ZM400/ZM600 Industrial/Commercial Printer User Guide...
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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.
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...
Compliance Information Compliance Information Compliance Information FCC Compliance Statement This device complies with Part 15 rules. Operation is subject to the following two conditions: This device may not cause harmful interference, and This device must accept any interference received, including interference that may cause undesired operation.
About This Document This section provides you with contact information, document structure and organization, and additional reference documents. Contents Who Should Use This Document ..........2 How This Document Is Organized .
About This Document Who Should Use 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 Introduction on page 7 Printer Setup on page 15...
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 Zebra Technologies International, 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109...
About This Document Document Conventions Document Conventions The following conventions are used throughout this document to convey certain information. Alternate Color (online only) Cross-references contain hot links to other sections in this guide. If you are viewing this guide online in .pdf format, you can click the cross-reference (blue text) to jump directly to its location.
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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. 3/27/07 Figure 1 • Sample Figure with Callouts button FEED CANCEL...
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About This Document Document Conventions Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ 79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07...
This section shows the operational controls and location of major components used when loading media. Contents External View ............8 Printer Media Compartment .
Introduction External View External View Figure 2 Figure 3 Power switch ( = off, AC power connector Wireless print server card slot (Ethernet) Wireless card ejector button 79695L-001 Rev. A show the components and connections on the outside of the printer. Figure 2 •...
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 and ZM600 are designed to work only with genuine Zebra™...
Introduction Control Panel Control Panel The control panel contains the lights that indicate basic operation and the buttons that you may need to press during basic operation. The control panel buttons and lights are labeled in Figure 5. Descriptions for each are located in 79695L-001 Rev.
Control Panel Buttons Button Function FEED Forces the printer to feed one blank label each time the button is pressed. • Printer not printing: one blank label immediately feeds. • Printing: one blank label feeds after the current batch of labels is complete. PAUSE Starts and stops the printing process.
Introduction Control Panel Control Panel Lights Light Status POWER PAUSE Flashing ERROR Flashing DATA One flash Slow flashing Fast flashing 79695L-001 Rev. A Table 2 • Control Panel Lights Indication The printer is off, or no power is applied. The printer is on. Normal printer operation.
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 ® •...
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Introduction Printer Language Modes Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ 79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07...
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 ............16 Handling the Printer .
Printer Setup Before You Begin Before You Begin Review this checklist, and resolve any issues before you set up or use your printer. Unpack and Inspect the Printer Have you unpacked the printer and inspected it for damage? If you have not, see Select a Site Have you selected an appropriate location for the printer? If you have not, Select a Site for the Printer on page Connect to a Data Source Have you determined how the printer will connect to a...
• 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.
Printer Setup Select a Site for the Printer Select a Site for the Printer Consider the following when selecting an appropriate location for your printer. Select a Surface Select a solid, level surface of sufficient size and strength to accommodate the printer and other equipment (such as a computer), if necessary.
Select a Data Communication Interface Table 5 provides basic information about data communication interfaces that you can use to connect your printer to a computer. You may send label formats to the printer through any data communication interface that is available. Select an interface that is supported by both your printer and your computer or your Local Area Network (LAN).
Printer Setup Select a Data Communication Interface Data Cables and Wireless Cards You must supply all data cables or wireless cards for your application. Data Cables Ethernet cables do not require shielding, but all other data cables must be fully shielded and fitted with metal or metallized connector shells.
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Table 6 • Connecting the Printer to a Computer or Network (Continued) Interface IEEE 1284 Bidirectional Parallel 3/27/07 Connection and Configuration No additional configuration is necessary. 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.
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Printer Setup Select a Data Communication Interface Table 6 • Connecting the Printer to a Computer or Network (Continued) Interface Internal wired Ethernet print server Wireless Ethernet print server 79695L-001 Rev. A Connection and Configuration Refer to the ZebraNet 10/100 Print Server User and Reference Guide for configuration instructions.
