Instruction/ maintenance manual of the product Z4M Zebra Technologies
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Customer order # 77965L Manufacturer part # 77965LB Rev. 1.
Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein.
Zebra Z 4M Printer User’s Guide iii I have determined that the Zebra printer identified as the Zebra Z4M Printer ™ manufactured by: Zebra T echnologies Corporation 333 Corporate W oods Parkway V ernon Hills, Illinois 60061-3109 U.
iv Zebra Z 4M Printer User’s Guide.
Welcome Hello! .......................................1 Unpacking and Inspection ............................1 Reporting Damage ...............................2 Storage .....................................2 Media and Ribbon Requirements .............
Loading the Ribbon ...............................1 2 Auto Calibration .................................1 3 Operator Controls ................................1 4 POWER Switch ...............................1 4 Front Panel .............................
Fanfold Media Loading .............................3 2 Ribbon Loading .................................3 4 Loading the Ribbon .............................3 4 Ribbon Removal .................................3 6 Configuration Entering the Setup Mode ..
Troubleshooting LCD Error Conditions and Warnings ......................6 7 Print Quality Problems ..............................6 9 Communications Problems ...........................7 1 Printer Diagnostics ................................7 3 Power-On Self Test .
Hello! n This user’s guide provides all the information you will need to operate the printer. n The ZPL II ® Programming Guide Volume I and Volume II (part #45540L) show you how to create the perfect label format for your application.
Reporting Damage If you discover shipping damage: n Immediately notify the shipping company and file a damage report. Zebra Technologies Corporation is not responsible for any damage incurred during the shipment of the equipment and will not repair this damage under warranty.
Printer Power The power supply in the printer automatically detects the applied line voltage and works in the 90 to 265 VAC range. WARNING!!! For personnel and equipment safety, always use a three-prong plug with an earth ground connection. NOTE: Depending on how your printer was ordered, a power cord may or may not be included.
Printer Overview Depending on the options you have selected, your printer may look slightly different. 4 Zebra Z 4M Printer User’s Guide Media supply guide Media guide Ribbon sensor Media supply han.
This chapter of the user’s guide is so important that we’ve printed it on a different color paper! That way, it will be easy for you to find when you must calibrate (set up) the printer for your particular application. Purpose n To calibrate the printer.
Types of Media Non-Continuous Web Media Non-continuous web media (refer to Figure 3) refers to individual labels that are separated by a gap, notch, or hole.
Non-Continuous Black Mark Media Non-continuous black mark media has black marks printed on the back that indicate the start and end of each label (refer to Figure 4). Continuous Media Continuous media (refer to Figure 5) is one uninterrupted roll of material that allows the image to be printed anywhere on the label.
Choosing the Print Mode n Tear-off mode allows you to tear off each label, or a strip of labels, after it is printed. n In peel-off mode, backing material is peeled away from the label as it is printed. After this label is removed from the printer, the next one is printed.
Loading the Media Figure 6 illustrates one method of media loading. For more detailed instructions, as well as information about how to load the different types of media and the various printing modes, refer to the instructions that begin on page 22.
Positioning the Media Sensor The correct positioning of the media sensor is important. It can make the difference between a perfect label and a call to Technical Support! There are two media sensors in this printer: “reflective” and “transmissive.
Adjusting the Reflective Sensor Refer to Figure 7. 1. Open the printhead assembly by pressing the printhead open lever. 2. Locate the reflective sensor positioning lever. 3. Move the reflective sensor positioning lever across the width of the media until the reflective sensor aligns with the start-of-label indicator.
Transmissive Sensor The transmissive sensor is in a fixed position and enabled via the front panel (details in “SENSOR SELECT” on page 41). Loading the Ribbon Refer to Figure 8. For more detailed information, refer to the instructions that begin on page 34.
Auto Calibration When auto calibrating, the printer is determining the label length and media/ribbon sensor settings. Auto calibration occurs when the printer is turned on and each time the printer recovers from an error condition. (To clear an error, open and close the printhead assembly and then press the PAUSE key.
Operator Controls POWER Switch The POWER switch is located at the back of the printer above the power cord. Turn on the printer. Front Panel For a more detailed explanation of the front panel keys and lights (as shown in Figure 9), refer to the instructions that begin on page 19.
Configuring the Printer The configuration procedure in the next table contains the information you need to get your printer up and running, but it is not comprehensive . Refer to page 40 for more information. n Press the SETUP/EXIT key at the “PRINTER READY” display to enter the configuration mode.
