the inter-label gap, webbing, or alignment notch or hole).

Default Value: GAP/NOTCH Selections: GAP/NOTCH, MARK, CONTINUOUS

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

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Control Panel Parameters

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Parameter

Table 12 • Printer Parameters (Page 6 of 26)

Action/Explanation

Select Print Method

The print method parameter tells the printer the method of printing that you want to use: direct thermal (no ribbon) or thermal transfer (using thermal transfer media and ribbon).

Default Value: THERMAL TRANSFER Selections: THERMAL TRANSFER, DIRECT THERMAL

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

Set Print Width

This parameter specifies the printable area across the width of the label.

Table 13 shows the ranges and default values for print width, which are

based on the printer model and the printhead resolution.

Table 13 • Print Width Ranges and Maximum Values

Printhead Resolution

200 dpi

300 dpi

600 dpi

ZM400 ZM600

Default Value: 832 Range: 2 to 832 dots

Default Value: 1248 Range: 2 to 1248 dots

Default Value: 2496

Printer

Default Value: 1344 Range: 2 to 1344 dots

Default Value: 1984 Range: 2 to 1984 dots

N/A

Range: 2 to 2496 dots

Note • Setting the width too narrow can result in portions of a label

format not being printed on the media. Setting the width too wide wastes formatting memory and can cause printing off of the label and on the platen roller. This setting can affect the horizontal position of the label format if the image was inverted using the ^POI ZPL II command.

To change the value shown:

1. Press SELECT to select the parameter.

2. Press

PLUS (+) or MINUS (-) to change the value shown. SELECT to accept any changes and deselect the parameter.

3. Press

Parameter

ZPL, XML, EPL, APL-I

APL-D only

Table 12 • Printer Parameters (Page 7 of 26)

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 14). 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.

For example, if the label length is 5.0 inches (126 mm) including the interlabel gap, set the parameter for 6.0 inches (152 mm). If the label length is 7.5 inches (190 mm), set the parameter for 9.0 inches (229 mm).

Figure 14 • Label Length

}

Label length (including interlabel gap)

Interlabel gap

Set maximum label length to approximately

this value

Default Value (ZPL, XML, EPL, APL-I): 39.0 inches (988 mm) Selections: Values are adjustable in one-inch (25.4 mm) increments

Default Value (APL-D): 1200i Range: 1200i to

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to change the value shown.

2. Press

3. Press

SELECT to accept any changes and deselect the parameter.

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Configuration

EARLY WAR NING MAIN TENANCE

OFF

WARNI NG C LEAN

PRINT HEAD

YES

WARNI NG R EPLACE

HEAD

YES

Control Panel Parameters

Configuration

Control Panel Parameters

Parameter

Table 12 • Printer Parameters (Page 8 of 26)

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

PLUS (+) or MINUS (-) to toggle between

prompted for a password, enter your password using the instructions in

Change Password-Protected Parameters onpage 66.)

3. Exit Setup mode and save changes to enable additional parameters related to the early warning system.

4. Enter Setup mode again and go to the following parameters to enter the printhead cleaning interval and the printhead life.

SELECT to accept any changes and deselect the parameter.

5. Press

Set Printhead Cleaning Interval for Early Warning

This parameter appears only when Early Warning for Maintenance is enabled. This value should correspond to the length of the media or ribbon roll that you are using.

and ON. (If you are

Default Value: 450 M/1476 FT Selections: 100 M/328 FT to 450 M/1476 FT in 50 M increments

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to set the printhead cleaning interval to

2. Press the desired number of inches of media or ribbon.

When the printhead reaches the set length, printer generates an alert.

3. Press

appears on the LCD. If the alert function is enabled, the

SELECT to accept any changes and deselect the parameter.

Reset Printhead Cleaning Counter for Early Warning

This parameter appears only when Early Warning for Maintenance is enabled.

To reset the printhead cleaning counter:

1. Press SELECT to select the parameter.

2. Did you clean the printhead?

• If you cleaned the printhead, press

• If you did not clean the printhead, press

3. Press

SELECT to accept any changes and deselect the parameter.

PLUS (+) to select

MINUS (-) to select

Table 12 • Printer Parameters (Page 9 of 26)

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:

, press

1. Press SELECT to select the parameter.

MINUS (-) to move the cursor.

2. Press

PLUS (+) to increase the value of the digit.

3. Press When the printhead reaches the set length,

appears on the LCD. If the alert function is enabled, the printer

generates an alert.

SELECT to accept any changes and deselect the parameter.

4. Press

Reset Printhead Life Counter for Early Warning

This parameter appears only when Early Warning for Maintenance is enabled.

To reset the printhead life counter:

1. Press SELECT to select the parameter.

2. Did you replace the printhead?

• If you replaced the printhead, press

PLUS (+) to select

• If you did not replace the printhead, press

SELECT to accept any changes and deselect the parameter.

3. Press

MINUS (-) to select

View Non-Resettable Counter

This parameter displays the total length of media that the printer has printed. You can use ZPL commands to change the unit of measure for this counter. For the commands, refer to the ZPL Programming Guide.

View User-Controlled Counter 1

This parameter displays the total length of media that the printer has printed since this parameter was last reset. You can use ZPL commands to change the unit of measure and reset this counter. For the commands, refer to the ZPL Programming Guide.

View User-Controlled Counter 2

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Control Panel Parameters

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Table 12 • Printer Parameters (Page 10 of 26)

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.

To print a list of the odometer readings:

1. Press SELECT to select the parameter.

2. Press

PLUS (+) to print the odometer readings. SELECT to deselect the parameter.

3. Press

List Fonts

This option prints a label that lists the available fonts in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM or Flash memory.

To print a list of the available fonts:

1. Press SELECT to select the parameter.

PLUS (+) to select

2. Press

SELECT to deselect the parameter.