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 Caution •...
Printer Setup Connect the Printer to a Power Source Power Cord Specifications Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation. This cord must use an IEC 320 female connector and the appropriate region-specific, three-conductor grounded plug configuration.
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.
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Printer Setup Types of Media Media Type How It Looks Non-Continuous Roll Media Non-Continuous Fanfold Media Continuous Roll Media 79695L-001 Rev. A Table 7 • Roll and Fanfold Media Description Roll media is wound on a 3-in. (76-mm) core. Individual labels are separated by one or more of the following methods: •...
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.
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Printer Setup Ribbon Overview Observe the results. Did flakes or particles of ink from the ribbon adhere to the label? If ink from the ribbon... Adhered to the label Did not adhere to the label Ribbon Scratch Test Perform the ribbon scratch test when labels are unavailable. To perform a ribbon scratch test, complete these steps: Unroll a short length of ribbon.
This section provides the procedures for loading and calibrating the printer. Note • Complete the tasks and resolve the issues in operating the printer. Contents Print Modes and Printer Options ......... . . 30 Print Mode Descriptions and Printer Requirements .
Operations Print Modes and Printer Options Print Modes and Printer Options The printer can use different print modes and options for label removal mode that matches the media being used and the printer options available. For more information on the types of media, see Select Print Mode on page Print Mode Descriptions and Printer Requirements Print Mode...
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 Tear-Off...
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Operations Print Modes and Printer Options Table 9 • Media Paths for Print Modes with Various Printer Options (Continued) Print Mode Printer Option Cutter or Cutter (shown with Delayed Cut an optional catch tray) Rewind Rewind Red solid lines = media, Blue dotted lines 79695L-001 Rev.
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.
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Operations Load Media Insert media into the printer. Follow the instructions for roll or fanfold media, as appropriate. Remove and discard any tags or labels that are dirty or that are held by adhesives or tape. Flip down the media supply guide. Place the roll of media on the media supply hanger.
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Roll Media (Continued) Slide in the media supply guide until it touches the edge of the roll. Feed the media under the dancer assembly ( sensor ( ). Slide the media back until it touches the inside back wall of the upper media sensor.
Operations Load Media Additional Steps for Tear-Off Mode After completing continue with this section to operate the printer in Tear-Off mode. To operate the printer in Tear-Off mode, complete these steps: Slide in the media guide until it touches the outer edge of the media. Set the printer to Tear-Off mode.
Additional Steps for Peel-Off Mode (with or without Liner Take-Up) After completing Beginning Steps for all Print Modes and Printer Options on page 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.
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Operations Load Media Push down the peel-off mechanism release lever to open the peel assembly. Feed the liner over the tear-off/peel-off bar ( sure that the end of the liner falls outside of the printer. 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.
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Rewind Option (Continued) Loosen the thumbscrew on the rewind media guide. Slide the rewind media guide all the way out, and then fold it down. Slide an empty core onto the rewind spindle. 3/27/07 Liner Take-Up Option (Continued) Push the liner back until it touches the back plate of the liner take-up spindle assembly.
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Operations Load Media Rewind Option (Continued) Wrap the liner around the core and turn the rewind spindle counterclockwise to tighten the liner. Fold up the rewind media guide, and then slide it in until it touches the liner. Tighten the thumbscrew on the rewind media guide.
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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.
Operations Load Media Additional Steps for Cutter or Delayed Cut Mode After completing 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 •...
Close the printhead assembly. If the printer is paused (the Pause light is on), press begins automatically. Additional Steps for Rewind Mode After completing Beginning Steps for all Print Modes and Printer Options on page continue with this section to operate the printer in Rewind mode. For additional procedures related to the rewind option, see To operate the printer in Rewind mode, complete these steps: Pull approximately 18 in.
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Operations Load Media Feed the media over the peel assembly ( Feed the media under the media alignment roller ( Loosen the thumbscrew on the rewind media guide. Slide the rewind media guide all the way out, and then fold it down. 79695L-001 Rev.
