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Zebra Technologies Zebra Z6000 Printer User Manual

1. or no motion In these cases the printer as sumes the media is correctly positioned and starts printing without cali brating 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 25 Color profile Disabled Composite Default screen p Z Series User s Guide H uspiran2 vp Thu Jun 18 15 55 18 1998 Color profile Disabled Composite H uspiran2 vp Default screen A Thu Jun 18 15 57 39 1998 Cleaning CAUTION Use only the cleaning agents indicated Zebra Technolo gies 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 Printhead q Alcohol Platen Roller r Alcohol Media Sensor o Air Blow Media Path See Figure 3 or 4 Alcohol Ribbon Sensor k Air B
2. PARAMETER SELECTIONS MEDIA POWER UP password reguired This parameter establishes the action of the media when the printer is turned ON Default Calibration Choices Calibration recalibrates media and ribbon sensors by feeding labels Feed feeds the label to the first web Length determines the length of the label by feeding labels No Motion media does not move HEAD CLOSE password reguired This parameter establishes the action of the media after the printhead has been opened and then closed Default Calibration Choices Calibration recalibrates media and ribbon sensors by feeding labels Feed feeds the label to the first web Length determines the length of the label by feeding labels No Motion media does not move MANUAL CALIBRATE If the auto calibration feature has been disabled by a ZPL command from the host or the HEAD CLOSE parameter is not Calibrate you may use this feature to calibrate the media and ribbon sensors Press to enable the Calibration process NOTE If the printer is configured for continuous media no media movement will occur during the Calibration process SENSOR PROFILE The Media and Ribbon Sensor Profile provides a graphical representation of the Media and Ribbon Sensor settings as an aid to the Service Technician if problems with inter label gap sensing occur Press to enable the Sensor Profile printout WEB S MED
3. Relative Humidity 5 to 85 non condensing Communications Interfaces RS 232 CCITT V 24 and RS 485 Serial Data Interface 110 to 38400 Baud Parity Bits Char and Xon Xoff or DTR DSR Handshake Protocols all selectable RS 485 Serial Data Interface 110 to 38400 Baud Parity Bits Char All selectable Xon Xoff Handshake Protocol required 8 Bit Parallel Data Interface Supports IEEE 1284 bi directional parallel communications in nibble mode Error Detection CRC Protocol Table 4 General Specifications 57 H uspiran2 vp Thu Jun 18 16 02 49 1998 Color profile Disabled Composite Default screen Printing Specifications PRINTING SPECIFICATIONS Z4000 Z6000 PRINTER PRINTER Print Resolution 203 dpi 8 dots mm or 300 dpi 11 8 dots mm Dot size 0 00492 0 125 mm sguare 0 0032 x 00039 0 84 mm x 0 99 mm Maximum print width 4 1 104 mm 6 6 168 mm Print length Minimum 1 dot row Maximum Std memory continuous 8 dot mm 37 940 mm 23 584 mm media 12 dot mm 16 406 mm 10 254 mm 39 Max Tor nons Opt memory 8 dot lmm 136 3 5 m 84 2 1 m 12 dot mm 61 1549 mm 38 965 mm continuous media Bar code modulus X dimension 5 mil to 50 mil Programmable constant printing speeds 2 sec 50 8 mm sec 3 sec 76 2 mm sec 4 sec 101 6 mm sec 5 sec 127 0 mm sec 6 sec 152 4
4. 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 dis tributor or Zebra Technologies Corporation for further information The Z Series Maintenance Manual part 77450L contains the in formation you may need to properly maintain your printer Getting Started Unpacking Save the carton and all packing materials in case shipping is reguired Inspect the printer for possible shipping damage m Check all exterior surfaces for damage m Raise the Media Access Door and inspect the Media Compartment for damage Reporting Damage If you discover shipping damage m Immediately notify the shipping company and file a damage report m Retain the carton and all packing material for inspection m 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 Color profile Disabled Composite Default screen For shipping information refer to Appen
5. when power is turned back on the printer reverts back to the PERMANENT values m CANCEL printer makes no changes and returns to the current settings m LOAD DEFAULTS all values return to the factory settings m LOAD LAST SAVE printer operates with last set of values saved either permanent or temporary Communication Interfaces Data cables must be fully shielded and fitted with metal or metalized connector shells to prevent radiation and reception of electrical noise To minimize electrical noise pickup in the cable Keep data cables as short as possible m Do not bundle the data cables tightly with power cords m Do not tie the data cables to power line conduits Serial Data Communications Table 11 illustrates the pin connections on the DB 25 connector at the rear of the printer DESCRIPTION Chassis Ground TXD Transmit Data output from the printer RXD Receive Data input to the printer RTS Reauest To Send output from the printer Not Used DSR Data Set Ready input to the printer RS 232 Signal Ground Not Used 5V 1A source Not Used RS 485 Signal Ground Not Used RS 485 Input B RS 485 Output B Not Used RS 485 Input A Not Used RS 485 Output A COIN O O1 Oo N DTR Data Terminal Ready output from the printer 21 25 Not Used Table 11 Rear Panel Serial Data Port Pinout RS 232 Interface The Z Ser
6. A 2 Megabyte memory upgrade is available for the Z Series printer as both a factory installed feature and a field installable kit This addi tional memory area can be used to store a higher quantity of label formats or larger label formats The content of the DRAM Memory is lost when power is turned OFF This option consists of an electronic memory device which is inserted into a holder on the Main Logic Board inside the printer Flash Memory Option Two non volatile memory options a Megabyte and a 2 Megabyte are available for the Z Series printer This additional memory area can be used to store optional printer fonts graphic formats and com plete label formats Color profile Disabled Composite Default screen H uspiran2 vp Wed Jul 08 11 39 02 1998 Once the option is installed in the printer information to be stored in Flash Memory is downloaded to the printer from the host computer A specific ZPLcommand is then sent to the printer which causes the information to be stored in the Flash Memory The content of the Flash Memory is not lost when power is turned OFF Communication Options Ethernet Ethernet Thinnet and 10BaseT connectivity are available through an external connection to the parallel port at the rear of the printer IPX LAT NetBIOS Net BEUI TCP IP protocols are supported with a data burst rate of 150 KB HP Bitronics mode is supported to provide bi directional high speed It is SNMP compatible and
7. Color profile Disabled Composite Default screen Figure 10 Printhead and Platen Roller Cleaning Z Series User s Guide H uspiran2 vp Thu Jun 18 15 57 44 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 15 57 44 1998 Cleaning the Cutter Module For printers eguipped with the Cutter option The Cutter Module reguires 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 freguency 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 reguired 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 Usea3 mm Allen Wrench to remove the cutter mounting screw Nn Carefully lift the Cutter Module up and away from the printer
8. Spindle Value Peel Option The Z Series printer also features a Value Peel option supporting the Peel off mode This option is available as both a factory installed fea ture and a field installable kit Label Movement in Peel Mode This option does nof capture the backing material on a spindle Instead the backing drops down from the front of the printer In the Peel mode when a label is completely printed the printer feeds the label forward to the take label position The label hangs from the printer and is held in place by that portion of the label still attached to the backing material When the operator removes the label the printer moves the next label forward to pre peel a portion of the label from the backing The label then backfeeds to be printed Refer to Appendix A for information on configuring the printer for the Value Peel mode of operation 38 Color profile Disabled Composite Default screen Media Loading Refer to Figure 17 while loading media l Place the roll of media on the Media Supply Hanger i and push it on all the way Fold the Media Supply Guide g up and slide it against the outer edge of the media roll Press the Printhead Open Lever e and raise the Printhead Assembly Feed the media under the Media Spindle j under the Ribbon Sen sor k and out the front of the printer Slide the Media Guide h in against the outer edge of the media Lift the Peel Assembly u and rotate it f
9. XOFF Choices XON XOFF or DTR DSR PROTOCOL password reguired Details on protocol can be found in the ZPL Programming Guide available from Zebra Technologies Corporation Default None Choices None Ack Nak Zebra NOTE Zebra Protocol is the same as ACK NAK except that with Zebra the response messages are sequenced If Ack Nak or Zebra is selected then DTR DSR Host Handshake must be selected H uspiran2 vp Thu Jun 18 16 03 36 1998 SERIAL COMM password required Select the choice that matches the one used by the host Default RS232 Choices RS232 RS422 RS485 or RS485 Multidrop Continued on the following page 72 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 03 36 1998 COMMUNICATIONS PARAMETER SELECTIONS NETWORK ID password required The network ID is used to assign a unique number to a printer used in a network This gives the host the means to address a specific printer Default 000 Choices 000 to 999 NOTE If the printer is used in a network you must select a network ID number COMMUNICATIONS password required The communications diagnostics mode is a trouble shooting tool for checking the interconnection between the printer and the host When Diagnostics is selected all data sent from the host to the printer will be printed as straight ASCII hex characters All received characters including c
10. mm sec Additional printing speeds for printers with 7 sec 177 8 mm sec the 203 dots inch 8 dots mm printheads 8 sec 203 2 mm sec 9 sec 228 6 mm sec 10 sec 254 0 mm sec Thin film printhead with Energy Control Table 5 Printing Specifications Ribbon Specifications RIBBON SPECIFICATION Z4000 PRINTER Z6000 PRINTER Ribbon Width Zebra Minimum 94 23 9 mm 1 57 39 9 mm recommends using ribbon E at loast as wide as tha Maximum 4 3 110 mm 6 85 174 mm media to protect the printhead from wear Standard 2 1 media to ribbon roll ratio 984 300 m Lengths 3 1 media to ribbon roll ratio 1476 450 m Ribbon core inside diameter 1 0 25 4 mm Table 6 Ribbon Specifications 58 H uspiran2 vp Thu Jun 18 16 02 49 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 02 49 1998 Media Specifications MEDIA SPECIFICATION Z4000 Z6000 PRINTER PRINTER Total media Maximum 4 5 115 mm 7 0 178 mm Width Minimum 1 0 25 4 mm 2 0 50 8 mm Label length Maximum See Printing Specifications Minimum Tear Off Mode 0 5 12 7 mm Rewind Mode 0 5 12 7 mm Peel Off Mode 1 0 25 4 mm Cutter Mode 1 0 25 4 mm Total thickness Maximum f above 0 07 includes liner printhead pressure may
