Zebra Technologies Z4000 User Manual
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User's Guide
For the Zebra Z4000™ and Z6000™ Printers
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Customer order # 77460L Manufacturer part # 77460LB Rev. 2
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Proprietary Statement
This manual contains proprietary information of Zebra Technologies Corporation. It is in-
tended solely for the information and use of parties operating and maintaining the equip-
ment described herein. Such proprietary information may not be used, reproduced, or
disclosed to any other parties for any other purpose without the expressed written permis-
sion of Zebra Technologies Corporation.
Product Improvements
Continuous improvement of products is a policy of Zebra Technologies Corporation. All
specifications and signs are subject to change without notice.
FCC Compliance Statement
NOTE:
This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential installation. This
equipment generates, uses and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions, may cause harmful interference to radio com-
munications. However, there is no guarantee that the interference will not occur in a par-
ticular installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by turning the equipment off and on, the
user is encouraged to try to correct the interference by one or more of the following
measures:
n
Reorient or relocate the receiving antenna.
n
Increase the separation between the equipment and the receiver.
n
Connect the equipment into an outlet on a circuit different from that to which the
receiver is connected.
n
Consult the dealer or an experienced Radio/TV technician for help.
NOTE:
This unit was tested with shielded cables on the peripheral devices. Shielded
cables must be used with the unit to insure compliance.
The user is cautioned that any changes or modifications not expressly approved by Zebra
Technologies Corporation could void the users authority to operate the equipment.
Canadian DOC Compliance Statement
This digital apparatus does not exceed the Class A limits for radio noise emissions from
digital apparatus as set out in the radio interference regulations of the Canadian Depart-
ment of Communications.
Liability Disclaimer
Zebra Technologies Corporation takes steps to assure that its published Engineering
Specifications and Manuals are correct; however, errors do occur. Zebra Technologies
Corpora tion reserves the right to correct any such errors and disclaims liability resulting
therefrom.
No Liability for Consequential Damage
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, damages for loss of
business profits, business interruption, loss of business information, or other pecuniary
loss) arising out of the use of or 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.
Because some states do not allow the exclusion or limitation of liability for consequential
or incidental damages, the above limitation may not apply to you.
Copyrights
This copyrighted manual and the label printers described herein are owned by Zebra Tech-
nologies Corporation. All rights are reserved. Unauthorized reproduction of this manual or
the software in the label printer may result in imprisonment of up to one year and fines of
up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability.
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®
IBM
is a registered trademark of IBM Corporation.
Goo Gone
Zebra
Z
®
is a Registered Trademark of Magic American Corporation
®
, Stripe®, ZPL®, and ZPL II®are registered trademarks, andZSeries,
4000, and Z6000 are trademarks of Zebra Technologies Corporation.
© Zebra Technologies Corporation
2
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Contents
Welcome
Getting Started 1
Communications 2
Printer Power 2
Printer Configuration
Z Series™ Configuration 3
Media & Ribbon Loading
Loading Media 5
Loading Ribbon 7
Removing Ribbon 8
Media Sensor Positioning
Media Sensor Operation 9
Media Sensor Position 9
Printer Operational Check 10
Printer Operation
Operator Interface 13
Front Panel Keys 13
Front Panel LEDs 14
Additional Front Panel Controls 14
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Media Calibration
Auto-Calibration 17
Calibration Control 17
Care & Adjustments
Cleaning 19
Lubrication 24
Printhead Pressure Adjustment 24
Power Rewind/Power Peel
Media Alignment 25
Printer Options
LCD Display (Deluxe Front Panel) 27
Power Rewind/Power Peel Option 28
Value Peel Option 30
Cutter Option 31
Electronics Options 33
Communication Options 33
Troubleshooting
Power On Self-Test 35
Troubleshooting Tables 35
Printer Self-Tests 38
Resetting Factory Defaults 44
Initializing the Flash Memory and PCMCIA Card 45
Automatically Executed Format 45
Print Error Conditions 46
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Printer Specifications
General Specifications 47
Printing Specifications 48
Ribbon Specifications 48
Media Specifications 49
Zebra Programming Language (ZPL II
®
)50
Bar Codes 50
Standard Printer Fonts 51
Optional Printer Fonts 53
Appendix A
Printer Configuration
(Standard Front Panel)
55
Printer Configuration
(Deluxe Front Panel)
Appendix B
Communication Interfaces 69
Serial Data Communications 69
Parallel Data Communications 72
Appendix C
AC Power Cord 73
Fuse Replacement 74
Shipping 74
Setting Darkness For “In-Spec” Bar Codes 74
ASCII Code Chart 77
Glossary
Index
59
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Welcome
Congratulations! You have just purchased a high-quality thermal demand printer manufactured by the industry leader in quality, service,
and value. For over 25 years, Zebra Technologies Corporation has
provided customers with the highest caliber of products and support.