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Slide an empty core onto the rewind spindle. 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. Fold up the rewind media guide, and then slide it in until it touches the media.
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Operations Load Media Slide in the media guide until it touches the outer edge of the media. Set the printer to Rewind mode. See Close the printhead assembly. If the printer is paused (the Pause light is on), press begins automatically. 79695L-001 Rev.
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.
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Operations Load Ribbon 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.
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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) Hold the ribbon with the loose end unrolling clockwise. Place the roll of ribbon on the ribbon supply spindle ( ) and push it all the way back.
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Operations Load Ribbon Close the printhead assembly. Wind the ribbon clockwise onto the ribbon take-up spindle ( 79695L-001 Rev. A Ribbon Coated Outside (black ribbon spindle) ZM400/ZM600 User Guide Ribbon Coated Inside (gray ribbon spindle) 3/27/07...
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 ( To loosen the ribbon, squeeze it against the ribbon take-up spindle tension blades ( the same time, turn the ribbon take-up spindle release knob counterclockwise ( The tension blades collapse into the ribbon take-up spindle, loosening the ribbon.
Operations Calibrate the Printer Calibrate the Printer Auto Calibration By default, the printer automatically calibrates on power up or when the printhead is closed. During auto calibration, the printer determines the label length and sensor settings. The results of the auto calibration are stored in the printer’s memory and are retained even if printer power is removed.
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. Figure 10. The ZM400 pressure adjustment dials have four possible settings designated by blocks of increasing size embossed on the print mechanism.
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Operations Adjust Printhead Pressure Media Width 2 in. (50 mm) 3 in. (75 mm) 4 in. (100 mm) 5 in. (125 mm) 5.5 in. and up (140 mm and up) If necessary, adjust the pressure adjustment dials as follows: If the media... Requires higher pressure to print well Shifts left while printing...
This section describes the control panel parameters that are used to configure the printer for operation. Contents Setup Mode ............56 Enter Setup Mode .
Configuration Setup Mode 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 Important •...
Exit Setup Mode To leave Setup mode, complete these steps: Press SETUP/EXIT The LCD displays Press PLUS (+) PERMANENT TEMPORARY CANCEL LOAD DEFAULTS LOAD LAST SAVE DEFAULT NET Press SETUP/EXIT When the configuration and calibration sequence is done, 3/27/07 SAVE CHANGES to display the save options: MINUS (-) Description...
Configuration Change Password-Protected Parameters Change Password-Protected Parameters Certain parameters, including the communication parameters, are password-protected by factory default. Caution • Do not change password-protected parameters unless you have a complete understanding of the parameters’ functions. If the parameters are set incorrectly, the printer may function unpredictably.
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: On the control panel, press Press or to scroll through the parameters until you reach...
Configuration Print a Network Configuration Label Print a Network Configuration Label If you are using a print server, you can print a network configuration label after the printer is connected to the network. To print a network configuration label, complete these steps: On the control panel, press Press PLUS (+)
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 MINUS (-) to return to the previous parameter in the cycle. Press 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.
Configuration Control Panel Parameters Standard Printer Parameters Table 12 shows parameters in the order in which they are displayed when you press after entering Setup mode. Parameter ZPL and XML 79695L-001 Rev. A Table 12 • Printer Parameters (Page 1 of 24) Action/Explanation Adjust Print Darkness Darkness (burn duration) settings depend on a variety of factors, including...
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Table 12 • Printer Parameters (Page 2 of 24) Parameter 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: 2 IPS Range: To change the value shown:...
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Configuration Control Panel Parameters Parameter 79695L-001 Rev. A Table 12 • Printer Parameters (Page 3 of 24) Action/Explanation Adjust the Tear-Off Position This parameter establishes the position of the media over the tear-off/peel-off bar after printing. 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).