3. Press

ZPL and XML only List Bar Codes

This option prints a label that lists the available bar codes in the printer. Bar codes may be stored in RAM or Flash memory.

To print a list of the available bar codes:

1. Press SELECT to select the parameter.

PLUS (+) to select

2. Press

SELECT to deselect the parameter.

3. Press

List Images

This option prints a label that lists the available images stored in the printer’s RAM, Flash memory, or optional memory card.

To print a list of the available images:

1. Press SELECT to select the parameter.

PLUS (+) to select

2. Press

SELECT to deselect the parameter.

3. Press

Table 12 • Printer Parameters (Page 11 of 26)

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.

ZPL, XML, EPL, APL-D

PLUS (+) to select

2. Press

3. Press

SELECT to deselect the parameter.

List Setup

This option prints a configuration label (see Figure 11 onpage 67), which lists the current printer configuration.

To print a configuration label:

1. Press SELECT to select the parameter.

PLUS (+) to select

2. Press

3. Press

SELECT to deselect the parameter.

APL-I only

APL-I only Print Software Configuration Label

A software configuration label lists pages, formats, and bar codes that are defined for the printer. Other printer settings also are included.

To print this label:

1. Press SELECT to select the parameter.

PLUS (+) to select

2. Press

SELECT to deselect the parameter.

3. Press

APL-I only Print Hardware Configuration Label

A hardware configuration label lists the memory options, printer metrics, and printhead information.

To print this label:

1. Press SELECT to select the parameter.

2. Press

PLUS (+) to select SELECT to deselect the parameter.

3. Press

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Configuration

ARE Y OU S URE?

FORMA T CA RD

YES

FORMA TTIN G CARD CO MPLE TED

Control Panel Parameters

Configuration

Control Panel Parameters

Table 12 • Printer Parameters (Page 12 of 26)

Parameter

Action/Explanation

APL-I only Print Quality Test Label

A print quality test label contains test bar codes and relevant printer settings.

To print this label:

1. Press SELECT to select the parameter.

PLUS (+) to select

2. Press

3. Press

SELECT to deselect the parameter.

APL-I only Print Pitch Test Label

To print this label:

1. Press SELECT to select the parameter.

PLUS (+) to select

2. Press

SELECT to deselect the parameter.

3. Press

List Network Settings

This option prints a network configuration label (see Figure 12

on page 68), which lists the settings for any print server that is installed.

To print a network configuration label:

1. Press SELECT to select the parameter.

PLUS (+) to select

2. Press

SELECT to deselect the parameter.

3. Press

ZPL, XML, EPL List All

This option prints labels that list the available fonts, bar codes, images, formats, and the current printer and network configurations.

To print labels for all settings:

1. Press SELECT to select the parameter.

PLUS (+) to select

2. Press

SELECT to deselect the parameter.

3. Press

APL-I only

Print Stored APL-I Page

Up to 20 pages can be stored and printed.

Selections: 0 through 19 Default Value: 0

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

Table 12 • Printer Parameters (Page 13 of 26)

Parameter

APL-I only

Action/Explanation

Print Stored APL-I Format

Up to 100 formats can be stored and printed.

Selections: 0 through 99 Default Value: 0

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

ZPL and XML only Format Memory Card

This option erases all previously stored information from the optional

64 MB flash chip on the Wireless Plus option board. This parameter appears only when a Wireless Plus option board with the flash chip populated is installed.

Caution • This option completely erases the flash chip.

To format a memory card:

1. Press SELECT to select the parameter.

PLUS (+) to select

2. Press If your printer is set to require a password, you are prompted to enter

the password.

3. Enter the password. For instructions, see Change Password-Protected

Parameters on page 66.

4. Press the appropriate button again to select the desired card. The display shows

5. Do you want to continue?

MINUS (-) to select

• Press

• Press When initialization is complete, the control panel displays

Note • Depending on the amount of memory in the memory card,

initialization may take up to 5 minutes to complete.

SELECT to deselect the parameter.

6. Press

prompt.

PLUS (+) to select

to cancel the request and return to

and begin initialization.

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INITI ALIZ E FLASH?

YES

ARE Y OU S URE?

INITI ALIZ E FLASH

YES

INITI ALIZ ING MEMOR Y CO MPLETED

LOAD BACK ING

REMOV E RI BBON

CALIB RATI NG PLEASE WAI T

RELOA D AL L

Control Panel Parameters

Configuration

Control Panel Parameters

Parameter

Table 12 • Printer Parameters (Page 14 of 26)

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 onpage 66.

The display shows

3. Press PLUS (+) to select The display shows

4. Do you want to continue?

MINUS (-) to select

• Press

PLUS (+) to select

When initialization is complete, the control panel displays

5. Press

Print Sensor Profile

A sensor profile shows sensor settings compared to actual sensor readings. This label (which will extend across several actual labels or tags) can be used to troubleshoot printing problems. To interpret the results of the sensor profile, see Sensor Profile onpage 131.

Note • Depending on the amount of free FLASH memory,

initialization may take up to 1 minute to complete.

SELECT to accept any changes and deselect the parameter.

to cancel the request and return to the

prompt.

and begin initialization.

To print a sensor profile:

1. Press SELECT to select the parameter.

PLUS (+) to start this standard calibration procedure and print a

2. Press media sensor profile.

3. If the sensitivity of the sensors must be adjusted, perform Calibrate

Media and Ribbon Sensor Sensitivity on page 84.

SELECT to accept any changes and deselect the parameter.

4. Press

Parameter

Table 12 • Printer Parameters (Page 15 of 26)

Action/Explanation

Calibrate Media and Ribbon Sensor Sensitivity

Use this procedure to adjust sensitivity of media and ribbon sensors.

Important • Follow this procedure exactly as presented. All of the

steps must be performed even if only one of the sensors requires adjustment. You may press to cancel the process.