This user’s guide provides all the information you will need to operate
the printer on a daily basis.
To create and print label formats, refer to the ZPL II Programming
Guide (part # 46469L). This guide is available by contacting your
distributor or Zebra Technologies Corporation.
In addition, label preparation software is available. Contact your distributor or Zebra Technologies Corporation for further information.
The Z Series™ Maintenance Manual (part # 77450L) contains the information you may need to properly maintain your printer.
Getting Started
Unpacking
Save the carton and all packing materials in case shipping is required.
Inspect the printer for possible shipping damage:
n
Check all exterior surfaces for damage.
n
Raise the Media Access Door and inspect the Media Compartment
for damage.
Reporting Damage
If you discover shipping damage:
n
Immediately notify the shipping company and file a damage report.
n
Retain the carton and all packing material for inspection.
n
Notify your local Zebra distributor of the damage.
Zebra Technologies Corporation is not responsible for any damage
incurred during shipment of the printer and will not cover the repair of
this damage under its warranty policy. Any damage claim should be
filed with the shipping company.
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For shipping information, refer to Appendix C.
Communications
Refer to Figure 1. The Z Series™ printer comes standard with both an
Electronics Industries Association (EIA) RS-232 serial data interface(a)
and a bi-directional parallel interface(b) compliant with the IEEE1284
standard. The serial interface is also configured for both RS-422/
RS-485 single drop and RS-485 multi-drop communication modes.
NOTE: You must supply the interface cable for your application. See
Appendix B of this manual for specific cable requirements.
Printer Power
The Power Supply in the Z Series™ printer automatically detects the
applied line voltage and works in the 90 to 265 VAC range.
Refer to Figure 1. The AC Power Cord must have a three-prong female
connector on one end which plugs into the mating connector(c) at the
rear of the printer. If a power cable was not included with your printer,
refer to Appendix C at the back of this guide.
WARNING!! For personnel and equipment safety, always use
a three-prong plug with an earth ground connection to the
AC Power Source.
Refer to Figure 1. Insure that the AC Power ON/OFF Switch(d) is in
the OFF (O) position before connecting the AC Power cord to a nearby
electrical outlet.
d
c
Figure 1. Printer Rear View
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b
a
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Printer Configuration
Z Series™ Configuration
The Z Series™ printer will have one of two different styled front panels. The deluxe front panel contains an LCD (Liquid Crystal Display),
but the standard front panel does not. With the deluxe front panel, the
LCD displays the parameters during the configuration process. For
those printers with the standard front panel, two banks of eight miniature switches located inside the printer’s front panel access door are
used when configuring the printer.
Communications Parameters
The Z Series™ printer is equipped with both serial data and parallel
data communication interfaces. This permits two sources to send label
formats to the printer.
The first source to send a “Start of Label Format” command controls
the printer. The printer will send a “printer busy” command to the
second source to inhibit data transmission.
The serial interface is factory preset to match the typical PC environment with RS232 communication:
9600 Baud, 8 Data Bits,
No Parity, Xon/Xoff Handshaking.