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Table 12 • Printer Parameters (Page 4 of 24) Parameter Action/Explanation Set Media Type This parameter tells the printer the type of media that you are using (see Types of Media on page 25 media requires that you include a label length instruction in your label format ( ^LLxxxx if you are using ZPL or ZPL II).
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Configuration Control Panel Parameters Parameter 79695L-001 Rev. A Table 12 • Printer Parameters (Page 5 of 24) Action/Explanation 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.
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Table 12 • Printer Parameters (Page 6 of 24) Parameter Action/Explanation Set Maximum Label Length This parameter is used during the media portion of the calibration process. Always set maximum label length to a value that is at least 1.0 in. (25.4 mm) greater than the actual label length to a smaller value than the label length, the printer assumes that continuous media is loaded, and the printer cannot calibrate.
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Configuration Control Panel Parameters Parameter 79695L-001 Rev. A Table 12 • Printer Parameters (Page 7 of 24) 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.
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Table 12 • Printer Parameters (Page 8 of 24) 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.
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Configuration Control Panel Parameters Parameter ZPL and XML only 79695L-001 Rev. A Table 12 • Printer Parameters (Page 9 of 24) Action/Explanation Print Counter Readings Prints a label that lists the odometer readings for the following: • the non-resettable counter •...
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Table 12 • Printer Parameters (Page 10 of 24) 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.
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Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 11 of 24) Parameter ZPL and XML only 79695L-001 Rev. A Action/Explanation 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.
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Table 12 • Printer Parameters (Page 12 of 24) Parameter Action/Explanation Initialize Flash Memory This option erases all previously stored information from Flash memory. Caution • This option completely erases the Flash memory. To initialize Flash memory: 1. Press 2. If prompted for a password, enter the printer password. For 3.
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Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 13 of 24) Parameter 79695L-001 Rev. A 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.
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Table 12 • Printer Parameters (Page 14 of 24) 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 2.
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Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 15 of 24) Parameter 79695L-001 Rev. A 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.
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Table 12 • Printer Parameters (Page 16 of 24) Parameter Action/Explanation 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.
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Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 17 of 24) Parameter ZPL and XML only ZPL and XML only 79695L-001 Rev. A Action/Explanation Set Control Prefix Character The printer looks for this two-digit hex character to indicate the start of a ZPL/ZPL II control instruction.
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Table 12 • Printer Parameters (Page 18 of 24) 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.
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Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 19 of 24) Parameter 79695L-001 Rev. A 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 •...
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Table 12 • Printer Parameters (Page 20 of 24) 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 ~JS when received as part of a label format (see the ZPL Programming Guide for more information).
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Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 21 of 24) Parameter ZPL and XML only See next column 79695L-001 Rev. A Action/Explanation Set Reprint Mode When reprint mode is enabled, you can reprint the last label printed either by issuing the ~PR ZPL command or by pressing panel.
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Table 12 • Printer Parameters (Page 22 of 24) Parameter Action/Explanation 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 →...
Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 23 of 24) Parameter 79695L-001 Rev. A Action/Explanation Set Real-Time Clock (RTC) Date This parameter allows you to set the date following the convention selected IDLE DISPLAY To change the value shown: 1.
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Table 12 • Printer Parameters (Page 24 of 24) Parameter Action/Explanation Select the Display Language This parameter changes the language displayed on the LCD. Each language selection is displayed in the language itself. Default Value: ENGLISH Selections: ENGLISH, SPANISH, FRENCH, GERMAN, ITALIAN, NORWEGIAN, PORTUGUESE, SWEDISH, DANISH, SPANISH 2, DUTCH, FINNISH, JAPANESE, KOREAN, SIMPLIFIED CHINESE, TRADITIONAL CHINESE...
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Configuration Control Panel Parameters Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ 79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07...