11. sensor label backing label liner The material on which labels are affixed during manufacture and which is discarded or recycled by the end users media Material onto which data is printed by the printer Types of media include tagstock die cut labels continuous with and with out backing material fanfold and roll media sensor This sensor is located behind the printhead to detect the presence of media and for non continuous media the position of the web hole or notch used to indicate the start of each label media supply hanger The stationary arm that supports the media roll 90 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 05 28 1998 non continuous media Consumable printing stock which contains an indication of where one label printed format ends and the next one begins Examples are die cut labels notched tagstock and stock with black mark registration marks non volatile memory Electronic memory that retains data even when the power to the printer is turned OFF print speed The speed at which printing occurs For thermal transfer printers this speed is expressed in terms of ips inches per second Zebra offers printers that can print from 2 ips to 12 ips printhead wear The degradation of the surface of the printhead and or the print elements over time Heat and abrasion can cause print head wear Therefore to maximize the life of the printhead use the lowest print d
12. supports MIB I MIB II and Parallel MIB as well as MPSCON NOVELL Netware PC console configuration utility IPX Color profile Disabled Composite Default screen 9 Z Series User s Guide H uspiran2 vp Wed Jul 08 11 39 02 1998 Color profile Disabled Composite Default screen Power On Self Test A Power On Self Test POST is performed each time the printer is turned ON During this test the front panel LEDs will turn ON and OFF to ensure proper operation At the end of this self test only the POWER LED will remain lit Once the Power ON Self Test is complete the media is advanced to the proper rest position as determined by the programmed media feed set ting Continuous media is assumed to be at the proper rest position Troubleshooting Tables The following tables provide trouble symptoms a diagnosis of specific causes and a recommended action which should result in proper printer operation SYMPTOM DIAGNOSIS ACTION All LEDs never light No AC Power applied to Ensure the AC Power the printer cable is connected to a working voltage source Faulty AC Power Fuse Refer to Appendix C for Fuse replacement procedures No voltage available Call a Service from the internal power Technician supply Printer locks up when Printer not configured Refer to the PAUSE and running the Power On properly FEED Key Self Test and Self Test with some or reload factory defaults all LEDs ON then reconfigu
13. 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 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 reguests 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 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 15 54 52 1998 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 no
14. Color profile Disabled Composite Default screen Z Series User s Guide For the Zebra Z4000 and Z6000 Printers Customer order 77460L Manufacturer part 77460LB Rev 2 H uspiran2 vp Thu Jun 18 15 49 04 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 15 49 05 1998 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 eguip 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 eguipment generates uses and can radiate radio freguency 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 i
15. Cutter Blades are dull Replace Cutter Module Labels are jamming up in the Cutter or are being cut more than once Cutter is dirty Clean Cutter Blades Label length too short Increase label length Printing stops PAUSE and ERROR LEDs Out of media Load media Out of ribbon Load ribbon Solid ON For printers with the Cutter Option installed Media jammed in the Cutter Remove media clean Cutter if necessary Cutter Module is dirty Clean Cutter Module If error condition persists after attempting each of the above solutions call a Service Technician Printer Self Tests The Z Series printer is designed to work with most Zebra media and ribbon combinations right out of the box However in some applica tions changes to the printer s configuration and mechanical settings may be required For these situations printer self test labels can be used to check print quality and insure proper operation These self tests produce sample printouts and provide specific informa tion which helps determine the operating conditions for the printer Each self test is enabled by pressing a specific Front Panel key or com bination of keys while turning the AC Power Switch ON Keep the key s pressed until the first front panel LED turns OFF Once the Power On Self Test is completed the selected self test begins automati cally NOTES Prior to performing sel
16. IA S RIBBON S MEDIA LED RIBBON LED THESE SETTINGS SHOULD ONLY BE CHANGED BY AN AUTHORIZED SERVICE TECHNICIAN A password is reguired Refer to the Z Series Maintenance Manual for additional information about these settings Continued on the following page 75 Color profile Disabled Composite Default screen ZPL CONTROL PARAMETER SELECTIONS CONTROL PREFIX password required The printer looks for this 2 digit hex value to indicate the start of a ZPL ZPL ll Control instruction Refer to the ZPL Programming Guide for more information Default 7E tilde displayed as a black square Choices most hex values between 00 and FF exclude the values indicated on the ASCII Code Chart in Appendix C FORMAT PREFIX password reguired The printer looks for this 2 digit hex value to indicate the start of a ZPL ZPL ll Format instruction Refer to the ZPL Programming Guide for more information Default 5E caret Choices most hex values between 00 and FF exclude the values indicated on the ASCII Code Chart in Appendix C DELIMITER CHAR password reguired The printer looks for this 2 digit hex value used as a parameter place marker in ZPL ZPL ll instruction Refer to the ZPL Programming Guide for more information Default 2C comma Choices most hex values between 00 and FF exclude the values indicated on the ASCII Code Chart in Appendix C ZPL MODE
17. M gt xCODE 39 N SPEC NHU gt 8 CODE 39 o pi SLIGHTLY DARK NY CODE 39m 700 DARK AA IL Figure 31 Bar Code Examples 86 H uspiran2 vp Thu Jun 25 11 20 50 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 25 11 20 51 1998 ASCII Code Chart American Standard Code for Information Interchange O o gt 3 Ix k o jalo o gt F Ko OO O Jor B Como A B C D E F G H l J K L M N O P Q R S T U V w X Y Z NK x lt lo lo o NOTE NOT recommended for use as a Command Prefix Format Prefix or Delimiter Character 87 Color profile Disabled Composite Default screen D Z Series User s Guide H uspiran2 vp Thu Jun 25 11 20 51 1998 Color profile Disabled Composite Default screen alphanumeric Indicating letters numerals and characters such as punctuation marks backfeed When the printer pulls the media and ribbon if used back ward into the printer so that the beginning of the label to be printed is properly positioned behind the printhead Backfeed occurs when operating the
18. Media Loading Refer to Figure 18 while loading media 1 Place the roll of media on the Media Supply Hanger 1 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 Press the Printhead Open Lever e and raise the Printhead Assembly Figure 18 Media Loading Cutter Option Z Series User s Guide H uspiran2 vp Wed Jul 08 11 39 02 1998 Color profile Disabled Composite Default screen 4 Feed the media under the Media Spindle j under the Ribbon Sen sor k through the Cutter Module and out the front of the printer 5 Slide the Media Guide h in against the outer edge of the media Go to the Loading Ribbon procedure earlier in this guide then continue through the Configuration and Media Sensor Position ing processes 41 H uspiran2 vp Wed Jul 08 11 39 02 1998 Color profile Disabled Composite Default screen H uspiran2 vp Wed Jul 08 11 39 02 1998 Electronics Options PCMCIA Option An optional PCMCIA Port is available for the Z Series printer This option is available as both a factory installed feature and a field installable kit Access to the PCMCIA port is from the rear of the printer Optional PCMCIA Memory Cards will provide non volatile storage for label formats downloadable fonts graphics files etc The content of the PCMCIA Memory Card is not lost when power is turned OFF DRAM Memory Option
19. N Self Test the LCD displays an idle message PRINTER READY 1024K Vxx x x B While a format is printing a label counter is displayed PRINTING 1 OF 99999999 W The LCD also indicates memory conditions when they occur CREATING BITMAP BUILDING FORMAT STORING GRAPHIC STORING FORMAT STORING BITMAP STORING FONT m The LCD also displays an error message when an error occurs HEAD OPEN PAPER OUT RIBBON OUT RIBBON IN BUFFER OVERFLOW CUTTER JAMMED HEAD COLD HEAD TOO HOT OUT OF MEMORY NOTE When an error condition is corrected the top line of that error display indicates ERROR CLEARED Once all of the errors have been cleared press the PAUSE key to resume printing B When configuring the printer s operating parameters the configuration menu is displayed on the LCD Refer to Appendix A for printer configuration parameters 35 Color profile Disabled Composite Default screen Power Rewind Power Peel Option The Z Series printer supports a rewind option with the capability of rewinding an entire roll of printed labels Rewind mode or backing material only Peel mode This option is available as both a factory installed feature and a field installable kit Label Movement in Rewind Mode In the Rewind mode labels are printed and fed forward in a continuous sequence As printing continues the media is wound onto the Take Up Spindle Label Movement in Peel Mode In the Peel mode when a label is completely
20. Peel Option Value Peel Option Cutter Option Electronics Options Communication Options Power On Self Test Troubleshooting Tables Printer Self Tests Resetting Factory Defaults Initializing the Flash Memory and PCMCIA Card Automatically Executed Format Print Error Conditions 17 17 19 24 24 25 27 28 30 31 33 33 35 35 38 44 45 45 46 Color profile Disabled Composite Default screen H uspiran2 vp Wed Jul 08 11 23 52 1998 General Specifications Printing Specifications Ribbon Specifications Media Specifications Zebra Programming Language ZPL II Bar Codes Standard Printer Fonts Optional Printer Fonts Printer Configuration Standard Front Panel Printer Configuration Deluxe Front Panel Communication Interfaces Serial Data Communications Parallel Data Communications AC Power Cord Fuse Replacement Shipping Setting Darkness For In Spec Bar Codes ASCII Code Chart 47 48 48 49 50 50 51 53 55 59 69 69 72 73 74 74 74 77 Color profile Disabled Composite Default screen lt p Z Series User s Guide H uspiran2 vp Wed Jul 08 11 23 52 1998 Color profile Disabled Composite Default screen H uspiran2 vp Mon Jun 22 10 28 44 1998 Congratulations You have just purchased a high guality thermal de mand printer manufactured by the industry leader in guality service and value For over 25 years Zebra Technologies Corporation has
21. X DELIMITER CHAR ZPL MODE MEDIA POWER UP HEAD CLOSE BACKFEED LABEL TOP LEFT POSITION WEB S MEDIA S RIBBON S MEDIA LED RIBBON LED LCD ADJUST MODES ENABLED MODES DISABLED RESOLUTION FIRMWARE CONFIGURATION MORY FIRMWARE IN THIS PRINTER IS COPYRIGHTED Figure 19 CANCEL Key Self test Label 49 H uspiran2 vp Thu Jun 18 16 02 06 1998 Color profile Disabled Composite Default screen PAUSE Key Self test Press and hold the PAUSE key while turning the printer power ON Release the key anytime after the first front panel LED turns OFF The PAUSE key self test prints a series of labels which can be used when making print guality adjustments m 9999 labels at two inches per second pausing every 15 labels m 9999 labels at six inches per second pausing every 15 labels m 9990 labels at two inches per second pausing every 50 labels m 9999 labels at six inches per second pausing every 50 labels When the printer pauses press the PAUSE key to restart printing at the same speed While paused press the CANCEL key to switch to the next set of labels Figure 20 provides an example of the PAUSE key self test label 1234567890 12345678961234567896123456789612345678991234567890 1234567 Figure 20 PAUSE Key Self Test Label H uspiran2 vp Thu Jun 18 16 02 06 1998 Color profile Disabled Composite Default screen FEED Key Self test Press and hold the FEED key while