If you need to change your printer’s serial communications settings to
match those of your host computer, refer to Appendix A. If you do not
know the settings of your host computer, refer to the instruction manual
provided with the computer or your software application.
See Appendix B of this guide for specific data communication cable
requirements.
The printer automatically senses if a parallel communications cable is
connected from your host computer.
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Operating Modes
When shipped from the factory, the printer is preset to the most commonly used modes of operation:
Tear-Off Mode, Thermal Transfer Printing,
Die-Cut Media, Serial Port RS-232 Communications.
Refer to Appendix A to configure the parameters for the following:
n
Options, such as Power Rewind/Power Peel, Value Peel,
or Cutter
n
Operating Modes
n
Print Darkness
n
Label Tear-Off/Cut-Off Position
n
Image Position on the label
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Media & Ribbon Loading
Loading Media
To load media, refer to Figure 2.
1. Raise the media cover.
2. Press the Printhead Open Lever(e).
[The Printhead Assembly(f) automatically springs up.]
3. Fold down the Media Supply Guide(g) and slide it out as far from
the printer frame as possible.
4. Slide the Media Guide(h) out as far from the printer frame as pos-
sible.
5. Determine the type of media required for your application and fol-
low the roll media or fanfold media loading procedure.
NOTE: If your printer has either the Power Rewind/Power Peel, Value
Peel, or Cutter option installed, refer to the Options section for media
loading instructions.
f
g
h
e
Figure 2. Loading Media
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Roll Media Loading
To load roll media, refer to Figure 3.
1. Place the roll of media on the Media Supply Hanger(i) and push it
on all the way.
2. Fold the Media Supply Guide(g) up and slide it against the outer
edge of the media roll.
3. Feed the media under the Media Spindle(j), under the Ribbon Sen-
sor(k), and out the front of the printer.
4. Slide the Media Guide(h) in until it is against the outer edge of the
media.
5. Close the Printhead Assembly and the Media Cover, or continue to
"Loading Ribbon".
g
i
k
h
j
Figure 3. Roll Media Loading
Fanfold Media Loading
To load fanfold media, place the media behind the printer and refer to
Figure 4.
1. Pass the fanfold media over the Media Supply Hanger(i).
2. Fold the Media Supply Guide(g) up and slide it against the outer
edge of the media.
3. Feed the media under the Media Spindle(j), under the Ribbon Sen-
sor(k), and out the front of the printer.
4. Slide the Media Guide(h) against the outer edge of the media.
5. Close the Printhead Assembly and the Media Cover, or continue to
"Loading Ribbon".
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Loading the Ribbon
CAUTION: Always use ribbon that is wider than the media. The
smooth backing of the ribbon protects the printhead from wear.
(For Direct Thermal printing, do not load ribbon in the printer.)
To load ribbon, refer to Figures 5a and 5b.
1. Place the roll on the Ribbon Supply Spindle(l) and push it on all
the way.
2. Pull the end of the ribbon over the Ribbon Sensor(k), under the
Printhead assembly(f), and up over the Ribbon Guide Plate(m).
3. Wind the ribbon onto the Take-up Spindle(n) for several turns in a
clockwise direction.
4. As you close the Printhead Assembly, keep the ribbon snug and
free of wrinkles, and in line with the guide mark near the left edge
of the Ribbon Guide Plate.
n
m
f
l
k
Figure 5b. Ribbon Loading
Removing Ribbon
To remove the ribbon, turn the Release Knob on the end of the Take-up
Spindle(n) counterclockwise and slide the ribbon off the Spindle.
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Media Sensor Positioning
Media Sensor Operation
When the printer is turned ON, a Power ON Self Test is performed
which checks the status of the electronic system and controls within the
printer. Additional operating parameters are determined by the type of
media being used and the position of the Media Sensor located behind
the Platen and under the media.