Routine Maintenance Replacing Printer Components Replacing Printer Components Some printer components, such as the printhead and platen roller, may wear out over time and can be replaced easily. Regular cleaning may extend the life of some of these components. See Cleaning Schedule and Procedures on page 89 Ordering Replacement Parts For optimal printing quality and proper printer performance across our product line, Zebra...
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. recommended cleaning schedule. These intervals are intended as guidelines only. You may have to clean more often, depending upon your application and media.
Routine Maintenance Cleaning Procedures Clean the Printhead and Platen Roller You can minimize printhead wear and maintain print quality with regular preventive measures. Over time, the movement of media or ribbon across the printhead wears through the protective ceramic coating, exposing and eventually damaging the print elements (dots). To avoid abrasion: •...
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Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. Caution • Before touching the printhead assembly, discharge any built-up static electricity by touching the metal printer frame or by using an antistatic wriststrap and mat. To clean the printhead and platen roller, complete these steps: Open the printhead assembly.
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Routine Maintenance Cleaning Procedures While manually rotating the platen roller, clean it thoroughly with the swab. Allow the solvent to evaporate. 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.
Clean the Media Compartment and Sensors To clean the media compartment and sensors, complete these steps: Brush or vacuum any accumulated paper lint and dust away from the media and ribbon paths. Brush or vacuum any paper lint and dust away from the sensors (see 3/27/07 Figure 16 •...
Routine Maintenance Cleaning Procedures 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.
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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.
Routine Maintenance Routine Maintenance for the Rewind Option 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.
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Slide the rewind media guide all the way out, and then fold it down. Slide the core with the liner from the take-up spindle. 3/27/07 Routine Maintenance for the Rewind Option ZM400/ZM600 User Guide Routine Maintenance 79695L-001 Rev. A...
Routine Maintenance Routine Maintenance for the Rewind Option 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.
This section provides information about errors that you might need to troubleshoot. Assorted diagnostic tests are included. Contents Troubleshooting Checklists ..........100 LCD Error Messages .
Troubleshooting Troubleshooting Checklists Troubleshooting Checklists If an error condition exists with the printer, review this checklist: Is there an error message on the LCD? If yes, see Are noncontinuous labels being treated as continuous labels? If yes, see and Ribbon Sensor Sensitivity on page Is the printer reporting a ribbon error when ribbon is loaded properly? If yes, see Media and Ribbon Sensor Sensitivity on page Are you experiencing problems with print quality? If yes, see...
LCD Error Messages The LCD displays messages when there is an error. See causes, and the recommended solutions. LCD Display/ Possible Cause Printer Condition The printhead was replaced with ERROR CONDITION one that is not a genuine Zebra™ INVALID HEAD printhead..
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Troubleshooting LCD Error Messages LCD Display/ Printer Condition WARNING RIBBON IN The ERROR light flashes. ERROR CONDITION PAPER OUT The printer stops; the ERROR light flashes. ERROR CONDITION HEAD OPEN The printer stops; the ERROR light flashes. THERMISTOR FAULT The ERROR light flashes. WARNING HEAD COLD THERMISTOR...
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Table 15 • LCD Error Messages (Continued) LCD Display/ Possible Cause Printer Condition WARNING HEAD COLD The printhead temperature is The printer prints while the approaching its lower operating ERROR light flashes. limit. The printhead data cable is not properly connected. The printhead has a faulty thermistor.
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Troubleshooting LCD Error Messages LCD Display/ Printer Condition DEFRAGMENTING The printer stops. ERROR CONDITION CUTTER JAM The printer stops; the ERROR light flashes. OUT OF MEMORY (function) 79695L-001 Rev. A Table 15 • LCD Error Messages (Continued) Possible Cause The printer is defragmenting memory.
Print Quality Problems Table 16 identifies problems with print quality, the possible causes, and the recommended solutions. Problem Possible Cause General print quality The printer is set at the issues incorrect print speed. You are using an incorrect combination of labels and ribbon for your application.