22. a mainframe mini PC Portable Data Terminal B In Spec OCR A and OCR B m UPC EAN nominal 100 mag nification 6 dot mm printheads only m LOGMARS m Plessey B EAN 8 EAN 13 EAN EXTENSIONS B UPC A UPC E UPC EXTENSIONS m MSI m PDF 417 2 dimensional bar code m POSTNET m MaxiCode m Datamatrix m QR Code added with Firmware Release V22 8 3 m Check digit calculation where applicable Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 02 50 1998 Standard Printer Fonts For more information on fonts refer to the ZPL JI Programming Guide 203 DOTS INCH 8 DOTS MM PRINTHEAD Dot Matrix Minimum h x w Character Defaults Size h x w 9x5 0 044 x 0 030 11x7 0 054 x 0 044 18 x 10 0 089 x 0 059 28 x 15 0 138 x 0 098 26 x 13 0 128 x 0 079 60 x 40 0 295 x 0 236 21x 13 0 103 x 0 093 0 118 x 0 118 SCALEABLE SMOOTH FONT Dot Matrix Minimum h x w Character Defaults Size h x w 9x5 0 030 x 0 020 11x7 0 036 x 0 030 18 x 10 0 059 x 0 040 42 x 20 0 138 x 0 085 26 x 13 0 085 x 0 053 60 x 40 0 197 x 0 158 34 x 22 0 111 x 0 098 24 x 24 0 079 x 0 079 Variable SCALABLE SMOOTH FONT Type U Upper Case L Lower Case D Descenders m Bit mapped fonts A B D E F G H and GS are expandable up to 10 times
23. al ity Media width and media thickness vary from one application to the Z Series User s Guide Color profile Disabled Composite Default screen next To maintain proper print guality refer to the Care amp 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 Figure 7 Printer Ready for Operation Z Series User s Guide 19 H uspiran2 vp Thu Jun 18 15 54 07 1998 Color profile Disabled Composite Default screen 12 Z Series User s Guide H uspiran2 vp Thu Jun 18 15 54 08 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 15 54 51 1998 Operator Interface The Z Series family of printers features either a standard or deluxe front panel The deluxe front panel features a Liguid 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
24. arkness setting sometimes called burn temperature or head temperature and the lowest printhead pressure necessary to produce good print guality In the thermal transfer printing method use ribbon that is as wide or wider than the media to protect the printhead from the rough media surface registration Alignment of printing with respect to the top of a label or tag ribbon A band of material consisting of a base film coated with wax or resin ink The inked side of the material is pressed by the printhead against the media The ribbon transfers ink onto the media when heated by the small elements within the printhead Zebra ribbons have a coating on the back that protects the print head from wear ribbon wrinkle A wrinkling of the ribbon caused by improper align ment or improper printhead pressure This wrinkle can cause voids in the print and or the used ribbon to rewind unevenly This condi tion should be corrected by performing adjustment procedures roll media Media that comes supplied rolled onto a core usually card board Contrast this with fanfold media supplies A general term for media and ribbon tag A type of media having no adhesive backing but featuring a hole or notch by which the tag can be hung on something Tags are usu ally made of cardboard or other durable material 21 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 05 28 1998 take label sensor See abel availa
25. ates noise If errors are indicated check that your communication parameters are correct AFS FOS394 2S AA 5E 46 53 5E 46 4F 33 39 34 2C 32 35 5E 41 41 N 18 10 FDCOOOO 4E 2C 31 38 2C 31 30 5E 46 44 28 30 30 30 30 2777 7777 29 39 39 39 2D 39 39 39 39 5E 46 53 D 0A FOO SO AAN 18 5E 46 4F 30 2C 35 30 5E 41 41 4E 2C 31 38 2C 1 O FDCENTER STA 31 30 5E 46 44 43 45 4E 54 45 52 20 53 54 41 Figure 23 Communications Diagnostics Self test 53 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 02 08 1998 Media and Ribbon Sensor Profile The Media and Ribbon Sensor Profile may be used to troubleshoot reg istration problems that may be caused when the Media Sensor experi ences difficulty in determining web location between labels To print a Media and Ribbon Sensor Profile you must press and hold the PAUSE key FEED key and CANCEL key while turning the printer power ON Release all three keys anytime after the first front panel LED turns OFF Figure 24 provides an example of the Media and Ribbon Sensor Profile sample printout RIBBON _ MEDIA MEDIA MEDIA MEDIA MEDIA GM RIBBON Figure 24 Media amp Ribbon Sensor Profile Resetting Factory Defaults From time to time it may be necessary to return the printer configura tion to a known state A set of Factory Defaults can be loaded into the printer as a starting point from which one can then reconfigur
26. ble sensor thermal direct See direct thermal thermal transfer A printing method in which the printhead presses an ink or resin coated ribbon against the media Heating the print head elements causes the ink or resin to transfer onto the media By selectively heating the printhead elements as the media and ribbon move past an image is printed onto the media Contrast this with direct thermal void A space where printing should have occurred but did not due to an error condition such as wrinkled ribbon or faulty print elements A void can cause a printed bar code symbol to be read incorrectly or not at all 92 Color profile Disabled Composite Default screen AC Power 2 Adjustments Media Sensor Position 9 Printhead Pressure 24 ASCII Control Codes XOFF DC3 71 XON DC1 71 Calibration 17 Caution Ribbon Width 8 Shipping 74 Unshielded Cables 71 CCITT V 24 71 Cleaning 19 Cutter Module 22 Platen 20 Printhead 20 Recommended Schedule 19 Sensors 20 Communication Interfaces 69 IEEE 1284 Parallel 72 RS 232 Serial 70 RS 485 Serial 71 Communications 2 Configuration 55 Factory Settings 3 4 Configuration Label 39 93 H uspiran2 vp Thu Jun 18 16 05 50 1998 Color profile Disabled Composite Default screen Damage Report 1 DIP Switches 55 DTR Data Terminal Ready 71 EIA RS232 71 Electrical Noise 69 Error Conditions 46 LCD Display 27 Factory Defaults 44 FCC Rules and Regulations 71 Front Pan
27. bvious The normal bar code will be In Spec Small character alphanumerics will be bold and could be slightly filled in The rotated bar code spaces are small when compared to the In Spec code possibly making the code un readable H uspiran2 vp Thu Jun 25 11 20 47 1998 Color profile Disabled Composite Default screen Slightly Light Slightly light labels are in some cases preferred to slightly dark for In Spec bar codes Both normal and rotated bar codes will be In Spec but small alphanumeric characters may not be complete Too Light Light labels are very obvious Both normal and rotated bar codes have incomplete bars and spaces Small alphanumeric char acters are unreadable In Spec The In Spec bar code can only be confirmed by a verifier but it should exhibit some very visible characteristics The normal bar code will have complete even bars and clear distinct spaces The ro tated bar code will also have complete bars and clear distinct spaces Although it may not look as good as a slightly dark bar code it will be In Spec In both normal and rotated styles small alphanumeric char acters will look complete ROTATED BAR CODES mm ll O umo JE Y m E Ses erai vue an p p EE ENSE H A E PIP MESE roue MATE THI er AE 73e suemvuee UMVI
28. 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 minia ture 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 environ ment 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 11 H uspiran2 vp Thu Jun 18 15 51 22 1998 Color profile Disabled Com
29. dia out ribbon out or cutter error condition stops the printer im mediately and turns the ERROR LED on solid A head open condition also stops the printer and the ERROR LED blinks The label being printed when the condition occurs is only partially printed The PAUSE LED is turned ON and the printer waits for the errors to be cleared and the PAUSE key to be pressed If all error conditions are cleared when the PAUSE KEY is pressed the PAUSE LED will turn OFF Media registration occurs through the auto calibration function for non continuous media and then the printing process resumes Printing resumes by reprinting the label that was in process when the condition occurred unless the printer is configured to NOT reprint par tial labels All of the other features of the printer e g communica tions parsing formatting and cancel function normally during the error condition and while the printer is recovering The feature of reprinting a label after an error condition occurs can be turned off by a ZPL command The type of media continuous or non continuous being monitored by the printer is controlled by a setting on the front panel LCD or DIP switches Printhead Over Temperature When the printhead becomes too hot all printing stops and the ERROR LED blinks slowly The printer will wait until the printhead has returned to an acceptable temperature prior to restarting All of the other features of the printer function norma
30. dix 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 cr NOTE You must supply the interface cable for your application See Appendix B of this manual for specific cable reguirements 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 e a three prong plug with an earth ground connection to the c 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 Figure 1 Printer Rear View Z Series User s Guide H uspiran2 vp Mon Jun 22 10 28 46 1998 Color profile Disabled Composite Default screen Z Series Configuration The Z Series printer will have one of two different styled front pan els The
31. e notch or hole is used to indicate the separations between labels Mark if a black mark printed on the back of the media is used to indicate the separations between labels If your media does not have black marks on the back leave the printer at the default Web Default Web Choices Web or Mark PRINT METHOD Select the method of printing you wish to use Direct thermal reguires the use of heat sensitive label stock no ribbon needed Thermal transfer uses many types of label stock along with an inked ribbon Default Thermal transfer Choices Thermal Transfer or Direct Thermal NOTE Selecting direct thermal when using thermal transfer media and ribbon creates a warning condition but printing will continue PRINT WIDTH Select a print width that is the closest to and at least as wide as your media Setting the width too narrow may result in unprinted portions of your label format Setting the width too wide wastes formatting memory and may cause printing off the right side of the label Default 104 mm Z4000 168 mm Z6000 Choices Up to 104 mm Z4000 Up to 168 mm Z6000 NOTE Move the curser under mm using the MINUS key use the PLUS key to change the reading from mm to inches or dots Continued on the following page 74 H uspiran2 vp Thu Jun 18 16 03 36 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 03 36 1998 CALIBRATION