Configuring the Software of Printer Driver Many printer settings may also be controlled by your printer’s driver or label preparation software. Refer to the driver or software documentation for more information. Printing a Test Label To print a test label: 1.
System Considerations Interfaces The method of interfacing this printer to a data source depends on the communication options installed in the printer. The standard interfaces are an RS-232/RS-422/RS-485 serial data port and a bi-directional parallel port.
When communicating via the parallel port (refer to Figure 12), the previously mentioned parameters are not considered. Refer to page 46 to configure the communication parameters for the printer. The values selected must be the same as those used by the host equipment connected to the printer.
Front Panel This section discusses the functions of the various controls and indicators on the printer. The operator should become familiar with each of these functions. Front Panel Display The front panel display communicates operational status and programming modes and parameters.
Front Panel Keys 20 Zebra Z 4M Printer User’s Guide Key Function FEED Forces the printer to feed one blank label each time the key is pressed. • Printer not printing: one blank label immediately feeds. • Printing: one blank label feeds after the current batch of labels is complete.
Front Panel Lights Zebra Z 4M Printer User’s Guide 21 Light Status Indication POWER Off The printer is off or no power is applied. On The printer is on.
Roll Media Loading Tear-Off Mode Refer to Figure 14. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger.
Zebra Z 4M Printer User’s Guide 23 Printhead open lever Printhead assembly Media supply guide Media guide Ribbon sensor Dancer T ransmissive sensor Media supply hanger Figure 14.
Cutter Mode (Cutter option required) Refer to Figure 15. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger.
Zebra Z 4M Printer User’s Guide 25 Printhead open lever Printhead assembly Media supply guide Media guide Media supply hanger Dancer T ransmissive sensor Ribbon sensor Cutter module Figure 15.
Value Peel-Off Mode (Value peel option required) Refer to Figure 16. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger.
Zebra Z 4M Printer User’s Guide 27 Media guide Dancer Ribbon sensor Label Lever Printhead open lever Printhead assembly Media supply guide Media supply hanger T ransmissive sensor Figure 16.
Power Peel-Off Mode (Power peel-off option required) Refer to Figure 17. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible.
Backing Removal 1. Cut the backing material prior to where it winds onto the take-up spindle. 2. Rotate the take-up spindle until the rewind media guide is in the “12 o’clock” position. 3. Loosen the thumbscrew and slide out the rewind media guide to the end of the take-up spindle.
Power Rewind Mode (Power rewind option required) Refer to Figure 18. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger.
Media Removal 1. Cut the media prior to where it winds onto the take-up spindle. 2. Rotate the take-up spindle until the rewind media guide is in the “12 o’clock” position. 3. Loosen the thumbscrew and slide out the rewind media guide to the end of the take-up spindle.
Fanfold Media Loading Fanfold media feeds through either the bottom or rear access slot. Refer to Figure 19. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible.
Zebra Z 4M Printer User’s Guide 33 Printhead assembly Media supply guide Media supply hanger Printhead open lever T ransmissive sensor Media guide Dancer Ribbon sensor Printhead open lever Printhead.
Ribbon Loading NOTE: The ribbon supply spindle in your printer is a "dual tension" variety. Most applications require the spindle to be in the "normal" position. The "low tension" position is recommended only when wide ribbon is used and normal tension hampers the ribbon movement.
Zebra Z 4M Printer User’s Guide 35 Ribbon supply spindle Ribbon take-up spindle Printhead o p en lever Ribbon guide plate Printhead assembly Ribbon sensor Ribbon supply spindle Ribb on ta k e-up sp .
Ribbon Removal To remove the ribbon: 1. Break the ribbon between the ribbon guide plate and the ribbon take-up spindle. 2. While turning the ribbon take-up spindle release knob counterclockwise, squeeze the ribbon against the ribbon take-up spindle tension blades.
After you have installed the media and ribbon and the power-on self test (POST) is complete, the front panel display will show “PRINTER READY.” (If the printer fails its POST, refer to page 73.) You may now set printer parameters for your application using the front panel display and the four keys directly below it.
Changing Password-Protected Parameters Certain parameters are password protected by factory default. NOTE: You have the option of making ALL parameters password protected.