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Troubleshooting Print Quality Problems Problem Possible Cause Wrinkled ribbon Ribbon fed through the machine incorrectly. Incorrect burn temperature. Incorrect or uneven printhead pressure. Media not feeding properly; “walking” from side to side. The strip plate needs adjusting. The printhead needs vertical adjustment.
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Table 16 • Print Quality Problems (Continued) Problem Possible Cause Vertical drift in The printer is out of calibration. Recalibrate the printer. top-of-form position Vertical drift occurs during normal printer operation. Note • ± 4 to 6 dot rows (approximately 0.5 mm) is within normal tolerances.
Troubleshooting Calibration Problems Calibration Problems Table 17 identifies problems with calibration, the possible causes, and the recommended solutions. Problem Possible Cause Loss of printing The platen roller is dirty. registration on labels. Excessive vertical drift in top-of-form Media guides are positioned registration.
Communications Problems Table 18 identifies problems with communications, the possible causes, and the recommended solutions. Table 18 • Communications Problems Problem Possible Cause A label format was sent to The communication the printer but was not parameters are incorrect. recognized. The DATA light does not flash.
Troubleshooting Ribbon Problems Ribbon Problems Table 19 identifies problems that may occur with ribbon, the possible causes, and the recommended solutions. Problem Possible Cause Broken or melted Darkness setting too high. ribbon The printer does not The printer was calibrated detect when the without ribbon.
Miscellaneous Printer Problems Table 20 identifies miscellaneous problems with the printer, the possible causes, and the recommended solutions. Table 20 • Miscellaneous Printer Problems Problem Possible Cause The LCD displays a The language parameter was language that I changed through the control cannot read panel or a firmware command.
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Troubleshooting Miscellaneous Printer Problems Table 20 • Miscellaneous Printer Problems (Continued) Problem Possible Cause While in Peel-Off You are using perforated media, mode, media liner which is not recommended for wraps around the Peel-Off mode. platen roller. The printer fails to The printer was not calibrated calibrate or detect the for the label being used.
Printer Diagnostics Self tests and other diagnostics provide specific information about the condition of the printer. The self tests produce sample printouts and provide specific information that helps determine the operating conditions for the printer. The most commonly used are the Power-On and the CANCEL self tests.
Troubleshooting Printer Diagnostics CANCEL Self Test CANCEL To perform the CANCEL Self Test, complete these steps: Turn off ( Press and hold control panel light turns off. A printer configuration label prints 79695L-001 Rev. A self test prints a configuration label ) the printer.
PAUSE Self Test This self test can be used to provide the test labels required when making adjustments to the printer’s mechanical assemblies or to determine if any printhead elements are not working. Figure 19 shows a sample printout. To perform a PAUSE self test, complete these steps: Turn off ( ) the printer.
Troubleshooting Printer Diagnostics FEED Self Test Different types of media may require different darkness settings. This section contains a simple but effective method for determining the ideal darkness for printing bar codes that are within specifications. During the FEED self test, labels are printed at different darkness settings at two different print speeds.
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Troubleshooting Printer Diagnostics Figure 21 Table 21. Inspect the test labels and determine which one has the best print quality for your application. If you have a bar code verifier, use it to measure bars/spaces and calculate the print contrast. If you do not have a bar code verifier, use your eyes or the system scanner to choose the optimal darkness setting based on the labels printed in this self test.
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Troubleshooting Printer Diagnostics Print Quality Too dark Slightly dark “In-spec” Slightly light Too light Note the relative darkness value and the print speed printed on the best test label. Add or subtract the relative darkness value from the darkness value specified on the configuration label.
FEED and PAUSE Self Test Performing this self test temporarily resets the printer configuration to the factory default values. These values are active only until power is turned off unless you save them permanently in memory. If the factory default values are permanently saved, a media calibration procedure must be performed.