32. e both keys anytime after the first front panel LED turns OFF The PAUSE and CANCEL key self test prints a seguentially numbered series of 500 labels When making print guality adjustments these la bels should be observed o insure the highest print guality has been set Figure 22 provides an example of the FEED key self test label 1234567890123456789012345678801234567890123456789012345678901234567 Figure 22 PAUSE and CANCEL Key Self test Label Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 02 08 1998 Communications Diagnostic Self test The Communications Diagnostic Mode is a troubleshooting tool for checking the interconnection between the printer and the host com puter When Diagnostics is selected all data sent to the printer will be printed as straight ASCII hex characters The printer prints all received characters including control codes like CR Carriage Return To enter the Communications Diagnostics mode open the front panel door and press and hold the key while turning the printer power ON Release the key anytime after the first front panel LED turns OFF Send a label format from the host computer to the printer and observe the printout on the label stock Figure 23 provides an example of the Diagnostic Mode printout NOTES An FE indicates a framing error An OE indicates an overrun error An PE indicates a parity error An NE indic
33. e the printer for the application desired To reset Factory Defaults press and hold both the PAUSE and FEED keys while turning the printer power ON Release both keys anytime after the first front panel LED turns OFF Once the Power On Self Test is completed open the printer s front panel door and press the Print Darkness Key two times to save the Factory Defaults parameters in EEPROM memory To signify that the parameters have been saved all three Control LEDs will flash on then off An alternate method of setting Factory Defaults is by sending the ZPL commands JUF JUS to the printer In addition for printers with the deluxe front panel factory default settings may be saved through the LCD configuration As of Firmware Release V22 8 4 this process no longer initializes the optional on board flash menory device nor the optional PCMCIA Card Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 02 08 1998 Initializing the Flash Memory and PCMCIA Card As of Firmware release V22 8 4 a new procedure is used to initialize the optional on board Flash Menory device and the optional PCMCIA Card Prior to uploading new contents into the Flash Memory and or the PCMCIA Card it is first necessary to initialize these devices This pro cedure is performed by pressing and holding all three left hand control keys inside the printer s front panel door while turning the printer power ON The keys may be rel
34. e to the list of available fonts Contact your sales representative for further information Once installed the optional fonts can be used in addition to the stan dard fonts available in the printer Refer to your ZPL II Programming Guide or if using another software package to drive your printer to the instructions accompanying that package 63 Color profile Disabled Composite Default screen a Z Series User s Guide 64 H uspiran2 vp Thu Jun 18 16 02 52 1998 Color profile Disabled Composite Default screen Appendiz A Printer Configuration standard Front Panel Cr NOTE To configure a Z Series printer having the optional deluxe front panel refer to the information found later in this section Serial Communications Parameters Refer to Figure 25 When using serial communication the Bank One left switches inside the front panel door must match the communica tion parameters of the printer with those of your host computer When shipped from the factory all switches are in the ON position This pre sets the printer to match the typical PC environment 9600 Baud 8 Data Bits No Parity and Xon Xoff Handshaking Figure 25 Standard Front Panel Z Series User s Guide 65 H uspiran2 vp Thu Jun 18 16 03 33 1998 Color profile Disabled Composite Default screen Refer to Table 8 if the settings need to be changed to match those of your host computer If you do not know the settings of you
35. eased anytime after the first front panel LED turns OFF The Front Panel DATA LED will remain on until the initialization process is finished NOTE Initialization will erase the current contents of both devices Be sure to enable the Write Protect feature of the PCMCIA Card if you do not want to initialize this device Automatically Executed Format Once the Power On Self Test is completed and any self test labels are printed a check is made of the optional PCMCIA Memory Card and then the optional Flash Memory for the presence of a stored format named AUTOEXEC ZPL If an AUTOEXEC ZPL format is encoun tered it is automatically recalled and the preformatted labels are printed If no AUTOEXEC ZPL format is found the printer enters the normal operating mode and waits for operator input from the front panel or la bel format data to be received from the host computer 55 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 02 08 1998 Print Error Conditions There are several error conditions that effect printing Some actually stop the printing process completely while others are only reported to the operator or host system A printhead open error condition stops any media movement while the printhead under temperature error has no effect on media movement Some error conditions must be corrected before the printer will feed or print labels again Media Out Ribbon Out Head Open or Cutter Error A me
36. ecrease the pressure of the printhead against the ribbon and or media The amount of pressure reguired varies from one application to the next and is determined by the type and thickness of the media as well as the media width If using narrow media you may need to reduce the pressure applied by the right hand dial to minimize the pressure over the unused printhead arca Figure 13 Printhead Pressure Adjustment 33 Color profile Disabled Composite Default screen Power Rewind Power Peel Media Alignment For printers equipped with the Power Rewind Power Peel option An adjustment to the Media Alignment Spindle allows the user to in sure that the media or backing material is properly winding onto the Take up Spindle Refer to Figure 14 Turn the adjustment dial v clockwise to align the media backing material more to the left Turn the dial counterclockwise to align the media backing material to align more to the right Figure 14 Power Rewind Power Peel Media Alignment Z Series User s Guide 34 H uspiran2 vp Thu Jun 18 15 58 05 1998 Color profile Disabled Composite Default screen H uspiran2 vp Wed Jul 08 11 38 49 1998 LCD Display Deluxe Front Panel The Z Series printers include the option of replacing the standard front panel with a deluxe front panel containing a Liquid Crystal Display LCD The LCD shows several types of information m When the printer completes its Power O
37. ed OFF OFF ERROR DETECTION SWITCH 8 NOTE Zebra Protocol is the default ON Error Detection Protocol enabled On OFF when On Switch 8 OFF is selected Table 8 Bank 1 Switch Settings 66 H uspiran2 vp Thu Jun 18 16 03 33 1998 Color profile Disabled Composite Default screen Operating Modes Use the Bank Two right switches to select printer operating modes When shipped from the factory all switches are in the ON position This presets the printer to match the most commonly used modes of operation Tear Off Mode Non continuous Media Thermal Transfer Operation and RS 232 Serial Communications If your printer is eguipped with an option such as rewind peel off or cutter or if your application reguires a different operating mode such as direct thermal or continuous media refer to Table 9 for the appropriate Bank Two switch settings DIP SWITCH ZPL CONTROL SWITCH 1 Dip Switches 2 6 Override ZPL ON ON ZPL Overrides Dip Switches 2 6 OFF PRINT MODE SWITCH 2 SWITCH 3 Tear Off ON ON Peel Off OFF ON OFF Cutter ON OFF DIP Switch Rewind OFF OFF Positions MEDIA TYPE SWITCH 4 SWITCH 5 Non Continuous ON ON Web Sensing Non Continuous ON Mark Sensing Continuous OFF PRINT METHOD SWITCH 6 Thermal Transfer ON Direct Thermal OFF SERIAL COM MODE SWITCH 7 SWITCH 8 RS 232 ON ON RS 422 RS485 OFF ON S
38. edia Sensor Media or ribbon improperly loaded Reload Media and Ribbon Changes in parameter settings did not take effect Parameters are set or saved incorrectly Continuing problems Reload the Factory Defaults reconfigure the printer cycle the Power OFF and ON Call a Service Technician H uspiran2 vp Thu Jun 18 16 02 05 1998 ZPL was sent to printer but not recognized The DATA LED remains OFF Communications parameters or DIP Switches are set incorrectly Check and reset communication parameters if needed Prefix and delimiter characters set in printer configuration do not match the ones sent in the ZPL Label Formats Set the characters in the printer to match ZPL format Check Configuration Label for correct characters If problem continues check the ZPL format for changed CC CT and CD instructions Continued on the following page 47 Color profile Disabled Composite Default screen SYMPTOM DIAGNOSIS ACTION In Peel Off Mode skewed or stuck labels Glue material from back of labels causing media movement problems Perform maintenance and clean the printer Media and backing not aligned in printer Check media guide positions Labels are not being cut Cutter Mode not selected Reconfigure the printer The Cutter is not cutting labels cleanly Cutter is dirty Clean Cutter Blades
39. el Deluxe 27 59 Standard 55 Front Panel Control Keys 58 Front Panel Keys 13 Front Panel LEDs 14 Fuse Replacement 73 Glossary 79 IN SPEC Bar Codes 74 Initialization Flash Memory 45 PCMCIA Card 45 Liguid Crystal Display 13 27 Loading Media 5 Ribbon 7 Lubrication 24 94 H uspiran2 vp Thu Jun 18 16 05 51 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 05 51 1998 Maintenance 1 Media Continuous 9 Fanfold 6 Non Continuous 9 Roll 6 Media Alignment Power Peel 25 Power Rewind 25 Media Guide 6 29 31 32 Media Loading 5 Media Sensor Operation 9 Position 9 Media Sensors 9 Media Supply Guide 6 29 31 32 Media Supply Hanger 6 29 31 32 Optional Fonts 53 Options Communication 33 Cutter 31 DRAM Memory 33 Flash Memory 33 PCMCIA Memory Card 33 Power Peel 28 Power Rewind 28 Value Peel 30 Power ON Self Test 35 Printer Configuration 59 Printer Configuration Label 39 Printer Options 28 Printer Power 2 Printer Specifications 47 48 Printhead Pressure 24 95 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 05 51 1998 Reporting Damage 1 Ribbon Loading 7 Ribbon Removal 8 Ribbon Supply Spindle 8 Ribbon Takeup Spindle 8 RS 232 70 Chassis Ground 69 DSR Data Set Ready 69 DTR Data Terminal Ready 69 RTS Request To Send 69 RXD Receive Data 69 Signal Ground 69 TXD Transmit Data 69 RS 485 71 Inp
40. ent shall Zebra Technologies corporation or anyone else involved in the creation production or delivery of the accompanying product including hardware and software e 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 IBM is a registered trademark of IBM Corporation Goo Gone is a Registered Trademark of Magic American Corporation Zebra Stripe ZPL and ZPL II are registered trademarks and Z Series Z4000 and Z6000 are trademarks of Zebra Technologies Corporation Zebra Technologies Corporation Color profile Disabled Composite Default screen DECLARATION OF CONFORMITY I have determined that the Zebra