To perform a media and ribbon sensor calibration:

MINUS (-) at any step in this procedure

1. Press SELECT to select the parameter.

PLUS (+) to start the calibration procedure.

2. Press The

prompt displays.

3. Open the printhead.

4. Remove approximately 8 in. (203 mm) of labels from the backing, and pull the media into the printer so that only the backing is between the media sensors.

5. Leave the printhead open.

PLUS (+) to continue.

6. Press The

prompt displays.

7. Remove the ribbon (if used).

8. Close the printhead.

PLUS (+) to continue.

9. Press The message The printer adjusts the scale (gain) of the signals that it receives from

the media and ribbon sensors based on the specific media and ribbon combination being used. On the sensor profile, this essentially corresponds to moving the peak of the graph up or down to optimize the readings for your application.

When calibration is complete,

10. Open the printhead and pull the media forward until a label is positioned under the media sensor.

displays.

11. Reload the ribbon (if used).

12. Close the printhead.

PLUS (+) to continue.

13. Press The printer performs an auto-calibration. During this process, the

printer checks the readings for the media and ribbon based on the new scale established, determines the label length, and determines the print mode. To see the new readings on the new scale, print a sensor profile.

SELECT to accept any changes and deselect the parameter.

14. Press

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Control Panel Parameters

Table 12 • Printer Parameters (Page 16 of 26)

Parameter

Action/Explanation

Set Parallel Communications

Select the communications port that matches the one being used by the host computer.

Default Value: BIDIRECTIONAL Selections: BIDIRECTIONAL, UNIDIRECTIONAL

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

ZPL and XML only Set Serial Communications

Select the communications port that matches the one being used by the host computer. This setting applies only when the serial port is used.

Note • Select RS232 if you are using an external adapter to enable

RS422/485 operation.

Default Value: RS232 Selections: RS232, RS485 MULTIDROP

To change the value shown:

1. Press SELECT to select the parameter.

2. Press

PLUS (+) or MINUS (-) to scroll through the options. SELECT to accept any changes and deselect the parameter.

3. Press

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.

Default Value: 9600 Selections (ZPL, XML): 300, 600, 1200, 2400, 4800, 9600, 14400, 19200,

28800, 38400, 57600, 115200 Selections (EPL): 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200

To change the value shown:

1. Press SELECT to select the parameter.

2. Press

PLUS (+) or MINUS (-) to scroll through the options. SELECT to accept any changes and deselect the parameter.

3. Press

Parameter

Table 12 • Printer Parameters (Page 17 of 26)

Action/Explanation

Set Data Bits

This setting applies only when the serial port is used. 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.

Default Value: 8BITS Selections: 7BITS, 8BITS

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to toggle between the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

Set Parity

This setting applies only when the serial port is used. The parity of the printer must match the parity of the host computer for accurate communications to take place. Select the parity that matches the one being used by the host computer.

Default Value: NONE Selections: EVEN, ODD, NONE

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

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 (ZPL, XML, APL-D): XON/XOFF Selections (ZPL, XML): XON/XOFF, DSR/DTR, RTS/CTS

Default Value (APL-I): XON/XOFF Selections (APL-I): XON/XOFF, DSR/DTR, RTS/CTS, APL-I

Default Value (EPL): DTR & XON/XOFF Selections (EPL): DTR & XON/XOFF, DTR

To change the value shown:

1. Press SELECT to select the parameter.

2. Press

PLUS (+) or MINUS (-) to scroll through the options. SELECT to accept any changes and deselect the parameter.

3. Press

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ZEBRA

ACK_N AK

ZEBRA

DSR/D TR

Control Panel Parameters

Configuration

Control Panel Parameters

Table 12 • Printer Parameters (Page 18 of 26)

Parameter

APL-I only

Action/Explanation

Send APL-I Status Response

Determines if a response is sent after inquiry commands.

Default Value: ON Selections: ON, OFF

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to toggle between the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

ZPL and XML only Set Protocol

Protocol is a type of error checking system. Depending on the selection, an indicator may be sent from the printer to the host computer signifying that data has been received. Select the protocol that is requested by the host computer. Further details on protocol can be found in the ZPL

Programming Guide. Default Value: NONE

Selections: NONE, ZEBRA, ACK_NAK

Note •

response messages are sequenced. If must use

To change the value shown:

1. Press SELECT to select the parameter.

2. Press

PLUS (+) or MINUS (-) to scroll through the options. SELECT to accept any changes and deselect the parameter.

3. Press

ZPL and XML only Set Network ID

This parameter assigns a unique number to the printer when the printer is operating in an RS422/485 multi-drop network environment (an external RS422/485 adapter is required). This gives the host computer the means to address a specific printer. This does not affect TCP/IP or IPX networks.

Default Value: 000 Range: 000 to 999

To change the value shown:

1. Press SELECT to select the parameter.

2. Press

MINUS (-) to move to the next digit position. PLUS (+) to increase the value of the digit.

3. Press

SELECT to accept any changes and deselect the parameter.

4. Press

is the same as

for host handshake protocol.

, except that

is selected, the printer

Table 12 • Printer Parameters (Page 19 of 26)

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 130.

Default Value: NORMAL MODE Selections: NORMAL MODE, DIAGNOSTICS

To select communication diagnostics mode:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to toggle between the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

ZPL and XML only Set Control Prefix Character

The printer looks for this two-digit hex character to indicate the start of a ZPL/ZPL II control instruction.

Note • Do not use the same hex value for the control, format, and

delimiter character. The printer must see different characters to work properly.

Default Value: 7E ~ Range: 00 to FF

To change the value shown:

1. Press SELECT to select the parameter.

2. Press

MINUS (-) to move to the next digit position. PLUS (+) to increase the value of the digit.

3. Press

SELECT to accept any changes and deselect the parameter.