Leaving the Setup Mode You can leave the program mode at any time by pressing the SETUP/EXIT key. The “SAVE CHANGES” display will appear. There are five choices, described below. Pressing the INCREMENT (+) or DECREMENT (-) key displays other choices and pressing the SELECT key selects the displayed choice.
Configuration and Calibration Sequence 40 Zebra Z 4M Printer User’s Guide Display Shows Action/Explanation PRINTER READY Normal printer operation. Setting Print Parameters DARKNESS Adjusting Print Darkness Press the INCREMENT (+) key to increase darkness.
Zebra Z 4M Printer User’s Guide 41 Display Shows Action/Explanation PRINT MODE Selecting Print Mode Press the INCREMENT (+) or DECREMENT (-) key to display other choices. Default: Tear-off Selections: Tear-off, peel-off, cutter, rewind Print mode settings tell the printer the method of media delivery that you wish to use.
42 Zebra Z 4M Printer User’s Guide Display Shows Action/Explanation PRINT METHOD Selecting Print Method Press the INCREMENT (+) key for the next value; press the DECREMENT (-) key for the previous value.
Zebra Z 4M Printer User’s Guide 43 Listing Printer Information Display Shows Action/Explanation LIST FONTS List Fonts Press the INCREMENT (+) key to print a label listing all of the available fonts.
44 Zebra Z 4M Printer User’s Guide Display Shows Action/Explanation INITIALIZE CARD Initialize Memory Card CAUTION: Perform this operation only when it is necessary to erase all previously stored information from the optional memory card. Press the SETUP/EXIT key to bypass this function.
Zebra Z 4M Printer User’s Guide 45 Media and Ribbon Sensor Calibration Performing the manual calibration procedure first resets the sensitivity of the sensors to better detect the media and ribbon you are using. With the sensors at their new sensitivity, the printer then performs the manual calibration.
46 Zebra Z 4M Printer User’s Guide Setting Communication Parameters Communication parameters must be set correctly for the printer to communicate with the host. These parameters make sure that the printer and host are “speaking the same language.” All communication parameters are password protected.
Zebra Z 4M Printer User’s Guide 47 Display Shows Action/Explanation PARITY Setting Parity Press the INCREMENT (+) or DECREMENT (-) key to display other choices. Default: Even Selections: Even, odd, none The parity of the printer must match the parity of the host for accurate communications to take place.
48 Zebra Z 4M Printer User’s Guide Display Shows Action/Explanation NETWORK ID Setting Network ID Press the DECREMENT (-) key to move to the next digit position, press the INCREMENT (+) key to increase the value of the digit. Default: 000 Range: 000 - 999 Network ID is used to assign a unique number to a printer used in an RS-422/RS-485 network.
Zebra Z 4M Printer User’s Guide 49 Selecting Prefix and Delimiter Characters Prefix and delimiter characters are 2-digit hex values used within the ZPL/ZPL II formats sent to the printer. The printer uses the last prefix and delimiter characters sent to it, whether from a ZPL II instruction or from the front panel.
50 Zebra Z 4M Printer User’s Guide Selecting ZPL Mode Display Shows Action/Explanation ZPL MODE Selecting ZPL Mode Press the INCREMENT (+) or DECREMENT (-) key to display other choices.
Zebra Z 4M Printer User’s Guide 51 Label Positioning Parameters Display Shows Action/Explanation BACKFEED Backfeed Sequence Press the INCREMENT (+) or DECREMENT (-) key to display other choices.
52 Zebra Z 4M Printer User’s Guide Display Shows Action/Explanation WEB S. These parameters are automatically set during the calibration procedure. They should only be changed by a qualified service technician. Refer to the maintenance manual for more information on these parameters.
Zebra Z 4M Printer User’s Guide 53 Display Shows Action/Explanation IP RESOLUTION* IP Resolution Press the INCREMENT (+) or DECREMENT (-) key to display other choices. Default: Dynamic Selections: Dynamic, permanent Depending on the selection, allows either the user (”permanent”) or the server (”dynamic”) to select the IP address.
54 Zebra Z 4M Printer User’s Guide Display Shows Action/Explanation LANGUAGE Selecting the Display Language Press the INCREMENT (+) or DECREMENT (-) key to display other choices.
Cleaning This table provides a recommended cleaning schedule. Specific cleaning procedures are provided on the following pages. CAUTION: Use only the cleaning agents indicated. Zebra Technologies Corporation will not be responsible for damage caused by any other cleaning fluids used on this printer.