Non-Continuous (Labels, Notched Tags) Media
This type of media has some type of physical characteristic (notch,
black mark, gap between die-cut labels, etc.) which indicates the startof-label position. The Media Sensor must be properly positioned to
sense these indicators.
Continuous Media
Continuous media typically does not contain start-of-label indicators.
Label length must be specified by commands sent to the printer.
If you are using ZPL II, include a Label Length (^LL) command in
each label format you send to the printer (refer to your ZPL II Programming Guide). If you are using other software to drive your printer, refer
to the instructions provided with that software.
Media Sensor Position
1. To properly position the Media Sensor(o), refer to Figure 6.
2. With the Printhead Assembly open, turn the AC Power ON
3. Look through the side of the print mechanism and locate the
Media Sensor Positioning Lever(p).
4. (non-continuous media - labels, notched tags) Move the lever
across the width of the media to position the sensor in line with the
start-of-label indicator (notch, black mark, gap between die-cut
labels, etc). The glow of the red LED through the media can help
to accurately position the sensor.
(continuous media - no notch or opening to sense) Position the
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sensor anywhere under the media so that an “Out-of-Media” condition will still be sensed.
5. Insure the media and ribbon are properly positioned within the
print mechanism. then close the Printhead Assembly.
6. Close the printer’s media cover, then turn the printer power OFF.
o
Figure 6. Sensor Positioning
Printer Operational Check
1. To insure proper setup and to check the initial printer configura-
tion, press and hold the CANCEL key while turning the printer
power ON. (Release the CANCEL key once the front panel indica-
tors begin to turn OFF.)
2. After an initial time period when the Power ON Self Test is per-
formed, the printer will feed out media while calibrating the label
length, then print a configuration label.
3. Check the current configuration printed on the label and note any
parameters which must be changed to insure the printer fits your
application. For information on changing the configuration for
your specific application, refer to Appendix A.
A visual check of the label also provides an indication of the print quality. Media width and media thickness vary from one application to the
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next. To maintain proper print quality, refer to the Care & Adjustments
section later in this guide.
Figure 7 illustrates a properly loaded Z Series™ printer. For loading
media and ribbon in printers with the Power Rewind/Power Peel, Value
Peel or Cutter options, see the Options section later in this guide.
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Figure 7. Printer Ready for Operation
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Printer Operation
Operator Interface
The Z Series™ family of printers features either a standard or deluxe
front panel. The deluxe front panel features a Liquid Crystal Display
(LCD) that provides both printer status information and configuration
option menus. This section of the user’s guide presents information
which is common to both printer front panels. Refer to Figures 8 and 9
to locate the keys and LEDs discussed in this section.
Front Panel Keys
Feed Key
The FEED key forces the printer to feed one blank label. If you press
the FEED key while the printer is idle or paused, a blank label is fed
immediately. If you press the FEED key while the printer is printing,
one blank label is fed after the completion of the current batch of
labels. Once the blank label has been fed, pressing the FEED key again
will feed a second label.
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Pause Key
The PAUSE key stops and restarts the printing process. The first time
you press the PAUSE key, any partially printed label is completed; then
the printing process is stopped. If the printer is idle when you press the
PAUSE key, no new print requests are accepted. Press the PAUSE key
a second time to resume the printing process.
Cancel Key
The CANCEL key only functions when the printer is paused. When
you press the CANCEL key, the label format that is currently printing
is canceled. If no label format is printing, then the next one to be
printed is canceled. If there are no label formats stored in the printer
and waiting to be printed, the CANCEL key is ignored.
If you press the CANCEL key for an extended period of time (more
than 3 seconds) the printer performs a “cancel all formats” operation.
The printer discards all of the label format data it has received, and
returns to the idle state.
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Front Panel LEDs
LEDs on the front panel are a quick indication of the printer's status.
The LEDs listed below are common to all Z Series™ printers .
POWER LED
The POWER LED is always ON when the printer is turned ON.