4. Press

ZPL and XML only Set Format Prefix Character

The format prefix is a two-digit hex value used as a parameter place marker in ZPL/ZPL II format instructions. The printer looks for this hex character to indicate the start of a ZPL/ZPL II format instruction. See the ZPL 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.

Default Value: 5E ^ Range: 00 to FF

To change the value shown:

1. Press SELECT to select the parameter.

MINUS (-) to move to the next digit position.

2. Press

PLUS (+) to increase the value of the digit.

3. Press

4. Press SELECT to accept any changes and deselect the parameter.

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Configuration

Control Panel Parameters

Configuration

Control Panel Parameters

Table 12 • Printer Parameters (Page 20 of 26)

Parameter

Action/Explanation

ZPL and XML only 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 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.

Default Value: 2C , Range: 00 to FF

To change the value shown:

1. Press SELECT to select the parameter.

MINUS (-) to move to the next digit position.

2. Press

PLUS (+) to increase the value of the digit.

3. Press

SELECT to accept any changes and deselect the parameter.

4. Press

ZPL and XML only Select ZPL Mode

The printer remains in the selected mode until it is changed by this parameter or by using a ZPL/ZPL II command. The printer accepts label formats written in either ZPL or ZPL II, eliminating the need to rewrite any ZPL formats that already exist. See the ZPL Programming Guide for more information on the differences between ZPL and ZPL II.

Default Value: ZPL II Range: ZPL II, ZPL

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to toggle between the options.

2. Press

3. Press

SELECT to accept any changes and deselect the parameter.

Parameter

Table 12 • Printer Parameters (Page 21 of 26)

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.

• Short Cal sets media and web thresholds without adjusting sensor gain, determines length, and feeds the media to the next web.

• Length determines label length using current sensor values, and feeds the media to the next web.

• No Motion tells the printer not to move the media. You must manually ensure that the web is positioned correctly, or press feed to position the next web.

• Feed—feeds the labels to the first registration point.

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

Select Head Close Option

This parameter sets the action of the media when you close the printhead.

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.

• Short Cal sets media and web thresholds without adjusting sensor gain, determines length, and feeds the media to the next web.

• Length determines label length using current sensor values, and feeds the media to the next web.

• No Motion tells the printer not to move the media. You must manually ensure that the web is positioned correctly, or press feed to position the next web.

• Feed—feeds the labels to the first registration point.

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

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Configuration

Control Panel Parameters

Configuration

Control Panel Parameters

Table 12 • Printer Parameters (Page 22 of 26)

Parameter

Action/Explanation

Select Backfeed Sequence

This parameter sets when label backfeed occurs after a label is removed in some print modes. It has no effect in Rewind mode. This setting is superseded by Programming Guide for more information).

~JS when received as part of a label format (see the ZPL

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. Press

PLUS (+) or MINUS (-) to scroll through the options. SELECT to accept any changes and deselect the parameter.

3. Press

ZPL, XML, EPL, APL-D

Adjust Label Top Position

This parameter adjusts the print position vertically on the label. Positive numbers adjust the label top position farther down the label (away from the printhead) by the specified number of dots. Negative numbers adjust the position up the label (toward the printhead).

Default Value: +000 Range (ZPL, XML, EPL): -120 to +120

APL-I only

Range (APL-D): –0.64i to 0.64i (when printer is set to operate in inches) Range (APL-I): –10 to 4000

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) to increase the value.

2. Press

MINUS (-) to decrease the value.

3. Press

SELECT to accept any changes and deselect the parameter.

4. Press

APL-I only Adjust Label Left Position

The label left position adjusts the print position horizontally on the label. Positive numbers move the left edge of the image toward the center of the label by the number of dots selected while negative numbers shift the left edge of the image toward the left edge of the label.

Default Value: +0000 Range: –9999 to +9999

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) to increase the value.

2. Press

MINUS (-) to decrease the value.

3. Press

4. Press

SELECT to accept any changes and deselect the parameter.

Table 12 • Printer Parameters (Page 23 of 26)

Parameter

Action/Explanation

Adjust Left Position

This parameter adjusts the print position horizontally on the label. Positive numbers adjust printing to the left by the specified number of dots. Negative numbers shift printing to the right.

Default Value: 0000 Range: –9999 to +9999 dots

To change the value shown:

1. Press SELECT to select the parameter.

MINUS (-) to move the cursor.

2. Press

PLUS (+) to change between +/- and to increase the value of the

3. Press digit. For a negative value, enter the value before changing to the minus sign.

SELECT to accept any changes and deselect the parameter.

4. Press

ZPL and XML only 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 panel.

Default Value: DISABLED Selections: ENABLED, DISABLED

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to toggle between the options.

2. Press

SELECT to accept any changes and deselect the parameter.

3. Press

MINUS (-) on the control

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Configuration

IDLE DISP LAY

Control Panel Parameters

Configuration

Control Panel Parameters

Table 12 • Printer Parameters (Page 24 of 26)

Parameter

Action/Explanation

See next column View Sensor Settings

These parameters are automatically set during the calibration procedure and should be changed only by a qualified service technician. Refer to the ZPL II Programming Guide for information on these parameters.

To skip these parameters:

1. Press PLUS (+) to skip each of the following parameters:

ZPL and XML only 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o 300, 150 o600, 200 o600, 300 o600

To change the value shown:

1. Press SELECT to select the parameter.

2. Press

PLUS (+) or MINUS (-) to scroll through the options. SELECT to accept any changes and deselect the parameter.

3. Press

Parameter

Table 12 • Printer Parameters (Page 25 of 26)

Action/Explanation

Select Idle Display

This parameter selects the LCD options for the real-time clock.

Note • If the default value is not selected, pressing PLUS (+) or

MINUS (-) briefly displays the firmware version of the printer.