Troubleshooting Printer Diagnostics Communications Diagnostics Test The communication diagnostics test is a troubleshooting tool for checking the interconnection between the printer and the host computer. When the printer is in diagnostics mode, it prints all data received from the host computer as straight ASCII characters with the hex values below the ASCII text.
Sensor Profile Use the sensor profile label to troubleshoot the following types of problems: • If the media sensor experiences difficulty in determining gaps (web) between labels. • If the media sensor incorrectly identifies preprinted areas on a label as gaps (web). •...
Specifications General Specifications General Specifications General Specifications Height Width Depth Weight (without options) Electrical Temperature Operating Storage Relative Operating Humidity Storage Communication Interfaces Memory Label formats accepted by firmware 79695L-001 Rev. A ZM400 13.3 in. 338 mm 10.9 in. 278 mm 18.7 in.
Specifications Printing Specifications Printing Specifications Printing Specifications Print resolution Dot size 203 dots/in. (width x length) 300 dots/in. 600 dots/in. First dot location measured from inside media backing edge Maximum print 203 dots/in. width Minimum print length Maximum 203 dots/in. continuous print 300 dots/in.
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Printing Specifications Programmable 203 dots/in. constant print speeds 300 dots/in. 600 dots/in. 3® Thin film printhead with E Element Energy Control 3/27/07 ZM400 • 2.4 in. (61 mm) per second • 3 in. through 10 in. per second in 1-in. increments (76 mm through 254 mm per second in 25-mm increments) •...
Specifications Media Specifications Media Specifications Media Specifications Label length Minimum Maximum Label width Minimum Maximum Total thickness (includes liner, if any) Core size Maximum roll diameter Maximum fanfold pack size (length x width x height) Inter-label gap Ticket/tag notch size (width x length) Hole diameter Notch or hole position (Centered from inner...
Ribbon Specifications 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.
adhesive test for ribbon coating, 27 adjustments left position, 81 media alignment for rewind, 98 print darkness, 62 printhead pressure, 53 tear-off position, 64 agency approvals, 125 auto calibration, 52 backfeed setting, 81 bar codes list available codes, 70 battery disposal, 88 baud setting, 75 before you begin setup, 16 bitmap scaling factor, 83...
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Index control panel buttons described, 11 enter Setup mode, 56 exit Setup mode, 57 LCD error messages, 101 lights described, 12 location, 8 overview and illustration, 10 parameters, 61 control prefix setting, 78 customer service, 3 cutter cleaning, 94 Cutter Jam message, 104 Cutter mode media path, 32 loading media for Cutter mode, 33...
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idle display setting, 83 images list, 70 initialize Flash memory, 73 initialize memory card, 72 inspect for shipping damage, 17 international safety organization marks, 24 INVALID HEAD message, 101 label length maximum setting, 67 label top printer cannot detect, 112 setting, 81 labels did not print, 109 language...
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Index PAPER OUT message, 102 parallel port characteristics of parallel connection, 19 connection and configuration, 21 connector location, 8 setting parallel communications, 75 parity setting, 76 passwords default, 58 disable, 58 entering, 58 setting password level, 84 PAUSE button description, 11 FEED and PAUSE self test, 119 PAUSE self test, 115 Peel-Off mode...
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Index Tear-Off mode loading media, 33 media path, 31 print mode use described, 30 selecting, 64 tear-off position adjustment, 64 technical support, 3 temperature requirements, 18 thermal transfer mode media scratch test, 27 setting, 65 THERMISTOR FAULT message cycling with other messages, 102 displayed alone, 102 time setting, 83 top of label...
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The Valley Centre, Gordon Road High Wycombe Buckinghamshire HP13 6EQ, UK Telephone: +44 (0) 1494 472872 Facsimile: +44 (0) 1494 450103 Zebra Technologies Asia Pacific, LLC 16 New Industrial Road #05-03 Hudson TechnoCentre Singapore 536204 Telephone: +65 6858 0722 Facsimile: +65 6885 0838 Part Number: 79695L-001 Rev.