41. f tests disconnect all data interface cables from the printer When canceling a self test prior to its actual completion always turn the printer power OFF and then back ON to restart the printer 48 H uspiran2 vp Thu Jun 18 16 02 06 1998 Color profile Disabled Composite Default screen Make sure that your print width is set correctly for the media you are using before you run any self tests otherwise the test may print out on the platen If your media is not wide enough or long enough to display a complete test label unexpected and or undesired results may occur When performing these self tests while in the Peel Mode you must remove the labels as they become available CANCEL Key Self test Press and hold the CANCEL key while turning the printer power ON Release the key anytime after the first front panel LED turns OFF The CANCEL key self test prints a configuration label showing m Printer configuration B Installed options W Software version m Copyright notice Figure 19 shows an example of the Printer Configuration Label The configuration information will print over several labels if a label is not long enough to display all of the configuration information at one time PRINTER CONFIGURATION 000 TEA NON WEB THERMAL TRANS PRINT METHOD 164 6 78 MM PRINT WIDTH 1228 LABEL LENGTH BAUD DATA BITS PARIT HOST HANDSHAKE PROTOCOL NETWORK ID COMMUNICATIONS CONTROL PREFIX FORMAT PREFI
42. fault screen Figure 8 Standard Front Panel Figure 9 Deluxe Front Panel Z Series User s Guide 23 H uspiran2 vp Thu Jun 18 15 54 53 1998 Color profile Disabled Composite Default screen 16 Z Series User s Guide H uspiran2 vp Thu Jun 18 15 54 55 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 15 55 17 1998 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 er rors 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 fol lowed by the label length calculation Once the label length is deter mined 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
43. formation about which printer functions are not working used for troubleshooting printer problems die cut labels See non continuous media direct thermal A printing method in which the printhead presses directly against the media Heating the printhead elements causes a discoloration of the heat sensitive coating on the media By selec tively heating the printhead elements as the media moves past an image is printed onto the media No ribbon is used with this print ing method Contrast this with thermal transfer direct thermal media Media that is coated with a substance which reacts to the application of direct heat from the printhead to produce an image fanfold media Media that comes folded in a rectangular stack Contrast this with roll media font A complete set of alphanumeric characters in one style of type Ex CG Times CG Triumvirate Bold Condensed ips inches per second The speed at which the label or tag is printed Zebra offers printers that can print from 2 ips to 12 ips label An adhesive backed piece of paper plastic or other material on which information is printed label available sensor For printers equipped with the Peel Off Option this sensor detects a printed label waiting to be taken or picked by the operator While it detects this label the printer will not print additional labels Once the label has been removed from the printer the next label is printed Also called the take label
44. g To load roll media refer to Figure 3 l Place the roll of media on the Media Supply Hanger i and push it on all the way Fold the Media Supply Guide g up and slide it against the outer edge of the media roll Feed the media under the Media Spindle j under the Ribbon Sen sor k and out the front of the printer Slide the Media Guide h in until it is against the outer edge of the media Close the Printhead Assembly and the Media Cover or continue to Loading Ribbon 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 Z Series User s Guide Color profile Disabled Composite Default screen H uspiran2 vp Thu Jul 02 09 48 48 1998 Figure 4 Fanfold Media Loading Loading Ribbon NOTE The Ribbon Supply Spindle in your printer may be a Dual Tension variety Most applications reguire the spindle to be in the Normal position The Low Tension position is recommended only when wide ribbons are used and normal tens
45. he left edge of a label the format will begin to print by adjusting the horizontal positioning on the label Positive numbers adjust the printing to the left by the number of dots selected Negative numbers shift printing to the right Default 000 Choices 9999 to 9999 NOTE For a negative value enter the value before entering the minus sign INITIALIZE CARD This parameter allows you to initialize erase the password PCMCIA Card installed in the optional PCMCIA Port required Press to initialize Then if not sure press for NO or if you are sure press for YES INIT FLASH MEM This parameter allows you to initialize erase the password optional non volatile memory installed in the required printer Press to initialize Then if not sure press for NO or if you are sure press for YES Continued on the following page 77 H uspiran2 vp Thu Jun 18 16 03 37 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 03 37 1998 Exiting the Configuration mode When you are finished changing or reviewing the necessary parame ters press the START SAVE key Use the NEXT ITEM key to select one of the SAVE choices shown below then press the STAR T SAVE key again to end the configuration process m PERMANENT new settings overwrite previous values in configuration memory m TEMPORARY printer operates with new settings until power is turned off
46. height and width independent However fonts E and H OCR B and OCR A are not considered in spec when expanded m The Scaleable Smooth Font CG Triumvirate Bold Condensed is expandable on a dot by dot basis height and width independent while maintaining smooth edges to a maximum of 1500 x 1500 dots m IBM Code Page 850 International characters available in fonts A B D E F G and O through software control 61 Color profile Disabled Composite Default screen Standard Printer Font Examples FONT ABCDuxyz 12345 FONT B ABCDHXYZ 12345 FONT D AByz 123 FONT E OCR B ABCxyz 123 FONT F ABCDwxyz 12345 FONT G Az4 FONT H OCR A UPPER CASE FONT 0 Scalable ABCDwxyz 12345 FONT GS Default Printer Fonts 300 dots inch 12 dots mm F NT A ABCDuxyz 12345 FONT B ABCDUKY 12345 FONT D ABCDwxyz 12345 FONT E OCR B ABCDwxyz 12345 FONT F ABCDwxyz 12345 FONT G Az4 FONT H COCReA UPPER CASE ONLY FONT 0 Scalable ABCDwxyz 12345 FONT GS Default Printer Fonts 203 dots inch 8 dots mm 62 H uspiran2 vp Thu Jun 18 16 02 51 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 02 51 1998 Optional Printer Fonts There are many optional character fonts that can be purchased for your Z Series printer in addition to those which are standard in the unit From time to time additions may be mad
47. ia Align ment Spindle v For Power Peel Lift the Media Plate u and rotate it forward Remove the labels from the backing material then pass the back ing over the Peel Bar w down behind the Media Plate u through the printer housing and under the Media Alignment Spindle v Return the Media Plate to its operating position Figure 16 Media Loading Power Peel Option Z Series User s Guide H uspiran2 vp Wed Jul 08 11 38 54 1998 37 Color profile Disabled Composite Default screen H uspiran2 vp Wed Jul 08 11 38 54 1998 8 Loosen the thumbscrew and slide the Rewind Media Guide x out to the end of the spindle and rotate it to its horizontal position 9 Place an empty media core on the Rewind Spindle y wrap the media around the core and turn the spindle counterclockwise to wind up the excess material 10 Rotate the Rewind Media Guide to its vertical position slide it in against the media and tighten the thumbscrew that locks it into position 11 Go to the Loading Ribbon procedure earlier in this guide then continue through the Configuration and Media Sensor Position ing processes Media Backing Removal 1 Loosen the thumbscrew and slide the Rewind Media Guide x out to the end of the spindle and rotate it to its horizontal position 2 Cut the media backing material prior to where it winds onto the Take up Spindle 3 Slide the roll of media backing material from the Take Up
48. ies 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 m 9 pin to 25 pin cable NULL Modem Cable must have a 9 pin D Type DB9S connector on the end that is plugged into the serial port at the computer and a 25 pin D Type DB25P connector on the other end that is plugged into the connector at the rear of the printer Figure 27 shows the reguired cable connections DB 9S DB 25P Connector Connector to P C to Printer Oo o NN O Ol O N Figure 27 9 Pin to 25 Pin Cable m 25 pin to 25 pin cable NULL Modem Cable must have a 25 pin D Type DB25S connector on the end that is plugged into the serial port at the computer and a 25 pin D Type DB25P connector on the other end that is plugged into the connector at the rear of the printer Figure 28 shows the reguired cable connections DB 25S DB 25P Connector Connector to P C to Printer Figure 28 25 Pin to 25 Pin Cable Hardware Control Signal Descriptions For all RS 232 input and output signals the Z Series printer follows both the Electronics Industries Association EIA RS 232 and the Con sultative Committee for International Telegraph and Telephone CCITT V 24 standard signal level specifications When DTR DSR handshaking is selected the Data Terminal Ready DTR control signal output from the printer controls when the hos
49. ing Instructions found in this User s Guide Insure the Print Method is appropriately characterized for either Direct Thermal or Thermal Transfer 2 To print a label for evaluation use the following procedure A With Power OFF press and hold the FEED Key B Turn the Printer Power ON then release the FEED Key C The Printer will power up and begin printing test la bels 3 Print a label then press the PAUSE Key The label will con tain two bar codes as well as other printer information Nor mal bar codes are printed in a horizontal format as they feed out of the printer Rotated bar codes are printed in a vertical format 4 Compare the test label printed to the bar codes in Figure 31 If the test label appears too light or too dark refer to Appen dix A and increase or decrease the DARKNESS Setting ac cordingly 3s Resume printing by pressing the PAUSE Key again Print a few labels at the new setting and verify that proper In Spec bar codes are being printed Repeat steps 3 4 and 5 until sat isfied 6 To terminate the printing of the test labels press the PAUSE Key then epress the CANCEL Key Printing Conditions Too Dark Dark labels are fairly obvious The normal bar code bars increase in size and the openings in small alphanumeric characters may fill in with ink It may be readable but not In Spec Rotated bar code bars and spaces will run together Slightly Dark Slightly dark labels are not as o
50. ingle Drop RS 485 Multi Drop OFF Table 9 Bank 2 Switch Settings C Fr NOTE The printer automatically senses if a parallel communications E cable is connected from your host computer The Bank One switches and Bank Two switches 7 and 8 have no effect on parallel communications To see a printout of the printer configuration perform the CANCEL Key Self Test See the Troubleshooting section for more details 67 H uspiran2 vp Thu Jun 18 16 03 34 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 03 34 1998 Standard Front Panel Control Keys If you need to adjust the print darkness label position or the image po sition on the label use the following control keys located inside the front panel door to configure these parameters Print Darkness Key Press this key LED turns ON to change the print darkness setting by pressing the PLUS or MINUS keys Each press of the or key changes the setting by one step Press the Print Darkness key a second time to save the new setting The darkness setting limits are from zero 0 to 30 Label Position Key Press this key LED turns ON to change the label tear off cut off position setting by pressing the or keys Each press of the or key changes the setting by four dot rows Press the Label Position key a second time to save the new setting From the default value the set ting may be changed 120 or 120 dot rows Image P