Default Value: FIRMWARE (FW) VERSION Selections: MM/DD/YY (24HR), MM/DD/YY (12HR), DD/MM/YY

(24HR), DD/MM/YY (12HR), FW VERSION

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

3. Press

SELECT to accept any changes and deselect the parameter.

Set Real-Time Clock (RTC) Date

This parameter allows you to set the date following the convention selected in

To change the value shown:

1. Press SELECT to select the parameter.

MINUS (-) to move to the next digit position.

2. Press

PLUS (+) to change the value of the digit.

3. Press

4. Press

SELECT to accept any changes and deselect the parameter.

Set RTC Time

This parameter allows you to set the time following the convention selected in

To change the value shown:

1. Press SELECT to select the parameter.

2. Press the left oval

3. Press the right oval

SELECT to accept any changes and deselect the parameter.

4. Press

MINUS (-) to move to the next digit position.

PLUS (+) to change the value of the digit.

Specify Password Level

This parameter allows you to select whether certain factory-selected menu items or all menu items are password protected.

Default Value: SELECTED ITEMS Selections: SELECTED ITEMS, ALL ITEMS

SELECT to select the parameter.

1. Press

PLUS (+) or MINUS (-) to toggle between the options.

2. Press

3. Press

SELECT to accept any changes and deselect the parameter.

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Parameter

Control Panel Parameters

Table 12 • Printer Parameters (Page 26 of 26)

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

Configuration

Control Panel Parameters

Notes • ___________________________________________________________________

To change the value shown:

1. Press SELECT to select the parameter.

PLUS (+) or MINUS (-) to scroll through the options.

2. Press

3. Press

SELECT to accept any changes and deselect the parameter.

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Routine Maintenance

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 onpage 99 for the recommended cleaning intervals.

Routine Maintenance

Replacing Printer Components

This section provides routine cleaning and maintenance procedures.

Contents

Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Cleaning Schedule and Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Clean the Printhead and Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Clean the Media Compartment and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Clean the Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Routine Maintenance for the Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Remove Printed Labels or Liner from the Rewind Spindle . . . . . . . . . . . . . . . . . . . . 106

Adjust Media Alignment for Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Ordering Replacement Parts

For optimal printing quality and proper printer performance across our product line, Zebra strongly recommends the use of genuine Zebra™ supplies as part of the total solution. Specifically, the ZM400 and ZM600 are designed to work only with genuine Zebra™ printheads, thus maximizing safety and print quality.

Contact your authorized Zebra reseller for part ordering information, or see Contacts

on page 11 for contact addresses and telephone numbers.

Recycling Printer Components

The majority of this printer’s components are recyclable. The printer’s main logic board includes a battery that you should dispose of properly.

Do not dispose of any printer components in unsorted municipal waste. Please dispose of the battery according to your local regulations, and recycle the other printer components according to your local standards. For more information, see

http://www.zebra.com/environment.

Lubrication

No lubrication is needed for this printer.

Caution • Some commercially available lubricants will damage the finish and the

mechanical parts if used on this printer.

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Cleaning Schedule and Procedures

Routine Maintenance

Cleaning Procedures

100

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 14 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.

Table 14 • Recommended Cleaning Schedule

Area Method Interval

Printhead Solvent* Direct Thermal Mode: After every roll of Platen roller Solvent* Media sensors Air blow Ribbon sensor Air blow Media path Solvent* Ribbon path Solvent* Pinch roller (part of Peel-Off option) Solvent* Cutter

module

If cutting continuous, pressure-sensitive media

If cutting tag stock or label liner material

Solvent* After every roll of media (or more often,

Solvent* and

air blow Tear-off/peel-off bar Solvent* Once a month. Take-label sensor Air blow Once every six months.

* Zebra recommends using Preventive Maintenance Kit (part number 47362). In place of this kit, you may use a clean swab

dipped in a solution of isopropyl alcohol (minimum 90%) and deionized water (maximum 10%).

Clean the Exterior

You may clean the exterior surfaces of the printer with a lint-free cloth and a small amount of a mild detergent, if necessary. Do not use harsh or abrasive cleaning agents or solvents.

media (or 500 feet of fanfold media). Thermal Transfer Mode: After every roll of

ribbon or three rolls of media.

depending upon your application and media). After every two or three rolls of media.

Clean the Printhead and Platen Roller

Yo u can minimize printhead wear and maintain print quality with regu lar preventive measures. Over time, the movement of media or ribbon across the printhead wears through the protective ceramic coating, exposing and eventually damaging the print elements (dots). To avoid abrasion:

• Clean the printhead frequently, and use well-lubricated thermal transfer ribbons with backings optimized to reduce friction.

• Minimize printhead pressure and burn temperature settings by optimizing the balance between the two.

• Ensure that the thermal transfer ribbon is as wide or wider than the label media to prevent exposing the elements to the more abrasive label material.

For best results, clean the printhead after changing every roll of ribbon. Inconsistent print quality, such as voids in the bar code or graphics, may indicate a dirty printhead.

Caution • While performing any tasks near an open printhead, remove all rings, watches,

Note • For printers with a peel assembly, keep the peel assembly closed while cleaning the

platen roller to reduce the risk of bending the tear-off/peel-off bar.

Figure 15 • Location of the Printhead and Platen Roller

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Printhead assembly

Platen roller

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Routine Maintenance

101

Cleaning Procedures

Routine Maintenance

Cleaning Procedures

102

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 thesesteps:

1. Open the printhead assembly.

2. Remove the media and ribbon.

3. Using the swab from the Preventive Maintenance Kit (part number 47362), wipe along the

brown strip on the printhead assembly from end to end. 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.

4. While manually rotating the platen roller, clean it thoroughly with the swab. Allow the

solvent to evaporate.

5. Reload media and ribbon, and close the printhead assembly.

Note • If performing this procedure does not improve print quality, try cleaning the

printhead with Save-A-Printhead cleaning film. This specially coated material removes contamination buildup without damaging the printhead. Call your authorized Zebra reseller for more information.