DATA LED
The DATA LED is normally OFF. When data is received, the LED acts
as follows:
n
SLOW BLINK - Printer is unable to accept more data
from the host
n
FAST BLINK - Printer is receiving data
n
LED ON - No data being received - data processing
or printing still occurring.
The DATA LED will also blink once when the CANCEL key is
pressed and a format is successfully canceled.
ERROR LED
The ERROR LED is normally OFF. When an error occurs that causes
an interruption in the printing process, the LED acts as follows:
n
SLOW BLINK - Ribbon In Warning, Under Temp
Warning, or Over Temp Error
n
FAST BLINK - Printhead Open
n
LED ON - Media Out, Ribbon Out, or Cutter Errors
With the Deluxe Front Panel, the type of error will also be visible on
the Liquid Crystal Display.
PAUSE LED
The PAUSE LED is normally OFF. When the LED is ON it indicates
the printer has stopped all printing operations. If the printer is printing
when a PAUSE condition is requested, the LED turns ON at the end of
the current label.
In the Peel operating mode, the PAUSE LED will blink when the label
is available for removal. No printing occurs when the printer is in the
Peel mode of operation and the Peel option is not installed.
Additional Front Panel Controls
The front panel door conceals the configuration and setup keys and/or
switches inside. Refer to the Printer Configuration section of this guide
to configure the printer for your application.
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Figure 8. Standard Front Panel
Figure 9. Deluxe Front Panel
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Media Calibration
Auto-Calibration
The auto-calibration of the Z Series™ printer occurs at power ON and
each time the printer recovers from error conditions such as media errors, ribbon errors, and printhead open errors. In the process of clearing
an error, open and close the printhead then take the printer out of
PAUSE. The printer will begin the auto-calibration process if all errors
have been cleared.
The printer automatically determines the label length, and media and
ribbon sensor settings.
When non-continuous media is sensed, the calibration process is followed by the label length calculation. Once the label length is determined, the media feeds to the rest position and stops.
The results of this 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.
Calibration Control
The auto-calibration process will not take place if the ZPL command or
the deluxe front panel setting for “Media Power Up” or “Head Close”
is set to either “feed” or “no motion.” In these cases, the printer assumes the media is correctly positioned and starts printing without calibrating.
As long as the printhead is closed, a calibration may be performed.
Calibration may clear error conditions that prevent media movement.
Ribbon and media error conditions are cleared by calibration, unless an
out-of-ribbon or out-of-media condition exists.
NOTE: If your printer has the standard front panel, the Calibration
function is controlled by a ZPL II command sent from the host computer.
No front panel calibration control is available.
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Care & Adjustments
Cleaning
CAUTION: Use only the cleaning agents indicated. Zebra Technologies Corporation will not be responsible for damage caused by any
other cleaning materials used on the Z Series™ printer.
Table 1 provides a recommended cleaning schedule. Cleaning Swabs
saturated with 70% Isopropyl Alcohol are available from your Zebra
distributor as a Preventive Maintenance Kit (part # 01429).
AREA METHOD INTERVAL
See Figure 10 for parts callouts. After every roll of media (or
Printhead (q) Alcohol
Platen Roller (r) Alcohol
Media Sensor (o) Air Blow
Media Path (See Figure 3 or 4) Alcohol
Ribbon Sensor (k) Air Blow
Ribbon Path (See Figure 5) Alcohol
Cutter
Assembly
Dust build-up
Air Blow
500 feet of fanfold media)
when printing in the direct
thermal mode.
After every roll of ribbon
when printing in the
thermal transfer mode.
After every two to three
rolls of media.
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Adhesive build-up
Tear-Off/Peel-Off Bar Alcohol Once per month.
Peel Blade Alcohol After every roll of media or
Label Available Sensor (z)
(See Fig. 17)
Citrus-Based
Cleaner
such as
Goo-Gone
Air Blow Once per six months.
After every roll of media or
more often depending upon
your application and the
®
type of media being cut.
more often depending upon
your application and media.