51. ion hampers the ribbon movement To place this spindle in the Normal position firmly pull out on the Spindle End Cap until it clicks into place as shown in Figure 5a To place the spindle in the Low Tension position firmly push in on the Spindle End Cap until it clicks into place SPINDLE END CAP SPINDLE END CAP EXTENDED RETRACTED aay SR Normal Position Low Tension Position Figure 5a Ribbon Supply Spindle Positioning Z Series User s Guide 15 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jul 02 09 48 50 1998 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 l Place the roll on the Ribbon Supply Spindle l and push it on all the way Pull the end of the ribbon over the Ribbon Sensor k under the Printhead assembly f and up over the Ribbon Guide Plate m Wind the ribbon onto the Take up Spindle n for several turns in a clockwise direction 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 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
52. irty printhead Clean printhead Defective printhead elements Replace the printhead Light printing or no printing on the left or right side of the label Too little printhead pressure Adjust printhead pressure Short printed lines at 45 to label edge on left or right side of label Too much Printhead pressure Adjust Printhead pressure Fine gray lines on blank labels at angles Wrinkled ribbon See Wrinkled Ribbon in this Table H uspiran2 vp Thu Jun 18 16 02 05 1998 Long tracks of missing print on several labels Wrinkled ribbon See Wrinkled Ribbon in this Table Print Element damaged Replace the printhead Continued on the following page Table 3 Printer Troubleshooting 46 Color profile Default screen SYMPTOM Wrinkled ribbon DIAGNOSIS Ribbon fed through printer incorrectly ACTION Reinstall ribbon Incorrect Darkness setting Set to the lowest value needed for good print quality Incorrect Printhead pressure Media not feeding properly it is walking from side to side Readjust Printhead pressure Readjust Media Guides Continuing problems Call a Service Technician Misregistration and misprint of 1 to 3 labels Media was pulled when motor was not moving Open and close the printhead so it calibrates to find the label length Incorrect Media Sensor Position Reposition M
53. le choices for each parameter are given Once in the configuration mode pressing the NEXT MENU key at any time will exit the current major menu feature list and move to the next major menu heading An asterisk appears in the upper left corner of the LCD if the value selected is different from the one currently saved NOTE Whenever a password is reguested during the configuration process the default value of 1234 may be entered This password may be changed via a programming command sent to the printer from the host computer Color profile Disabled Composite Default screen GENERAL SETUP MENU PARAMETER SELECTIONS LANGUAGE Use the PLUS key or MINUS key to sequence through the LCD selections until the appropriate language is displayed Default English Choices English Spanish French German Italian Norwegian Portuguese Swedish Danish Spanish2 Dutch Finnish or Custom DARKNESS Set the darkness to the lowest setting possible for consistent high quality printing To observe the effects of the newly entered value go to the Print Listings parameter and print a setup label Default 10 Range 0 to 30 TEAR OFF This value sets the media rest position over the Tear Peel Bar after printing or the cut off point for cutter applications Default 00 Range 120 to 120 PRINT MODE Select a print mode that your hardware configuration supports since some selections are for optional printer featu
54. lly while the head is over temperature including feeding and calibrating without printing a label Printhead Under Temperature A similar condition occurs when the printhead is cooler than desired The printer does NOT stop but the ERROR LED blinks slowly to indi cate the error condition All other printer features continue to work nor mally This includes printing which should heat the printhead to the desired temperature Color profile Disabled Composite Default screen Ur NOTE Printer specifications are subject to change without notice Your printer may not have all of the options described in these specifications If you have questions as to the ability of the Z Series printer to meet the needs of your application contact either your Zebra Distributor or Zebra Technologies Corporation General Specifications SPECIFICATION 24000 PRINTER 26000 PRINTER Height 11 5 292 5 mm 11 5 292 5 mm Width 8 25 209 6 mm 12 8 325 1mm Depth 16 406 4 mm 18 3 464 8 mm Weight option dependent 24 5 Ibs 11 1 kg 26 5 Ibs 12 0 kg Electrical 90 to 265VAC 48 62 Hz 5 Amps Fused Agency Approvals Built to CISPR 22B IEC 950 801 2 3 and 4 standards Complies with FCC class B and Canadian Doc class A rules Carries the CE mark of compliance Temperature Operating 40 F to 105 F 5 C to 40 C Storage 40 F to 140 F 40 C to 60 C
55. low Ribbon Path See Figure 5 Alcohol After every roll of media or 500 feet of fanfold media when printing in the direct thermal mode After every roll of ribbon when printing in the thermal transfer mode Cutter Dust build up Assembly Adhesive build up Air Blow Citrus Based Cleaner such as Goo Gone After every two to three rolls of media After every roll of media or more often depending upon your application and the type of media being cut Tear Off Peel Off Bar Alcohol Once per month Peel Blade Alcohol After every roll of media or more often depending upon your application and media Label Available Sensor z See Fig 17 Air Blow Once per six months 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 neces sary a mild detergent or desktop cleaner may be used sparingly 27 Color profile Disabled Composite Default screen A H uspiran2 vp Thu Jun 18 15 57 40 1998 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 follo
56. n a par ticular installation If this eguipment does cause harmful interference to radio or television reception which can be determined by turning the eguipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and the receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected 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 user s 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 om tion reserves the right to correct any such errors and disclaims liability resulting therefrom No Liability for Consequential Damage In no ev
57. need adjustment 0 010 0 25 mm Minimum 0 0023 0 058 mm Core size 3 0 76 2 mm Maximum roll diameter 8 0 203 mm Inter label gap Maximum Minimum 0 7787 3 mm preferred 0 157 4 mm 0 079 2 mm Ticket tag notch size Width x Length 0 236 6 mm x 0 12 3 0 mm Pressure sensitive media release liner must be free of preprint with the exception of black mark registration and is recommended to not exceed 0035 089 mm thickness 60 Ib stock Table 7 Media Specifications 59 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 02 50 1998 Zebra Programming Language ZPL II m Downloadable graphics with data compression B Programmable quantity with print pause m Bit image data transfer and print Communicates in printable ing mixed text graphics W Format inversion m Mirror image printing B Four position field rotation 09 909 1809 270 B Slew command m Serialized fields Bar Codes m Code 11 m Code 39 supports ratios of 2 1 to 3 1 m Code 49 2 dimensional bar code m Code 93 m Code 128 supports serial ization in all subsets and UCC case codes m Codabar supports ratios of 2 1 to 3 1 B Codablock m Interleaved 2 of 5 supports ratios of 2 1 to 3 1 modulus 10 check digit B Industrial 2 of 5 B Standard 2 of 5 60 ASCII characters m Controlled vi
58. o 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 Ifadhesive 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 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 15 57 54 1998 CUTTER MOUNTING MODULE SCREW ROTATION CONTROL Figure 11 Cutter Cleaning NOTE Disassembly of the Cutter module should only be performed by a Service Technician Z Series User s Guide 31 Color profile Disabled Composite Default screen EN H uspiran2 vp Thu Jun 18 15 57 59 1998 Cleaning the Peel Blade For printers equipped with the Value Peel or Power Peel option l Open the Media Door and press the Printhead Open Lever to raise the Printhead Assembly Refer to Figure 12 Open the Peel Mechani
59. ontrol codes like CR Carriage Return are printed Default Normal Mode Choices Normal Mode or Diagnostics Mode NOTES An FE indicates a framing error An OE indicates an overrun error An PE indicates a parity error An NE indicates noise If errors are indicated check that your communication parameters are correct PRINT LISTINGS PARAMETER SELECTIONS LIST FONTS LIST BARCODES Press to print a list of all standard and optional fonts currently available in the printer Press to print a list of all the barcodes currently available in the printer LIST IMAGES Press to print a list of all the images currently available in the printer LIST FORMATS Press to print a list of all the formats currently available in the printer LIST SETUP Press to print the printer s current configuration LIST ALL Press to print all of the previously indicated lists Continued on the following page 73 Color profile Disabled Composite Default screen MEDIA SETUP PARAMETER SELECTIONS MEDIA TYPE Select the type of media you are using Default Non Continuous Choices Continuous or non continuous NOTE Selecting continuous media requires that you include a label length instruction in your label format LLxxxx if you are using ZPL or ZPL ll SENSOR TYPE Select the type of media sensing you will use Web if a gap spac
60. orward away from the printer Pull about 12 to 18 inches of backing only down over the edge of the Peel Tear Bar w and close the printhead Return the Peel Assembly to its operating position Insure the Assem bly is reseated on the tabs of the Peel Tear Bar w go to the Loading Ribbon procedure carlier in this guide then continue through the Configuration and Media Sensor Positioning processes Figure 17 Media Loading Value Peel Off Option Z Series User s Guide H uspiran2 vp Wed Jul 08 11 38 58 1998 39 Color profile Disabled Composite Default screen Cutter Option The Z Series printer also features a cutter option This option is avail able as both a factory installed feature and a field installable kit A label catch tray is included which holds up to 10 labels up to 6 in length Label Movement in Cutter Mode When the label is completely printed the printer feeds the media into the cutter mechanism The cutter blade is activated and the printer waits for the cutter mechanism to complete its cycle After cutting the printer backfeeds the media to the rest position or to the start of the next label if another label is in the print queue If the cut cycle is not completed the printer automatically stops the print cycle and turns the ERROR LED ON This will normally identify a cutter jam Refer to Appendix A for information on configuring the printer for the Cutter mode of operation