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Routine Maintenance

Cleaning Procedures

103

Routine Maintenance

Cleaning Procedures

104

Clean the Media Compartment and Sensors

To clean the media compartment and sensors, complete these steps:

1. Brush or vacuum any accumulated paper lint and dust away from the media and ribbon

paths.

2. Brush or vacuum any paper lint and dust away from the sensors (see Figure 16).

Figure 16 • Cleaning the Sensors

Take-label sensor

Ribbon sensor

Media sensor

Clean the Cutter Module

If the cutter is not cutting the labels cleanly or if it jams with labels, clean the cutter.

Caution • For personnel safety, always power off and unplug the printer before performing

this procedure.

To clean the cutter module, complete these steps:

1. Turn the printer off (O), and unplug the printer from its power source.

Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers.

Remove the cutter shield (1) by removing the cutter shield thumbscrew and lock

2).

washer (

3. To expose the V-shaped cutter blade, turn the cutter motor thumbscrew (1)

counterclockwise to lower the blade.

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Routine Maintenance

105

Cleaning Procedures

Routine Maintenance for the Rewind Option

Routine Maintenance

106

4. See Figure 17. Using the swab from the Preventive Maintenance Kit (part number 47362),

wipe along the upper cutting surface ( 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.

1) and the cutter blade (2). In place of the

Figure 17 • Cleaning the Cutter Module

5. Replace the cutter shield.

6. Plug the printer into its power source, and then turn on (I) the printer.

The lower cutter blade returns to its correct operating position.

7. If the cutter continues to perform unsatisfactorily, contact an authorized service

technician.

Routine Maintenance for the Rewind Option

When you use the Rewind option, you will periodically need to remove printed labels or used liner from the rewind spindle. You may also need to adjust the media alignment for the Rewind option.

Remove Printed Labels or Liner from the Rewind Spindle

To remove printed labels or liner from the rewind spindle, complete these steps:

1. Cut the liner between the media alignment spindle and the rewind spindle.

2. Rotate the take-up spindle counterclockwise until the rewind media guide is fully upright.

3. Loosen the thumbscrew on the rewind media guide.

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Routine Maintenance

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Routine Maintenance for the Rewind Option

Routine Maintenance

108

4. Slide the rewind media guide all the way out, and then fold it down.

5. Slide the core with the liner from the take-up spindle.

Adjust Media Alignment for Rewind Option

The instructions below apply only if the printer has a Rewind option. The liner should be installed flush against the backplate of the rewind spindle to prevent the media/backing from winding too loosely.

Perform the adjustments in the order given. Do only what is needed to solve the problem.

To adjust the media alignment for printers with the Rewind option, complete these steps:

1. Turn the adjustment dial (1) clockwise to move the media toward the backplate (2).

2. Turn the adjustment dial (1) counter clockwise to move the media away from the

backplate (

2).

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Troubleshooting

This section provides information about errors that you might need to troubleshoot. Assorted diagnostic tests are included.

Contents

Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Miscellaneous Printer Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Printer Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

FEED Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

FEED and PAUSE Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Communications Diagnostics Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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

and Ribbon Sensor Sensitivity on page 84.

 Is the printer reporting a ribbon error when ribbon is loaded properly? If yes, see Calibrate

Media and Ribbon Sensor Sensitivity on page 84.

 Are you experiencing problems with print quality? If yes, see Print Quality Problems

on page 115.

 Are you experiencing communications problems? If yes, see Communications Problems

on page 119.

If the labels are not printing or advancing correctly, review this checklist:

 Are you using the correct type of labels? Review the types of label in Types of Media

on page 33.

 Are you using a label that is narrower than the maximum print width? See Set Print Width

on page 75.

 Review the label- and ribbon-loading illustrations in Load Media onpage 41 and Load

Ribbon on page 55.

 Does the printhead need to be adjusted? See Adjust Printhead Pressure onpage 61 for

more information.

 Do the sensors need to be calibrated? See Calibrate Media and Ribbon Sensor Sensitivity

on page 84 for more information.

If none of the above suggestions correct the problem, review this checklist:

 Perform one or more of the self-tests given in Printer Diagnostics on page 123. Use the

results to help identify the problem.

 If you are still having problems, see Contacts onpage 11 for customer support

information.

Troubleshooting

Troubleshooting Checklists

110

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Troubleshooting

ERROR CON DITION

INVAL ID H EAD

ERROR CONDITION

RIBBON OUT

WARNING

RIBBON IN

ERROR CONDITION

PAPER OUT

ERROR CONDITION

HEAD OPEN

THERM ISTO R

FAULT

WARNING

HEAD COLD

THERM ISTO R

FAULT

ERROR CONDITION

HEAD ELEMENT BAD

LCD Error Messages

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Troubleshooting

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LCD Error Messages

The LCD displays messages when there is an error. See Table 15 for LCD errors, the possible causes, and the recommended solutions.

LCD Display/ Printer Condition

The ERROR light flashes.

The printer stops; the ERROR light flashes.

Possible Cause Recommended Solution

The printhead was replaced with one that is not a genuine Zebra™ printhead.

In thermal transfer mode, ribbon is not loaded or incorrectly loaded.

In thermal transfer mode, the ribbon sensor is not detecting ribbon that is loaded incorrectly.

In thermal transfer mode, media is blocking the ribbon sensor.

In thermal transfer mode, the printer did not detect the ribbon even though it is loaded correctly.

Table 15 • LCD Error Messages

Install a genuine Zebra™ printhead.

Load ribbon correctly. See Load

Ribbon on page 55.

1. Load ribbon correctly. See Load

2. Calibrate the sensors. See

1. Load media correctly. See Load

2. Calibrate the sensors. See

1. Print a sensor profile. See Print

2. Calibrate the sensors or load

Ribbon on page 55.