Table 1. Recommended Cleaning Schedule
Cleaning the Exterior
The exterior of the Z Series™ printer may be cleaned with a lint-free
cloth. Do not use harsh, abrasive cleaning agents or solvents. If necessary, a mild detergent or desktop cleaner may be used sparingly.
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Cleaning the Interior
Remove any accumulated dirt and lint from the interior of the printer
using a soft bristle brush and/or vacuum cleaner.
Cleaning the Printhead and Platen Roller
Inconsistent print quality, such as voids in the bar code or graphics,
may indicate a dirty printhead. For best results, perform the following
cleaning procedure after every roll of ribbon.
NOTE: The printer can remain ON while you are cleaning the
printhead. In this way all label formats, images, and all temporary
parameter settings stored in the printer's internal memory will be saved.
To clean the printhead, refer to Figure 10 and follow these steps:
1. Open the Media Compartment Door.
2. Open the Printhead Assembly by pressing the Printhead Open
Lever(e).
3. Remove the media and ribbon (if present).
4. Raise the Printhead Assembly by hand and, using a cleaning swab
soaked in alcohol, wipe along the printhead(q) print elements from
end to end. (The print elements are located within the brown strip
just behind the chrome strip on the printhead.) Allow a few seconds for the solvent to evaporate.
5. Rotate the platen roller(r) and clean thoroughly with a cleaning
swab soaked in alcohol.
6. Brush/vacuum any accumulated paper lint and dust away from the
media and ribbon paths.
7. Reload media and ribbon, close the printhead assembly, close the
Media Compartment Door, and continue printing.
Cleaning the Sensors
Refer to Figure 10. The Media Sensor(o) and Ribbon Sensor(k) should
be cleaned on a regular basis to ensure proper operation of the printer.
For printers with the Value Peel option or the Power Rewind/Power
Peel option installed refer to Figure 17 and clean the Label Available
Sensor(z). Brush or vacuum any accumulated paper lint and dust away
from the sensors.
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q
o
r
k
e
Figure 10. Printhead and Platen Roller Cleaning
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Cleaning the Cutter Module
(For printers equipped with the Cutter option.)
The Cutter Module requires periodic cleaning to remove paper dust
and gummed label residue. If labels are not being cut properly, or if the
cutter jams with labels, this is an indication that the cutter probably
needs cleaning. The cleaning frequency depends on your application
and the type of media you use.
When the stationary cutter blade and the v-shaped moveable cutter
blade become gummed up with label adhesive and/or paper debris,
clean them according to the procedure below. Steps 4 and 5 detail the
method of removal of the Cutter Module from the printer. This portion
of the procedure will only be required when there is an extremely
heavy buildup of adhesive residue.
Refer to Figure 11 during the following cleaning procedure.
1. Turn the AC power off and unplug the printer power cord.
2. Open the Media Door and press the Printhead Open Lever to raise
the Printhead Assembly.
3. Remove the thumb screw and lift off the Finger Guard (and Catch
Tray if used).
4. Usea3mmAllen Wrench to remove the cutter mounting screw.
5. Carefully lift the Cutter Module up and away from the printer.
6. Remove all paper and label residue from the cutter blades and
housing.
WARNING!! The cutter blades are very sharp. Take great
care in the following step to insure personal safety.
7. Use cotton swabs soaked with a citrus-based cleaner (Goo Gone)
to remove all adhesive residue from the cutter blades. (While
cleaning, rotate the cutter motor to access the entire length of the
moveable blade.)
8. If adhesive has accumulated on the Platen and the Tear/Peel Bar,
clean these areas in a similar manner.
9. When the cleaning is completed, reinstall the Cutter Module, the
Finger Guard and the Catch Tray, if used.
10. Install media, then close and latch the Printhead Assembly.
11. Connect the printer to an AC power source, and turn the printer on.
12. The printer should be ready to print and cut labels once again.
22 Z Series™ User’s Guide
30
H:...uspiran2.vp
Thu Jun 18 15:57:44 1998
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