61. osition Key Press this key LED turns ON to change the image position setting by pressing the or Keys Each press of the or key changes the setting by four dot rows Press the Jmage Position key a second time to save the new setting From the default value the setting may be changed 120 or 120 dot rows Plus Key When setting print darkness each press of this key increases the dark ness setting by 1 When setting the label position each press of this key moves the label tear off cut off position four dot rows away from the end of the label just printed When setting the image position each press of this key moves the image four dot rows away from the leading edge of the label being printed Minus Key Pressing this key has the opposite effect on the settings from the PLUS key 68 Color profile Disabled Composite Default screen r H uspiran2 vp Thu Jun 18 16 03 35 1998 Printer Configuration Deluxe Front Panel NOTE To configure a Z Series printer having the standard front panel refer to the information found earlier in this section Deluxe Front Panel Control Keys Refer to Figure 26 Opening the door on the front panel provides access to the control keys used for configuring the printer s operating features The Liquid Crystal Display LCD shows the menus as you proceed through the configuration process Figure 26 Deluxe Front Panel The configuration sequence is a serie
62. password reguired H uspiran2 vp Thu Jun 18 16 03 37 1998 The printer will remain in the selected mode until it is changed by this parameter or by sending a ZPL ZPL Il command The printer accepts label formats written in either ZPL or ZPL Il This eliminates the need to rewrite any ZPL formats you already have Refer to the ZPL Programming Guide for more information Default ZPL Il Choices ZPL Il or ZPL Continued on the following page 76 Color profile Disabled Composite Default screen ADVANCED SETUP PARAMETER SELECTIONS BACKFEED In the Cutter mode this parameter establishes password when and how much label backfeed occurs after a required label is cut It has no effect in the Tear Off Peel or Rewind modes This parameter can be superseded by the JS instruction when received as part of a label format Refer to the ZPL Programming Guide Default Default default is defined as 90 Choices Default After Off Before 10 20 30 40 50 60 70 80 NOTE The difference between the value entered and 100 establishes how much backfeed occurs before the next label is printed For example a value of 40 means that 40 of the backfeed takes place after the label is cut The remaining 60 takes place before the next label prints A value of before means that all backfeed will take place before the next label is printed LEFT POSITION This parameter establishes how far from t
63. posite Default screen H uspiran2 vp Thu Jun 18 15 51 22 1998 Operating Modes When shipped from the factory the printer is preset to the most com monly 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 m Options such as Power Rewind Power Peel Value Peel or Cutter m Operating Modes m Print Darkness m Label Tear Off Cut Off Position m mage Position on the label Color profile Disabled Composite Default screen Media amp hibbon Loading Loading Media To load media refer to Figure 2 2 Raise the media cover Press the Printhead Open Lever e The Printhead Assembly f automatically springs up Fold down the Media Supply Guide g and slide it out as far from the printer frame as possible Slide the Media Guide h out as far from the printer frame as pos sible Determine the type of media reguired for your application and fol low the roll media or fanfold media loading procedure gt 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 Figure 2 Loading Media Z Series User s Guide H uspiran2 vp Thu Jul 02 09 48 43 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jul 02 09 48 45 1998 Roll Media Loadin
64. printed the printer feeds the label forward to the take label position The label hangs from the printer and is held in place by that portion of the label still attached to the backing material When the operator removes the label the printer moves the next label forward to pre peel a portion of the label from the backing The label then backfeeds to be printed As printing contin ues the backing material is wound onto the Take Up Spindle Refer to Appendix A for information on configuring the printer for either the Power Rewind or Power Peel mode of operation Figure 15 Media Loading Power Rewind Option Z Series User s Guide 36 H uspiran2 vp Wed Jul 08 11 38 51 1998 Color profile Disabled Composite Default screen Media Loading Refer to Figure 15 Power Rewind or Figure 16 Power Peel while loading media 1 Place the roll of media on the Media Supply Hanger i and push it on all the way Fold the Media Supply Guide g up and slide it against the outer edge of the media roll Press the Printhead Open Lever e and raise the Printhead Assembly Feed the media under the Media Spindle j under the Ribbon Sen sor k and out the front of the printer Slide the Media Guide h in until it is against the outer edge of the media Pull about three feet of media through the front of the printer For Power Rewind Pass the media down over the Media Plate u through the printer housing and under the Med
65. printer in tear off peel off or cutter mode bar code A code by which alphanumeric characters can be represented by a series of adjacent stripes of different widths Many different code schemes exist such as the universal product code UPC or Code 39 calibration of a printer A process in which the printer determines some basic information needed to print accurately with a particular media and ribbon combination To do this the printer feeds some media and ribbon if used through the printer and senses whether to use the direct thermal or thermal transfer print method and if using non continuous media the length of individual labels or tags character set The set of all letters numerals punctuation marks and other characters that can be expressed by a particular font or barcode check digit A character added to a barcode symbol that indicates to the scanner that it has read the symbol correctly continuous media Label or tagstock media that has no notch gap or web backing material only to separate the labels or tags the media is one long piece of material core diameter The inside diameter of the cardboard core at the center of a roll of media or ribbon cutter A device that can cut the media into individual labels or tags immediately after it is printed 89 H uspiran2 vp Thu Jun 18 16 05 27 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 05 27 1998 diagnostics In
66. printers identified as the Z Series Z4000TM amp Z Series Z6000TM manufactured by Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills Illinois 60061 3109 USA have been shown to comply with the applicable technical standards of the FCC for Home Office Commercial and Industrial use if no unauthorized change is made in the eguipment and if the eguipment is properly maintained and operated CL H uspiran2 vp Thu Jun 18 15 49 10 1998 Color profile Disabled Composite Default screen D Z Series User s Guide H uspiran2 vp Thu Jun 18 15 49 10 1998 Color profile Disabled Composite Default screen H uspiran2 vp Wed Jul 08 11 23 52 1998 Welcome Getting Started Communications Printer Power Printer Configuration Z Series Configuration Media amp Ribbon Loading Loading Media Loading Ribbon Removing Ribbon Media Sensor Positioning Media Sensor Operation Media Sensor Position Printer Operational Check Printer Operation Operator Interface Front Panel Keys Front Panel LEDs Additional Front Panel Controls Z Series User s Guide Contents 10 13 13 14 14 Color profile Disabled Composite Default screen H uspiran2 vp Wed Jul 08 11 23 52 1998 Auto Calibration Calibration Control Cleaning Lubrication Printhead Pressure Adjustment Power Rewind Power Peel Media Alignment LCD Display Deluxe Front Panel Power Rewind Power
67. r host com puter refer to the instruction manual provided with the computer The serial port supports an Error Detection Protocol which sends and receives data in packets This Zebra protocol must be compatible with your host computer and your application software Received packets are checked for accuracy If received correctly the data in the packet is processed and an acknowledge packet is sent back to the host If an error is found in the received packet either a negative acknowledge packet or no response will be sent to the host DO NOT enable Error Detection unless your host is programmed to use it For additional information refer to the ZPL JI Programming Guide If the Bank One switches are in the proper position to match the com munication configuration of the host computer and the printer is not receiving data see Appendix B to make sure you are using the correct interface cable BAUD RATE SWITCH 1 SWITCH 2 SWITCH 3 9600 ON ON ON 19200 OFF ON ON ON 28800 ON ON 38400 OFF ON 600 ON OFF 1200 OFF DIP Switch 2400 ON Positions 4800 OFF OFF OFF DATA BITS SWITCH 4 NOTE The printer requires one 1 8 Data Bits ON stop bit minimum on received data 7 Data Bits OFF and automatically supplies two 2 stop bits for transmitted data HANDSHAKE SWITCH 5 Xon Xoff ON DTR DSR OFF PARITY SWITCH 6 SWITCH 7 Parity Disabled ON ON Even OFF ON Odd ON OFF Parity Disabl
68. re the printer for the application Internal printer failure Call a Service Technician Table 2 Power ON Troubleshooting 45 H uspiran2 vp Thu Jun 18 16 02 05 1998 Color profile Disabled Composite Default screen SYMPTOM DIAGNOSIS ACTION Printer stops PAUSE LED ON and ERROR LED FLASHING Fast Printhead is not fully closed Close printhead completely Malfunctioning Printhead Open Sensor Call a Service Technician Printer stops PAUSE LED BLINKING Printer in Peel mode and no Peel option installed Change printer operating mode to fit application Printer stops PAUSE LED ON and ERROR LED FLASHING Slow Printhead element is overheated Printer resumes printing when the printhead element cools Dots missing in printed area of label Printhead element bad Print quality problems Replace the printhead Loss of printing registration on labels Possible Media Sensor problem Adjust Sensor Position and Call a Service Technician if necessary Printer set for non continuous media but continuous media loaded Set printer for correct media Improperly adjusted Media Guides Reposition Media Guides Excessive Vertical Drift in Top of Form registration Incorrect media loaded or Media Sensor adjustments Reload Media and check Media Sensor position Light vertical lines running through all labels D
69. removal of the fuse To install a new fuse reverse the seguence Shipping To ship the Z Series printer remove all ribbon and media from the supply and take up spindles to prevent damage to the printer Carefully pack the printer in a suitable container to avoid damage during transit Whenever possible use the original carton within a carton packing materials from the factory A shipping container can be purchased from Zebra Technologies Corporation if the original packaging is lost or de stroyed If you use a different container package the printer carefully to avoid damage CAUTION When packaging the printer in a rigid container use shock mounts or shock absorbing packing material Setting Darkness For In Spec Bar Codes All Direct Thermal and Thermal Transfer materials do not have the same Darkness reguirements The best way to check for the proper darkness setting is to use a Bar Code Verifier that actually measures bars spaces and will calculate the PCS ratio Without the assistance of a verifier your eyes and or the scanner to be used in the system are the best bet for picking the optimum darkness setting The following is a simple yet effective method for adjusting the darkness setting to print In Spec bar codes Refer to Figure 31 for sample bar codes Color profile Disabled Composite Default screen 1 Load media and Ribbon if required according to the appro priate Media Loading and Ribbon Load