Calibrate Media and Ribbon Sensor Sensitivity on page84.

Media on page 41.

Calibrate Media and Ribbon Sensor Sensitivity on page84.

Sensor Profile onpage 83. The

ribbon out threshold (marked by

RIBBON) is likely too

the word high, above the black area that indicates where the ribbon is detected.

printer defaults. See Calibrate

Media and Ribbon Sensor Sensitivity on page 84 or LOAD DEFAULTS on page 65.

LCD Display/ Printer Condition

The ERROR light flashes.

The printer stops; the ERROR light flashes.

The ERROR light flashes.

The printer stops; the ERROR light is on; the printer cycles through these three messages.

Table 15 • LCD Error Messages (Continued)

Possible Cause Recommended Solution

Ribbon is loaded, but the printer is set for direct thermal mode.

The media is not loaded or is loaded incorrectly.

Misaligned media sensor. Check position of the media sensor. The printer is set for

noncontinuous media, but continuous media is loaded.

The printhead is not fully closed. Close printhead completely. The head open sensor is not

working properly.

The printhead has a faulty thermistor.

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 printhead has a faulty thermistor.

Ribbon is not required with direct thermal media. If you are using direct thermal media, remove the ribbon. This error message will not affect printing.

If you are using thermal transfer media, which requires ribbon, set the printer for Thermal Transfer mode. See Select

Print Method on page 75.

Load media correctly. See Load Media

on page 41.

Install proper media type, or reset printer for current media type and perform calibration.

Call a service technician.

Caution • Turn off (O) the printer

before performing this procedure. Failure to do so can damage the printhead.

1. Turn off (O) the printer.

2. Disconnect and reconnect the data cable to the printhead.

3. Ensure that the cable connector is fully inserted into the printhead connector.

4. Turn on (

Call a service technician.

I) the printer.

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Troubleshooting

WARNING

HEAD COLD

WARNING

HEAD TOO HOT

DEFRAGMENTING

ERROR CONDITION

CUTTER JAM

OUT OF MEMORY

(function)

LCD Error Messages

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LCD Error Messages

LCD Display/ Printer Condition

The printer prints while the ERROR light flashes.

The printer stops; the ERROR light flashes.

Table 15 • LCD Error Messages (Continued)

Possible Cause Recommended Solution

Caution • An improperly connected printhead data or power cable

can cause this error message. The printhead may be hot enough to cause severe burns. Allow the printhead to cool.

The printhead temperature is approaching its lower operating limit.

The printhead data cable is not properly connected.

Continue printing while the printhead reaches the correct operating temperature. If the error remains, the environment may be too cold for proper printing. Relocate the printer to a warmer area.

Caution • Turn off (O) the printer

before performing this procedure. Failure to do so can damage the printhead.

1. Turn off (O) the printer.

2. Disconnect and reconnect the data cable to the printhead.

3. Ensure that the cable connector is fully inserted into the printhead connector.

4. Turn on (

The printhead has a faulty thermistor.

Caution • The printhead may be hot enough to cause severe

burns. Allow the printhead to cool.

The printhead is over temperature. Allow the printer to cool. Printing

Call a service technician.

automatically resumes when the printhead elements cool to an acceptable operating temperature.

I) the printer.

LCD Display/ Printer Condition

The printer stops.

The printer stops; the ERROR light flashes.

Table 15 • LCD Error Messages (Continued)

Possible Cause Recommended Solution

The printer is defragmenting memory.

Caution • The cutter blade is sharp. Do not touch or rub the blade

with your fingers.

The cutter blade is in the media path.

There is not enough memory to perform the function specified on the second line of the error message.

Caution • Do NOT turn off the printer

power during defragmenting. Doing so can damage the printer.

Allow the printer to finish defragmenting. If you get this error message frequently, check your label formats. Formats that write to and erase memory frequently may cause the printer to defragment often. Using properly coded label formats usually minimizes the need for defragmenting.

If this error message does not go away, contact Technical Support. The printer requires service.

Turn off the printer power and unplug the printer. Inspect the cutter module for debris and clean as needed following the cleaning instructions in

Clean the Cutter Module on page 104.

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. See Set Print Width

on page 75.

Ensure that the data is not directed to a device that is not installed or is unavailable.

Refer to the Maintenance Manual for more information about the specified function.

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Troubleshooting

Print Quality Problems

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Troubleshooting

116

Print Quality Problems

Table 16 identifies problems with print quality, the possible causes, and the recommended

solutions.

Table 16 • Print Quality Problems

Problem Possible Cause Recommended Solution

General print quality issues

Long tracks of missing print on several labels

The printer is set at the incorrect print speed.

Y ou are using an incorrect combination of labels and ribbon for your application.

The printer is set at an incorrect darkness level.

The printhead is dirty. Clean the printhead. See Clean the Printhead

Incorrect or uneven printhead pressure.

The printhead is improperly balanced.

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 71. You may want to

perform the FEED Self Test onpage 126.

1. Switch to a different type of media or ribbon to try to find a compatible combination.

2. If necessary, consult your authorized Zebra reseller or distributor for information and advice.

For optimal print quality, set the darkness to the lowest possible setting for your application via the control panel, the driver, or the software. See

Adjust Print Darkness/Density on page 70. You

may want to perform the FEED Self Test

on page 126 to determine the ideal darkness

setting.

and Platen Roller on page 100.

Set the printhead pressure to the minimum needed for good print quality. See Adjust

Printhead Pressure onpage 61.

Call a service technician.

Print element damaged. Call a service technician.

Table 16 • Print Quality Problems (Continued)

Problem Possible Cause Recommended Solution

Wrinkled ribbon Ribbon was fed through the

ribbon system incorrectly. Incorrect burn temperature. Set the darkness to the lowest possible setting for

Incorrect or uneven printhead pressure.