Cleaning the Exterior The exterior surfaces of the printer may be cleaned with a lint-free cloth. Do not use harsh or abrasive cleaning agents or solvents.
NOTE: If print quality has not improved after performing this procedure, try cleaning the printhead with Save-a-Printhead cleaning film. This specially coated material removes contamination buildup without damaging the printhead. Call your authorized Zebra reseller for more information.
Cleaning the Power Peel-Off Module (Power peel-off option required) Perform the following procedure if adhesive buildup begins to affect peel performance. Refer to Figure 24. 1. Open the printhead assembly. 2. Open the front housing assembly by lifting the two handles; then, pivot down the front housing assembly.
Cleaning the Value Peel-Off Module (Value peel-off option required) Perform the following procedure if adhesive buildup begins to affect peel-off performance. Refer to Figure 25. 1. Open the printhead assembly. 2. Open the pivot bracket assembly by pivoting the module toward you.
Cleaning the Cutter Module (Cutter option required) WARNING!!! For personnel safety, ALWAYS turn off and unplug the printer before performing this procedure. Refer to Figure 26. To clean adhesive off of the upper and lower cutter blades: 1. Use a swab moistened with the Zebra-recommended solvent to wipe along the upper cutter blade.
Lubrication CAUTION! No lubricating agents of any kind should be used on this printer! Some commercially available lubricants will damage the finish and the mechanical parts, if used.
Printhead Pressure Adjustment This adjustment may be necessary if printing is too light on one side or if thick media is used. Refer to Figure 27. The pressure adjustment dials each have four possible settings designated by blocks of increasing size embossed on the print mechanism.
Zebra Z 4M Printer User’s Guide 63 P ressure a dj ustment di a l s Figure 27.
Power Rewind Media Alignment (Power rewind option required.) NOTE: Under normal operating conditions, media alignment should not be necessary if the media/backing was initially installed tightly against the backplate of the take-up spindle. Perform the following adjustment if the media does not track properly onto the take-up spindle.
Zebra Z 4M Printer User’s Guide 65 Printhead assembly Adjustment dial T ake-up spindle Figure 28.
Fuse Replacement A user-replaceable AC power fuse is located just below the AC power switch at the rear of the printer. The replacement fuse is a 3AG fast blow style rated at 5 Amp/250 VAC. Before replacing the fuse, turn off the AC power switch and unplug the AC power cord.
LCD Error Conditions and Warnings Error condition RIBBON OUT Error condition PAPER OUT Zebra Z 4M Printer User’s Guide 67 Troubleshooting Problem Solution In thermal transfer mode, the ribbon is not loaded or loaded incorrectly. Load the ribbon correctly.
Error condition HEAD OPEN Error condition RIBBON IN Warning HEAD OVER TEMP Warning HEAD UNDER TEMP 68 Zebra Z 4M Printer User’s Guide Problem Solution The printhead is not fully closed. Close the printhead. The ribbon is loaded incorrectly; it is covering the head open sensor.
Warning CUTTER JAM OUT OF MEMORY* Print Quality Problems General print quality issues Zebra Z 4M Printer User’s Guide 69 Problem Solution Cutter blade is in the media path. Turn off the printer power and unplug the printer. Inspect the cutter module for debris and clean as needed following the cleaning instructions on page 60.
Gray lines on blank labels with no consistent pattern Light, consistent vertical lines running through all of the labels Intermittent creases on the left and right edges of the label Wrinkled ribbon 70 Zebra Z 4M Printer User’s Guide Problem Solution The printhead is dirty.
Calibration Communications Problems A label format was sent to the printer but not recognized. The DATA light does not flash. Zebra Z 4M Printer User’s Guide 71 Problem Solution Loss of printing registration on labels. Excessive vertical drift in top-of-form registration.
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 not recognized. The DATA light flashes but no printing occurs. 72 Zebra Z 4M Printer User’s Guide Problem Solution The host is set to EPP parallel communications.
Printer Diagnostics Power-On Self Test A power-on self test (POST) is performed automatically each time the printer is turned on. During this test sequence, the front panel lights and liquid crystal display monitor the progress of the POST. If the printer fails any of these tests, the word “FAILED” will be added to the display.
CANCEL Key Self Test This self test prints a listing of the configuration parameters currently stored in the printer’s memory. See Figure 29. (Depending on the options ordered, your label may look different.) 1. Turn off the printer. 2. Press and hold the CANCEL key while turning on the power.
PAUSE Key Self Test This self test can be used to provide the test labels required when making adjustments to the printer’s mechanical assemblies. See the sample printout in Figure 30. 1. Turn off the printer. 2. Press and hold the PAUSE key while turning on the power.
FEED Key Self Test See Figure 31. 1. Turn off the printer. 2. Press and hold the FEED key while turning on the power. 3. Release the key after the DATA light turns off (approximately five seconds). The FEED key self test prints out at various darkness settings above and below that of the darkness value shown on the configuration label.
Communications Diagnostics Test This test is controlled from the front panel display. Refer to page 48. A typical printout from this test is shown in Figure 32. Turn off the power to exit this self test. NOTE: This label will be inverted when printed.
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NOTE: Printer specifications are subject to change without notice. General Specifications Zebra Z 4M Printer User’s Guide 79 Specifications General Specifications Z 4M Height 13.3” 338 mm Width 10.9” 277 mm Depth 18.7” 475 mm Weight (without options) 32.
Printing Specifications Ribbon Specifications 80 Zebra Z 4M Printer User’s Guide Printing Specifications Z 4M Print resolution 203 dots/inch 8 dots/mm 300 dots/inch 12 dots/mm Dot size (width x length) 203 dots/inch 0.00492” x 0.00492” 0.125 mm x 0.
Media Specifications Options Z 4M n Cutter n Value peel-off n PCMCIA card n 1M Ba n d2M BF L A S H n 300 dpi printhead Zebra Z 4M Printer User’s Guide 81 Media Specifications Z 4M Label length Minimum Tear-off 0.5” 13 mm Peel-off 1” 25.4 mm Rewind 0.
Zebra Programming Language (ZPL II) Bar Codes 82 Zebra Z 4M Printer User’s Guide n Downloadable graphics (with data compression) n Bit image data transfer and printing, mixed text/graphics n Format .
AC Power Cord Since many areas of the world have specific power requirements, an AC power cord may not be included with your printer. The power cord must meet your local electrical requirements. WARNING!!! For personnel and equipment safety, always use a three-prong plug with an earth ground connection to the AC power source.
84 Zebra Z 4M Printer User’s Guide.
Printer Interface Technical Information Serial Data Communications The following table illustrates the pin connections on the DB-25 connector at the rear of the printer.
RS-232 Interface This printer is configured as Data Terminal Equipment (DTE). The serial data cable used to connect the printer to the host computer will be one of two styles: n 9-pin to 25-pin cable .
Hardware Control Signal Descriptions For all RS-232 input and output signals, this printer follows both the Electronics Industries Association (EIA) RS-232 and the Consultative Committee for International Telegraph and Telephone (CCITT) V.24 standard signal level specifications.
RS-485 Interface Figure 37 illustrates the pin connections on the DB-25 connector at the rear of the printer that are used for the RS-485 communication protocol.
Parallel Data Communications The following table illustrates the pin connections on the bi-directional parallel connector at the rear of the printer. Parallel Interface The 8-bit parallel data interface supports IEEE 1284 bi-directional parallel communications in “nibble mode.
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Zebra Z 4M Printer User’s Guide 91 Index A Adjustments Printhead pressure ..........6 2 Reflective sensor ...........1 1 Auto calibration .............1 3 C Cabling requirements ...........1 8 Calibrating the printer ...........5 Calibration, auto .
92 Zebra Z 4M Printer User’s Guide M Maintenance manual ............1 Media loading Cutter .................2 4 Fanfold ................3 2 Power peel-off ............2 8 Power rewind .............3 0 Roll ..................2 2 Tear-off ............
Zebra Z 4M Printer User’s Guide 93 U Unpacking .................1 Z ZebraNet Networking: PrintServer II Installation and User's Guide ......1 ZPL II Programming Guide Volume I and Volume II .
94 Zebra Z 4M Printer User’s Guide.
An important point after buying a device Zebra Technologies Z4M (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Zebra Technologies Z4M yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Zebra Technologies Z4M - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Zebra Technologies Z4M you will learn all the available features of the product, as well as information on its operation. The information that you get Zebra Technologies Z4M will certainly help you make a decision on the purchase.
If you already are a holder of Zebra Technologies Z4M, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Zebra Technologies Z4M.
However, one of the most important roles played by the user manual is to help in solving problems with Zebra Technologies Z4M. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Zebra Technologies Z4M along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