70. res Default Tear Off Choices Tear Off Rewind Cutter Peel Off LABEL TOP This value sets the print position vertically on the label A more positive value moves the label top position farther down the label A negative value moves the label top position up the label Default 00 Range 120 to 120 LCD ADJUST If the LCD is difficult to read use the PLUS key or MINUS key to adjust the brightness of your display Default 10 Range 00 to 19 Continued on the following page Table 10 Deluxe Front Panel Configuration 71 H uspiran2 vp Thu Jun 18 16 03 36 1998 Color profile Default screen COMMUNICATIONS PARAMETER SELECTIONS BAUD password reguired Select the value that matches the one used by the host Default 9600 Choices 600 1200 2400 4800 9600 19200 28800 or 38400 DATA BITS password reguired Select the value that matches the one used by the host Must be set to 8 data bits to use Code Page 850 Default 8 bits character Choices 7 bits character or 8 bits character NOTE The printer reguires one 1 stop bit minimum on received data and automatically supplies two 2 stop bits for transmitted data PARITY password reguired Select the value that matches the one used by the host Default None Choices Even Odd None HOST HANDSHAKE password reguired Select the value that matches the one used by the host Default XON
71. rmally OFF When data is received the LED acts as follows m SLOW BLINK Printer is unable to accept more data from the host m FAST BLINK Printer is receiving data m 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 m SLOW BLINK Ribbon In Warning Under Temp Warning or Over Temp Error m FAST BLINK Printhead Open m LED ON Media Out Ribbon Out or Cutter Errors With the Deluxe Front Panel the type of error will also be visible on the Liguid 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 reguested 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 Color profile Disabled Composite De
72. s of menus and prompts with pro grammable parameters for each menu listing START SAVE Key Press this key to enter the configuration mode Once in the configura tion mode the first major menu selection General Setup is displayed Z Series User s Guide 69 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 03 36 1998 NEXT MENU Key Press this key to increment through the major menu headings showing the top level of each configuration section When the end of the menu listing is reached the list repeats automatically NEXT ITEM Key Once the appropriate major menu is visible on the LCD display the NEXT ITEM key can be used to seguence through the configuration prompts for that menu When the end of the item listing is reached the list repeats automatically When the appropriate item is displayed the PLUS and MINUS keys can be used to select the setting for that item PLUS Key Press this key to increment the value of the item selected on the LCD MINUS Key Press this key to decrement the value of the item selected on the LCD NOTE When entering specific numeric values use the MINUS key to select the digit position and the PLUS key to select the value for that position Front Panel Programming Table 10 provides the printer configuration parameters in the seguence in which they appear on the front panel LCD display The DEFAULT value as well as the availab
73. safety always use A a three prong plug with an earth ground connection to the AC Power Source AC Power Cord Specifications m The overall length must be less than 9 8ft 3 0 meters E t must be rated for at least 5A 250V m The chassis ground earth MUST be connected to assure safety and reduce electromagnetic interference The ground connection is handled by the third wire earth in the power cord m The AC power plug and IEC320 connector must bear the certification mark of at least one of the Known international safety organizations shown in Figure 30 IEC 320 CONTACT 3conpucToR CONNECTOR VIEW AC POWER lt HAR gt CABLE NEUTRAL m YOUR COUNTRY a ll NE RA G N Q 00 NOETH G3 0 GD SO Figure 30 AC Power Cord Requirements H uspiran2 vp Thu Jun 25 11 20 47 1998 Color profile Disabled Composite Default screen A H uspiran2 vp Thu Jun 25 11 20 47 1998 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 the AC Power Switch OFF and unplug the AC Power Cable To replace the fuse insert the tip of a flatblade screwdriver into the slot in the end of the Fuse Holder End Cap Press in slightly on the End Cap and turn the screwdriver slightly counterclockwise This will disengage the End Cap from the Fuse Holder and permit
74. sm by gently lifting up on the Media Plate and pivoting it toward you Refer to Figure 12 The primary area requiring cleaning is the backside of the Separator Bar Remove the major portion of the accumulated adhesive by pressing the sticky side of a blank label against the adhesive and lifting it away Do this step repeatedly until most of the adhesive is gone Aggressively wipe the area with a cloth soaked in alchohol to remove any residual adhesive Move the media backing material out of the way to allow inspec tion of the Tear Peel Bar If any adhesive has accumulated repeat the cleaning process on the Tear Peel Bar When the cleaning process is completed align the media backing material and return the Media Plate to the operating position Align the ribbon if used as you close and latch the Printhead Assembly 10 Close the Media Door and resume operation Z Series User s Guide 32 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 15 58 03 1998 Lubrication CAUTION No lubricating agents of any kind should be used on this printer Some commercially available lubricants if used will damage the finish and the mechanical parts inside the printer Printhead Pressure Adjustment Printhead pressure is adjustable to insure maximum print guality Refer to Figure 13 and rotate the Pressure Adjustment Dials s amp t clockwise to increase the pressure or counterclockwise to d
75. t computer may send data DTR ACTIVE positive voltage permits the host to send data When the printer places DTR in the INACTIVE negative voltage state the host must not send data NOTE When Xon Xoff handshaking is selected data flow is controlled by the ASCII Control Codes DCI XON and DC3 XOFF The DTR Control lead will have no effect Reguest To Send RTS is a control signal from the printer which is connected to the Clear To Send CTS input at the host computer RTS is always ACTIVE positive voltage when the printer is ON CAUTION The Z Series printers comply with FCC Rules and Regulations Part 15 for Class B Equipment using fully shielded six foot data cables Use of longer cables or unshielded cables may increase radiated emissions above the Class B limits RS 485 Interface Figure 29 illustrates the pin connections on the DB 25 connector at the rear of the printer which are used for the RS 485 communication protocol NOTE Xon Xoff handshaking must be used for RS 485 communications DB 25P Connector to Printer hield Signal Ground Reference Data Input A Data Output A 14 Data Input B 16 lt Data Output B 19 U Figure 29 RS 485 Cable Parallel Data Communications Table 12 illustrates the pin connections on the Bi directional Parallel connector at the rear of the printer Parallel Interface The 8 Bit Parallel Da
76. ta Interface supports IEEE 1284 bi directional parallel communications in nibble mode The parallel interface pro vides a means of communication which is typically faster than the pre viously mentioned serial interface methods In this method the bits of data which make up a character are sent all at one time over several wires in the cable one bit per wire Parallel Cabling Reguirements An IEEE 1284 compatable bi directional parallel data cable is reguired when this communication method is used The reguired cable must have a standard 36 pin parallel connector on one end which is plugged into the mating connector located at the rear of the printer The other end of the cable connects to the printer connector at the host computer PARALLEL CONNECTOR PINOUT nStrobe Host Clk Data Bits 1 8 nAck PtrClk Busy Per Busy PError Ack Data Req Select Xflag nAuto Fd Host Busy Not Used Ground 5V Q9 1A Ground ninit nFault nData Avail Not Used 5V thru 3 3KQ Resistor nSelectln 1284 active Table 12 Rear Panel Parallel Data Connector Pinout Color profile Disabled Composite Default screen AC Power Cord Since many areas of the world have specific power requirements an AC Power Cord may not be included with your printer Refer to Figure 30 A power cord must be provided by you that meets your local elec trical requirements s ED WARNING For personnel and equipment
77. the Spindle Z Series User s Guide Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 15 54 02 1998 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 start of 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 SLL command in each label format you send to the printer refer to your ZPL II Program ming 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 Mo
78. turning the printer power ON Re lease the key anytime after the first front panel LED turns OFF The guantity of labels printed during this print guality test depends on the dot density of the printhead m 300 dpi printers 7 labels are printed at the 2 ips and 6 ips print speeds m 200 dpi printers 7 labels are printed at the 2 ips 6 ips and 10 ips print speeds Each label is printed at a different darkness setting starting at three set tings below the currently configured value and continuing to increase until it is three settings darker than the configured value The relative darkness and speed are printed on each label The bar codes on these labels can be ANSI graded to check print quality Figure 21 provides an example of the FEED key self test label Relative Darkness Print Speed 2 in sec VXXX mOSPis Te ZAXMANLSYOdONW DIDIHO 130989 zfixman sibdouw gt fty8sepoqe szIB6BS GGRPZI TO te a m J oo wo 5m ra n 123456789x 123456799 ABCDEFGHI JKLMNOPQRSTUVWXYZ abcdefghijkKlmnopgrstuvwxyz Figure 21 FEED Key Self Test Label 51 H uspiran2 vp Thu Jun 18 16 02 07 1998 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 02 07 1998 PAUSE and CANCEL Key Self test Press and hold both the PAUSE key and CANCEL key while turning the printer power ON Releas
79. ut A 69 Input B 69 Output A 69 Output B 69 Signal Ground 69 RTS Request To Send 71 Self Test Labels 38 Self Tests Power ON 35 Printer 38 Sensor Positioning 9 Settings Communicaitons 56 Darkness 58 Operating Modes 57 Print Darkness 58 Shipping 74 Shipping Container 74 Shipping Damage 1 Specifications 48 Standard Fonts 51 Storage and Reshipping 71 Switch Settings 55 96 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 16 05 51 1998 Troubleshooting 35 Unpacking 1 Warning AC Power 2 73 Earth Ground 2 73 Eguipment Safety 2 73 Personnel Safety 2 73 ZPLII 1 17 50 ZPL II Instructions Changing Prefixes amp Delimiters CC CD CT 37 Configuration Update JUS 44 Label Length LL 9 97 Color profile Disabled Composite Default screen D Z Series User s Guide 98 H uspiran2 vp Thu Jun 18 16 05 52 1998
80. ve 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 Color profile Disabled Composite Default screen H uspiran2 vp Thu Jun 18 15 54 04 1998 sensor anywhere under the media so that an Out of Media condi tion will still be sensed Insure the media and ribbon are properly positioned within the print mechanism then close the Printhead Assembly Close the printer s media cover then turn the printer power OFF 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 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 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 gu
81. wing 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 Remove the media and ribbon if present 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 sec onds 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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