Media not feeding properly; “walking” from side to side.

Load the ribbon correctly. See Load Ribbon

on page 55.

good print quality. See Adjust Print

Darkness/Density on page 70.

Set the printhead pressure to the minimum needed for good print quality. See Adjust

Printhead Pressure onpage 61.

Make sure that media is snug by adjusting the media guide, or call a service technician.

The strip plate needs adjusting. Call a service technician.

Printing too light or too dark over the entire label

Smudge marks on labels

Misregistration/skips labels

Misregistration and misprint of one to three labels

The printhead needs vertical adjustment.

The printhead is improperly balanced.

The printhead and platen roller need to be realigned.

The media or ribbon is not designed for high-speed operation.

Y ou are using an incorrect combination of media and ribbon for your application.

Y ou are using ribbon with direct thermal media.

Incorrect or uneven printhead pressure.

The media or ribbon is not designed for high-speed operation.

The printer is not calibrated. Recalibrate the printer. Improper label format. Use correct label format. The platen roller is dirty. See Clean the Printhead and Platen Roller

Media does not meet specifications.

Call a service technician.

Replace supplies with those recommended for high-speed operation.

1. Switch to a different type of media or ribbon to try to find a compatible combination.

2. If necessary, consult your authorized Zebra reseller or distributor for information and advice.

Direct thermal media does not require ribbon. To check if you are using direct thermal media, perform the label scratch test in When to Use

Ribbon on page 35.

Set the pressure to the minimum needed. See

Adjust Printhead Pressure onpage 61.

Replace supplies with those recommended for high-speed operation.

on page 100.

Use media that meets specifications.

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Print Quality Problems

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Troubleshooting

Calibration Problems

118

Table 16 • Print Quality Problems (Continued)

Problem Possible Cause Recommended Solution

Vertical drift in top-of-form position

Vertical image or label drift

The bar code printed on a label does not scan.

The printer is out of calibration. Recalibrate the printer. 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.

The platen roller is dirty. Clean the platen roller. See Clean the Printhead

The printer is using non-continuous labels but is configured in continuous mode.

The media sensor is positioned incorrectly.

The media sensor is calibrated improperly.

The platen roller is dirty. Clean the platen roller. See Clean the Printhead

Improper printhead pressure settings (toggles).

Improperly loaded ribbon or media.

Incompatible media. Ensure that the interlabel gaps or notches are 2 to

The bar code is not within specifications because the print is too light or too dark.

Not enough blank space around the bar code.

Calibrate the printer.

and Platen Roller on page 100.

Configure the printer for non-continuous and run calibration routine, if necessary.

Ensure that the media sensor is properly positioned to read a single/consistent interlabel gap.

See Calibrate Media and Ribbon Sensor

Sensitivity on page 84.

and Platen Roller on page 100.

Adjust the printhead pressure to ensure proper functionality.

Verify that the printer is loaded properly.

4 mm and consistently placed. Media must not exceed minimum specifications for mode of operation.

Perform the FEED Self Test onpage 126. Adjust the darkness or print speed settings as necessary.

Leave at least 1/8 in. (3.2 mm) between the bar code and other printed areas on the label and between the bar code and the edge of the label.

Calibration Problems

Table 17 identifies problems with calibration, the possible causes, and the recommended

solutions.

Table 17 • Calibration Problems

Problem Possible Cause Recommended Solution

Loss of printing registration on labels. Excessive vertical drift in top-of-form registration.

Auto Calibrate failed. Media or ribbon is loaded

The platen roller is dirty. Clean the platen roller according to the

Media guides are positioned improperly.

The media type is set incorrectly.

The media is loaded incorrectly. Load media correctly. See Load Media

incorrectly. The sensors could not detect the

media or ribbon. The sensors are dirty or

positioned improperly. The sensors are dirty, or media is positioned improperly for the sensors to detect.

The media type is set incorrectly.

instructions in Clean the Printhead and Platen

Roller on page 100.

Ensure that the media guides are properly positioned.

Set the printer for the correct media type (gap/notch, continuous, or mark). See Set Media

Type on page 74.

on page 41.

Ensure that media and ribbon are loaded correctly.

Manually calibrate the printer. See Calibrate

Media and Ribbon Sensor Sensitivity on page 84.

Ensure that the sensors are clean and that media is positioned properly.

Set the printer for the correct media type (gap/notch, continuous, or mark). See Set Media

Type on page 74.

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Communications Problems

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Troubleshooting

Ribbon Problems

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Communications Problems

Table 18 identifies problems with communications, the possible causes, and the recommended

solutions.

Table 18 • 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.

A label format was sent to the printer. Several labels print, then the printer skips, misplaces, misses, or distorts the image on the label.

A label format was sent to the printer but was not recognized. The DATA light flashes but no printing occurs.

The communication parameters are incorrect.

The serial communication settings are incorrect.

The prefix and delimiter characters set in the printer do not match the ones in the label format.

Incorrect data is being sent to the printer.

Check the printer driver or software communications settings (if applicable).

If you are using serial communication, check the serial port setting in the control panel menu. See Set Serial Communications

on page 85.

If you are using serial communication, make sure that you are using a null modem cable or a null modem adapter.

Using the control panel controls, check the protocol setting. It should be set to

Set Protocol on page 87.

If a driver is used, check the driver communication settings for your connection.

Ensure that the flow control settings match. Check the communication cable length. See

Table5 on page 27 for requirements.

Check the printer driver or software communications settings (if applicable).

Verify the prefix and delimiter characters. See

Set Format Prefix Character on page 88 and Set Delimiter Character on page 89 for the

requirements. Check the communication settings on the

computer. Ensure that they match the printer settings.

If the problem continues, check the label format.

. See

Ribbon Problems

Table 19 identifies problems that may occur with ribbon, the possible causes, and the

Zebra Technologies URFIDM5E User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual