Zebra Z Series Zm400 Users Manual ZM400/ZM600 User Guide

ZM400 to the manual 8c8ce421-1cff-4806-a3c0-c032109e0d51

2015-01-26

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Declaration of Conformity
- Compliance Information
Contents
About This Document
Introduction
Printer Setup
Operations
Configuration
Routine Maintenance
Troubleshooting
Specifications
Index

ZM400/ZM600

Industrial/Commercial Printer

User Guide

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

firmware 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.

This product may contain ZPL®, ZPL II®, and ZebraLink™ programs; Element Energy Equalizer® Circuit;

ZebraLink and all product names and numbers are trademarks, and Zebra, the Zebra logo, ZPL, ZPL II, Element

All other brand names, product names, or trademarks belong to their respective holders. For additional

trademark information, please see “Trademarks” on the product CD.

Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation

and its subsidiaries (“Zebra Technologies”). It is intended solely for the information and use of parties operating

and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or

disclosed to any other parties for any other purpose without the express, written permission of Zebra

Technologies Corporation.

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

Corporation. All specifications and designs are subject to change without notice.

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

specifications and manuals are correct; however, errors do occur. Zebra Technologies Corporation reserves the

right to correct any such errors and disclaims liability resulting therefrom.

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

creation, production, or delivery of the accompanying product (including hardware and software) be liable for

any damages whatsoever (including, without limitation, consequential damages including loss of business

profits, business interruption, or loss of business information) arising out of the use of, the results of use of, or

inability to use such product, even if Zebra Technologies Corporation has been advised of the possibility of such

damages. Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so

the above limitation or exclusion may not apply to you.

Part Number: 79695L-001 Rev. A

iii

Declaration of Conformity

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Declaration of Conformity

I have determined that the Zebra printers identified as the

ZM™ Series

Z4M, Z6M, Z4Mplus, Z6Mplus, R4Mplus, ZM400, ZM600

manufactured by:

Zebra Technologies Corporation

333 Corporate Woods Parkway

Vernon Hills, Illinois 60061-3109 U.S.A.

Have been shown to comply with the applicable technical standards of the FCC

For Home, Office, Commercial, and Industrial use

If no unauthorized change is made in the equipment,

and if the equipment is properly maintained and operated.

Compliance Information

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Compliance Information

FCC Compliance Statement

This device complies with Part 15 rules. Operation is subject to the following two conditions:

1. This device may not cause harmful interference, and

2. This device must accept any interference received, including interference that may cause

undesired operation.

The user is cautioned that any changes or modifications not expressly approved by Zebra

Technologies Corporation could void the user’s authority to operate the equipment. To ensure

compliance, this printer must be used with Shielded Communication Cables.

FCC Rules and Regulations for Data Cables

Zebra printers comply with FCC Rules and Regulations, Part 15 for Class B Equipment using

fully shielded, 6.5 ft. (2 m) data cables. Use of unshielded cables may increase radiation above

the Class B limits.

Canadian DOC Compliance Statement

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

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

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Contents

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Compliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Web Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

The Americas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Europe, Africa, Middle East, and India . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Asia Pacific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 • Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Control Panel Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Printer Language Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Firmware Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Additional Printer Language Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Contents

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

2 • Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Ship the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Select a Site for the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Select a Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Provide a Data Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Provide a Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Select a Data Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Data Cables and Wireless Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connect the Printer to the Computer or Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Ribbon Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

When to Use Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Coated Side of Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3 • Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Print Modes and Printer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Print Mode Descriptions and Printer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Media Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Beginning Steps for all Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . 33

Additional Steps for Tear-Off Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Additional Steps for Peel-Off Mode (with or without Liner Take-Up). . . . . . . . . . . . . . 37

Additional Steps for Cutter or Delayed Cut Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Additional Steps for Rewind Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Load Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Remove Used Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

vii

Contents

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

4 • Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Enter Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Exit Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Default Password Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Print a Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Print a Network Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Control Panel Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

How to View or Modify Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Additional Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Standard Printer Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5 • Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Replacing Printer Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Cleaning Schedule and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Clean the Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Clean the Printhead and Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Clean the Media Compartment and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Clean the Cutter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Routine Maintenance for the Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Remove Printed Labels or Liner from the Rewind Spindle . . . . . . . . . . . . . . . . . . . . . 96

Adjust Media Alignment for Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

6 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Troubleshooting Checklists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Calibration Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Communications Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

Miscellaneous Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Contents

viii

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

Power-On Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

FEED Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

FEED and PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

7 • Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Agency Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Printing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

About This Document

This section provides you with contact information, document structure and organization, and

additional reference documents.

Contents

Who Should Use This Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

About This Document

Who Should Use This Document

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Who Should Use This Document

This User Guide is intended for use by any person who needs to operate or to troubleshoot

problems with the printer.

How This Document Is Organized

The User Guide is set up as follows:

Section Description

Introduction on page 7 This section shows the operational controls and

location of major components used when loading

media.

Printer Setup on page 15 This section provides the tasks that you must

complete and the issues that you must consider

before you load and configure your printer.

Operations on page 29 This section provides the procedures for loading

and calibrating the printer.

Configuration on page 55 This section describes the control panel parameters

that are used to configure the printer for operation.

Routine Maintenance on page 87 This section provides routine cleaning and

maintenance procedures.

Troubleshooting on page 99 This section provides information about errors that

you might need to troubleshoot. Assorted

diagnostic tests are included.

Specifications on page 123 This section provides the features of and

specifications for the printer.

About This Document

Contacts

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Contacts

You can contact Zebra Technologies Corporation at the following:

Web Site

http://www.zebra.com

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

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

The Americas

Europe, Africa, Middle East, and India

Asia Pacific

Regional Headquarters Technical Support Customer Service Dept.

Zebra Technologies International,

LLC

333 Corporate Woods Parkway

Vernon Hills, Illinois 60061.3109

U.S.A

T: +1 847 793 2600

Toll-free +1 800 423 0422

F: +1 847 913 8766

T: +1 847 913 2259

F: +1 847 913 2578

Hardware: hwtsamerica@zebra.com

Software: swtsamerica@zebra.com

For printers, parts, media, and ribbon,

please call your distributor, or

T: +1 866 230 9494

E: VHCustServ@zebra.com

Regional Headquarters Technical Support Internal Sales Dept.

Zebra Technologies Europe Limited

Zebra House

The Valley Centre, Gordon Road

High Wycombe

Buckinghamshire HP13 6EQ, UK

T: +44 (0)1494 472872

F: +44 (0) 1494 450103

T: +44 (0) 1494 768298

F: +44 (0) 1494 768210

Germany: Tsgermany@zebra.com

France: Tsfrance@zebra.com

Spain/Portugal: Tsspain@zebra.com

All other areas: Tseurope@zebra.com

For printers, parts, media, and ribbon,

please call your distributor, or

T: +44 (0) 1494 768316

F: +44 (0) 1494 768244

E: mseurope@zebra.com

Regional Headquarters Technical Support Customer Service

Zebra Technologies Asia Pacific, LLC

16 New Industrial Road

#05-03 Hudson TechnoCentre

Singapore 536204

T: +65 6858 0722

F: +65 6885 0838

T: +65 6858 0722

F: +65 6885 0838

E: tsasiapacific@zebra.com

For printers, parts, media, and ribbon,

please call your distributor, or

T: +65 6858 0722

F: +65 6885 0837

About This Document

Document Conventions

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Document Conventions

The following conventions are used throughout this document to convey certain information.

Alternate Color (online only) Cross-references contain hot links to other sections in this

guide. If you are viewing this guide online in .pdf format, you can click the cross-reference

(blue text) to jump directly to its location.

LCD Display Examples Text from a printer’s Liquid Crystal Display (LCD) appears in

Bubbledot ICG font.

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

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

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

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

Icons Used

Caution • Warns you of the potential for electrostatic discharge.

Caution • Warns you of a potential electric shock situation.

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

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

harm to you.

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

physical harm to the hardware.

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

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

points of the main text.

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

About This Document

Document Conventions

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Illustration Callouts Callouts are used when an illustration contains information that needs

to be labeled and described. A table that contains the labels and descriptions follows the

graphic. Figure 1 provides an example.

Figure 1 • Sample Figure with Callouts

1FEED button

2CANCEL button

About This Document

Document Conventions

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Notes • ___________________________________________________________________

__________________________________________________________________________

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Introduction

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

loading media.

Contents

External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Printer Media Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Control Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Printer Language Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Introduction

External View

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

External View

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

Figure 2 • Front of Printer

Figure 3 • Rear of Printer

1Control panel

2Media door

1Power switch (O = off, I = on) 5Serial port

2AC power connector 6Internal wired print server port (Ethernet)

3Wireless print server card slot (Ethernet) 7USB port

4Wireless card ejector button 8Parallel port

Introduction

Printer Media Compartment

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Printer Media Compartment

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

installed options, your printer may look slightly different.

Figure 4 • Printer Components

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

Zebra strongly recommends the use of genuine Zebra™ supplies as part of the total solution.

Specifically, the ZM400 and ZM600 are designed to work only with genuine Zebra™

printheads, thus maximizing safety and print quality.

1Printhead assembly 6Ribbon take-up spindle

2Control panel 7Ribbon supply spindle

3Media door 8Dancer assembly

4Media supply guide 9Printhead release latch

5Media supply hanger

Introduction

Control Panel

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Control Panel

The control panel contains the lights that indicate basic operation and the buttons that you may

need to press during basic operation. The control panel buttons and lights are labeled in

Figure 5. Descriptions for each are located in Table 1 and Table 2.

Figure 5 • Control Panel

1Power LED

2Pause LED

3Error LED

4Data LED

5LCD

6CANCEL button

7PLUS (+) button

8SETUP/EXIT button

9MINUS (–) button

10 SELECT button

11 FEED button

12 PAUSE button

1 2 3 4

Introduction

Control Panel

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Control Panel Buttons

Table 1 • Control Panel Buttons

Button Function

FEED Forces the printer to feed one blank label each time the button is pressed.

• Printer not printing: one blank label immediately feeds.

• Printing: one blank label feeds after the current batch of labels is complete.

PAUSE Starts and stops the printing process.

• Printer not printing: no printing occurs. (Press PAUSE again to resume printing.)

• Printing: printing stops after the current label is complete.

CANCEL Cancels print jobs when the printer is paused.

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

• Printing: current label completes printing, and the next label format is cancelled.

Press and hold for several seconds to cancel all print jobs in memory.

SETUP/EXIT Enters and exits the configuration mode.

SELECT Toggles the function of PLUS (+) and MINUS (–) between the Scroll and Change

Modes.

• Press once to use PLUS (+) and MINUS (–) to change the values of the selection.

• Press again to use PLUS (+) and MINUS (–) to scroll through the menu items.

PLUS (+)

(scroll mode) Scrolls to the next selection.

PLUS (+)

(change mode) • Increases the value.

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

MINUS (–)

(scroll mode) Scrolls to the previous selection.

MINUS (–)

(change mode) • Decreases the value.

• Moves to the next available digit in a number.

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

Introduction

Control Panel

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Control Panel Lights

Table 2 • Control Panel Lights

Light Status Indication

POWER Off The printer is off, or no power is applied.

On The printer is on.

PAUSE Off Normal printer operation.

On The printer has stopped all printing operations.

Flashing The Pause light flashes when initializing FLASH memory and in

Peel-Off Mode when the label is available.

ERROR Off Normal printer operation (no errors).

On An error condition is preventing printing. This includes MEDIA

OUT and RIBBON OUT errors.

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

includes RIBBON IN warning, HEAD UNDER TEMP warning,

and HEAD OVER TEMP error.

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

One flash CANCEL was pressed and a format is successfully cancelled.

Slow flashing The printer cannot accept more data from the host.

Fast flashing The printer is receiving data.

On A partial format has been received and no subsequent data activity.

Introduction

Printer Language Modes

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Printer Language Modes

Depending on how your printer was ordered, it came from the factory with firmware that

operates in or allows you to use certain commands for one of the following printer languages:

• Zebra Programming Language (ZPL®)

•Eltron

® Programming Language (EPL™)

Firmware Downloads

You may download firmware to the printer at any time to change from one printer language to

another. For the latest firmware versions and instructions for downloading them, go to

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

Additional Printer Language Information

The following manuals contain specific information about the different printer language

modes. Copies of these manuals are on the CD that came with your printer and at

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

•ZPL II

® Programming Guide

• EPL2™ Programming Guide

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

appear on the LCD, and some control panel lights may activate in error mode. You may

ignore these error messages and lights. When the firmware download is complete, reboot the

printer and then load printer defaults to return the printer to Operating mode.

Introduction

Printer Language Modes

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Notes • ___________________________________________________________________

__________________________________________________________________________

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Printer Setup

This section provides the tasks that you must complete and the issues that you must consider

before you load and configure your printer.

Contents

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Ship the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Select a Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Provide a Data Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Provide a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Select a Data Communication Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Data Cables and Wireless Cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connect the Printer to the Computer or Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Types of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Ribbon Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

When to Use Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Coated Side of Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Printer Setup

Before You Begin

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Before You Begin

Review this checklist, and resolve any issues before you set up or use your printer.

Unpack and Inspect the Printer Have you unpacked the printer and inspected it for

damage? If you have not, see Unpack and Inspect the Printer on page 17.

Select a Site Have you selected an appropriate location for the printer? If you have not,

see Select a Site for the Printer on page 18.

Connect to a Data Source Have you determined how the printer will connect to a

data source (usually a computer)? For more information, see Select a Data

Communication Interface on page 19.

Attach a Power Cord Do you have the correct power cord for your printer? If you are

unsure, see Power Cord Specifications on page 24. To attach the power cord and connect

the printer to a power source, see Connect the Printer to a Power Source on page 23.

Select Media Do you have the correct media for your application? If you are unsure,

see Types of Media on page 25.

Select Ribbon Do you need to use ribbon, and is the appropriate ribbon available, if

needed? If you are unsure, see Ribbon Overview on page 27.

Printer Setup

Handling the Printer

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Handling the Printer

This section describes how to handle your printer.

Unpack and Inspect the Printer

When you receive the printer, immediately unpack it and inspect for shipping damage.

• Save all packing materials.

• Check all exterior surfaces for damage.

• Raise the media door, and inspect the media compartment for damage to components.

If you discover shipping damage upon inspection:

• Immediately notify the shipping company and file a damage report.

• Keep all packaging material for shipping company inspection.

• Notify your authorized Zebra reseller

Store the Printer

If you are not placing the printer into immediate operation, repackage it using the original

packing materials. You may store the printer under the conditions shown in Table 3.

Ship the Printer

If you must ship the printer:

• Turn off (O) the printer, and disconnect all cables.

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

• Close the printhead.

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

avoid damage during transit. A shipping container can be purchased from Zebra if the

original packaging has been lost or destroyed.

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

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

Table 3 • Storage Temperature and Humidity

Temperature Relative Humidity

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

Printer Setup

Select a Site for the Printer

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Select a Site for the Printer

Consider the following when selecting an appropriate location for your printer.

Select a Surface

Select a solid, level surface of sufficient size and strength to accommodate the printer and

other equipment (such as a computer), if necessary. The choices include a table, countertop,

desk, or cart. For the printer’s weight and dimensions, see General Specifications on page 124.

Provide Proper Operating Conditions

This printer is designed to function in a wide range of environmental and electrical conditions,

including a warehouse or factory floor. For more information on the required conditions, see

General Specifications on page 124.

Table 4 shows the temperature and relative humidity requirements for the printer when it is

operating.

Allow Proper Space

The printer should have enough space around it for you to be able to open the media door. To

allow for proper ventilation and cooling, leave open space on all sides of the printer.

Provide a Data Source

If the printer will be located away from the data source (such as a computer), the selected site

must provide the appropriate connections to that data source. For more information on the

types of communication interfaces and their limitations, see Select a Data Communication

Interface on page 19.

Provide a Power Source

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

Table 4 • Operating Temperature and Humidity

Mode Temperature Relative Humidity

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

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

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

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

Printer Setup

Select a Data Communication Interface

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Select a Data Communication Interface

Table 5 provides basic information about data communication interfaces that you can use to

connect your printer to a computer. You may send label formats to the printer through any data

communication interface that is available. Select an interface that is supported by both your

printer and your computer or your Local Area Network (LAN).

Table 5 • Characteristics of the Data Communication Interfaces

Interface Standard or

Optional on

Printer Characteristics

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

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

computer.

• You need to use a null-modem adaptor to connect to the printer

if using a standard modem cable.

IEEE 1284

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

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

• No printer parameter changes required to match the host

computer.

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

• No printer parameter changes required to match the host

computer.

Internal wired

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

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

pages.

• Computer must be equipped with an Ethernet board.

• The printer must be configured to use your LAN.

Wireless Ethernet

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

Local Area Network (WLAN).

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

pages.

• Computer must be equipped with an Ethernet board.

• The printer must be configured to use your WLAN.

Printer Setup

Select a Data Communication Interface

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Data Cables and Wireless Cards

You must supply all data cables or wireless cards for your application.

Data Cables Ethernet cables do not require shielding, but all other data cables must be fully

shielded and fitted with metal or metallized connector shells. Unshielded data cables may

increase radiated emissions above the regulated limits.

To minimize electrical noise pickup in the cable:

• Keep data cables as short as possible.

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

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

Wireless Cards For supported wireless cards, refer to the ZebraNet Wireless Print Server

and Wireless Plus Print Server User Guide. A copy of the manual is available at

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

Connect the Printer to the Computer or Network

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

The connectors on the back of your computer may be in different locations than on the sample

computer shown in this section. For another view of the connectors on the printer, see Figure 3

on page 8.

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

cables. Connecting a data communications cable while the power is on (I) may damage the

printer.

Table 6 • Connecting the Printer to a Computer or Network

Interface Connection and Configuration

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

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

Control Panel Parameters on page 61 to view or change these parameters.

Printer Setup

Select a Data Communication Interface

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

IEEE 1284

Bidirectional

Parallel

No additional configuration is necessary.

USB No additional configuration is necessary.

Caution • Be careful not to plug the USB cable into the wired Ethernet

print server connector on the printer because doing so will damage the

connector.

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

Interface Connection and Configuration

Printer Setup

Select a Data Communication Interface

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Internal wired

Ethernet print

server

Refer to the ZebraNet 10/100 Print Server User and Reference Guide for

configuration instructions. A copy of this manual is available at

http://www.zebra.com/manuals or on the user CD that came with your

printer.

Wireless

Ethernet print

server

Refer to the ZebraNet Wireless Print Server and Wireless Plus Print

Server User Guide for configuration instructions. A copy of this manual is

available at http://www.zebra.com/manuals or on the user CD that came

with your printer.

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

Interface Connection and Configuration

Printer Setup

Connect the Printer to a Power Source

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Connect the Printer to a Power Source

The AC power cord must have a three-prong female connector on one end that plugs into the

mating AC power connector at the rear of the printer. If a power cable was not included with

your printer, refer to Power Cord Specifications on page 24.

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

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

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

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

4. Turn on (I) the printer.

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

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

power cord specific to the region or country intended for installation. This cord must use an

IEC 320 female connector and the appropriate region-specific three-conductor grounded

plug configuration.

Printer Setup

Connect the Printer to a Power Source

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Power Cord Specifications

Depending on how your printer was ordered, a power cord may or may not be included. If one

is not included or if the one included is not suitable for your requirements, see Figure 6 and

refer to the following guidelines:

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

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

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

interference.

Figure 6 • Power Cord Specifications

Figure 7 • International Safety Organization Certifications

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

power cord specific to the region or country intended for installation. This cord must use an

IEC 320 female connector and the appropriate region-specific, three-conductor grounded

plug configuration.

1AC power plug for your country—This should bear

the certification mark of at least one of the known

international safety organizations (Figure 7).

23-conductor HAR cable or other cable approved for

your country.

3IEC 320 connector—This should bear the

certification mark of at least one of the known

international safety organizations (Figure 7).

4Length ≤ 9.8 ft. (3 m). Rating 10 Amp, 250 VAC.

Printer Setup

Types of Media

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Types of Media

Your printer can use various types of media:

•Standard media—Most standard media uses an adhesive backing that sticks individual

labels or a continuous length of labels to a liner.

•Tag stock—Tags are usually made from a heavy paper. Tag stock does not have adhesive

or a liner, and it is typically perforated between tags.

•Radio frequency identification (RFID) “smart” media—RFID

media can be used in a printer that is equipped with an RFID

reader/encoder. RFID labels are made from the same materials and

adhesives as non-RFID labels. Each label has an RFID transponder

(sometimes called an “inlay”), made of a chip and an antenna,

embedded between the label and the liner. The shape of the transponder varies by

manufacturer and is visible through the label. All “smart” labels have memory that can be

read, and many have memory that can be encoded.

Table 7 on page 26 describes roll and fanfold media. Roll media is loaded into the printer

while fanfold media may be located inside or outside of the printer.

Important • Zebra strongly recommends the use of Zebra-brand supplies for continuous

high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl stock has

been specifically engineered to enhance the printing capabilities of the printer and to prevent

premature printhead wear. To purchase supplies, go to http://www.zebra.com/howtobuy.

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

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

Printer Setup

Types of Media

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Table 7 • Roll and Fanfold Media

Media Type How It Looks Description

Non-Continuous

Roll Media Roll media is wound on a 3-in. (76-mm) core. Individual

labels are separated by one or more of the following methods:

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

•Black mark media uses pre-printed black marks on the back

side of the media to indicate label separations.

•Perforated media has perforations that allow the labels or

tags to be separated from each other easily. The media may

also have black marks or other separations between labels

or tags.

Non-Continuous

Fanfold Media Fanfold media is folded in a zigzag pattern. Fanfold media can

have the same label separations as non-continuous roll media.

The separations would fall on or near the folds.

Continuous

Roll Media Roll media is wound on a 3-in. (76-mm) core.

Continuous roll media does not have gaps, holes, notches, or

black marks to indicate label separations. This allows the

image to be printed anywhere on the label. Sometimes a cutter

is used to cut apart individual labels.

Printer Setup

Ribbon Overview

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Ribbon Overview

Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is

transferred to the media during the thermal transfer process. The media determines whether

you need to use ribbon and how wide the ribbon must be.

When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is

narrower than the media, areas of the printhead are unprotected and subject to premature wear.

When to Use Ribbon

Thermal transfer media requires ribbon for printing while direct thermal media does not.

To determine if ribbon must be used with a particular media, perform a media scratch test.

To perform a media scratch test, complete these steps:

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

2. Did a black mark appear on the media?

Coated Side of Ribbon

Ribbon can be wound with the coated side on the inside or outside. The ribbon used must

match the Thermal Transfer option installed. The standard Thermal Transfer option (black

ribbon spindle) uses ribbon coated on the outside, and the alternate Thermal Transfer option

(gray ribbon spindle) uses ribbon coated on the inside. If you are unsure which side of a

particular roll of ribbon is coated, perform an adhesive test or a ribbon scratch test to

determine which side is coated.

Adhesive Test

If you have labels available, perform the adhesive test to determine which side of a ribbon is

coated. This method works well for ribbon that is already installed.

To perform an adhesive test, complete these steps:

1. Peel a label from its liner.

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

3. Peel the label off of the ribbon.

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

Does not appear on the media Thermal transfer. A ribbon is required.

Appears on the media Direct thermal. No ribbon is required.

Printer Setup

Ribbon Overview

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

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

Ribbon Scratch Test

Perform the ribbon scratch test when labels are unavailable.

To perform a ribbon scratch test, complete these steps:

1. Unroll a short length of ribbon.

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

ribbon in contact with the paper.

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

4. Lift the ribbon from the paper.

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

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

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

used with the standard Thermal Transfer

option (black ribbon spindle). In the ribbon

loading procedure, instructions are marked

with this symbol.

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

used with the alternate Thermal Transfer

option (gray ribbon spindle). In the ribbon

loading procedure, instructions are marked

with this symbol.

If the ribbon... Then...

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

used with the standard Thermal Transfer

option (black ribbon spindle). In the ribbon

loading procedure, instructions are marked

with this symbol.

Did not leave a mark on the

paper The ribbon is coated on the inside and can be

used with the alternate Thermal Transfer

option (gray ribbon spindle). In the ribbon

loading procedure, instructions are marked

with this symbol.

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Operations

This section provides the procedures for loading and calibrating the printer.

Note • Complete the tasks and resolve the issues in Printer Setup on page 15 before

operating the printer.

Contents

Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Print Mode Descriptions and Printer Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Media Paths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Beginning Steps for all Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . . 33

Additional Steps for Tear-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Additional Steps for Peel-Off Mode (with or without Liner Take-Up) . . . . . . . . . . . . . . 37

Additional Steps for Cutter or Delayed Cut Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Additional Steps for Rewind Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Load Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Remove Used Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Manual Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Operations

Print Modes and Printer Options

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Print Modes and Printer Options

The printer can use different print modes and options for label removal (Table 8). Use a print

mode that matches the media being used and the printer options available. For more

information on the types of media, see Types of Media on page 25. To select a print mode, see

Select Print Mode on page 64.

Print Mode Descriptions and Printer Requirements

Table 8 • Print Modes and Printer Options

Print Mode When to Use/Printer Options Required Printer Actions

Tear-Off

(default setting) Use for most applications. This mode can

be used with any printer options and most

media types.

The printer prints label formats as it

receives them. The printer operator can tear

off the printed labels any time after they

print.

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

Liner Take-Up, or Rewind option. The printer peels the label from the liner

during printing and then pauses until the

label is removed.

In Peel-Off mode, the liner exits the front of

the printer. In Peel-Off mode with Liner

Take-Up, the liner winds onto the liner

take-up spindle or the rewind spindle.

Cutter Use if the printer has a cutter option when

you want the labels to be cut apart. The printer prints a label and then cuts it

free.

Delayed Cut Use if the printer has a cutter option when

you want the printer to cut the labels apart

at a signal.

The printer prints a label, pauses, and cuts

the label when it receives the ~JK (delayed

cut) ZPL command.

Rewind Use if the printer has the Rewind option and

you want the labels to rewind on a core. The printer prints without pausing between

labels. The media or liner is wound onto a

core after printing.

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

Linerless

Rewind Reserved for future options. Reserved for future options.

Operations

Print Modes and Printer Options

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Media Paths

Table 9 shows the media paths for print mode and printer option combinations using roll

media. Fanfold media uses the same print modes and printer options as roll media.

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

Print Mode Printer Option Media Path

Tear-Off Printers with any

printer options can

use Tear-Off mode

Peel-Off Peel, Liner take-up,

or Rewind

Peel-Off (with Liner

Take-Up) Liner take-up

Rewind

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

Operations

Print Modes and Printer Options

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Cutter or

Delayed Cut Cutter (shown with

an optional catch

tray)

Rewind Rewind

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

Print Mode Printer Option Media Path

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

Operations

Load Media

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Load Media

The beginning steps for loading media apply to all printers, including those that have the

peel-off, liner take-up, cutter, or rewind option. When you have completed these beginning

steps, continue with the media loading instructions for the print mode and printer options that

apply to you. For more information about print modes and printer options, see Print Modes

and Printer Options on page 30.

Beginning Steps for all Print Modes and Printer Options

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

steps:

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

latches open.

2. Slide out the media guide.

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

hanging necklaces, identification badges, or other metallic objects that could touch the

printhead. You are not required to turn off the printer power when working near an open

printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose

all temporary settings, such as label formats, and you must reload them before you resume

printing.

Operations

Load Media

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

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

appropriate.

Roll Media Fanfold Media

a. Remove and discard any tags or

labels that are dirty or that are held

by adhesives or tape.

a. Flip down the media supply guide.

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

bottom access slot.

Rear Feed

Bottom Feed

c. Place the roll of media on the media

supply hanger. Push the roll as far

back as it will go.

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

supply hanger.

Operations

Load Media

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

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

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

sensor.

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

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

Descriptions and Printer Requirements on page 30 for more information.

•Additional Steps for Tear-Off Mode on page 36

•Additional Steps for Peel-Off Mode (with or without Liner Take-Up) on page 37

•Additional Steps for Cutter or Delayed Cut Mode on page 42

•Additional Steps for Rewind Mode on page 43

e. Slide in the media supply guide until

it touches the edge of the roll. d. Flip up the media supply guide.

e. Slide in the media supply guide until

it touches the edge of the media.

Roll Media (Continued) Fanfold Media (Continued)

13 2

Operations

Load Media

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Additional Steps for Tear-Off Mode

After completing Beginning Steps for all Print Modes and Printer Options on page 33,

continue with this section to operate the printer in Tear-Off mode.

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

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

2. Set the printer to Tear-Off mode. See Select Print Mode on page 64 for instructions.

3. Close the printhead assembly.

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

Operations

Load Media

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

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

After completing Beginning Steps for all Print Modes and Printer Options on page 33,

continue with this section to operate the printer in Peel-Off mode with or without liner take-up.

Your printer must have the Peel option, the Liner Take-Up option, or the Rewind option

installed. See Print Modes and Printer Options on page 30 for more information.

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

Rewind Option on page 96.

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

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

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

Operations

Load Media

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

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

4. Feed the liner over the tear-off/peel-off bar (1) and behind the peel assembly (2). Make

sure that the end of the liner falls outside of the printer.

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

must have the Liner Take-Up option or the Rewind option installed. Follow the

instructions for your printer option.

Rewind Option Liner Take-Up Option

a. Feed the liner under the media

alignment roller (1). a. Slide the liner into the slot in the

liner take-up spindle (1).

Operations

Load Media

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

b. Loosen the thumbscrew on the

rewind media guide. b. Push the liner back until it touches

the back plate of the liner take-up

spindle assembly.

c. Slide the rewind media guide all the

way out, and then fold it down.

d. Slide an empty core onto the rewind

spindle. c. Wrap the liner around the liner

take-up spindle and turn the spindle

counterclockwise to tighten the liner.

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

Operations

Load Media

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

e. Wrap the liner around the core and

turn the rewind spindle

counterclockwise to tighten the liner.

(No additional steps for the liner take-up

option.)

f. Fold up the rewind media guide, and

then slide it in until it touches the

liner.

g. Tighten the thumbscrew on the

rewind media guide.

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

Operations

Load Media

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

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

8. Set the printer to Peel-Off mode. See Select Print Mode on page 64 for instructions.

9. Close the printhead assembly.

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

liner take-up (if used) begin automatically.

Caution • Use the peel release lever and your right hand to close the peel assembly.

Do not use your left hand to assist in closing. The top edge of the peel roller/assembly

could pinch your fingers.

Close the peel assembly using the peel-off mechanism release lever.

Operations

Load Media

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Additional Steps for Cutter or Delayed Cut Mode

After completing Beginning Steps for all Print Modes and Printer Options on page 33,

continue with this section to operate the printer in Cutter or Delayed Cut mode.

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

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

3. Set the printer to Cutter or Delayed Cut mode. See Select Print Mode on page 64 for

instructions.

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

Feed the media through the cutter (1).

Operations

Load Media

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

4. Close the printhead assembly.

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

begins automatically.

Additional Steps for Rewind Mode

After completing Beginning Steps for all Print Modes and Printer Options on page 33,

continue with this section to operate the printer in Rewind mode. For additional procedures

related to the rewind option, see Routine Maintenance for the Rewind Option on page 96.

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

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

Operations

Load Media

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

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

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

4. Loosen the thumbscrew on the rewind media guide.

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

Operations

Load Media

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

6. Slide an empty core onto the rewind spindle.

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

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

spindle.

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

9. Tighten the thumbscrew on the rewind media guide.

Operations

Load Media

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

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

11. Set the printer to Rewind mode. See Select Print Mode on page 64 for instructions.

12. Close the printhead assembly.

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

begins automatically.

Operations

Load Ribbon

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Load Ribbon

Always use ribbon that is wider than the media to protect the printhead from wear. For direct

thermal printing, do not load ribbon in the printer.

The standard Thermal Transfer option (black ribbon spindle) uses ribbon coated on the

outside, and the alternate Thermal Transfer option (gray ribbon spindle) uses ribbon coated on

the inside. To avoid damaging your printer, follow the directions for the Thermal Transfer

option installed in your printer.

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

inside. The coated surfaces of the ribbon are shown in gray when they are visible. To

determine which side of a ribbon is printed, see Coated Side of Ribbon on page 27.

Figure 8 • Ribbon Path

Ribbon Coated Outside

(black ribbon spindle) Ribbon Coated Inside

(gray ribbon spindle)

1Tension blade

2Ribbon take-up spindle

3Ribbon supply spindle

4Printhead assembly

5Printhead release latch

Operations

Load Ribbon

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

To load ribbon, complete these steps:

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

• To place the ribbon supply spindle in the normal position, firmly pull out the spindle

end cap until it extends and clicks in place, as shown in Figure 9. Use this setting for

most applications.

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

cap until it retracts and clicks in place, as shown in Figure 9. Use this setting when

using a narrow ribbon or if normal tension hampers ribbon movement.

Figure 9 • Ribbon Spindle—Normal and Low Tension

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

latches open.

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

hanging necklaces, identification badges, or other metallic objects that could touch the

printhead. You are not required to turn off the printer power when working near an open

printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose

all temporary settings, such as label formats, and you must reload them before you resume

printing.

1Normal Position (Spindle End Cap Extended)

2Low-Tension Position (Spindle End Cap Retracted)

1 2

Operations

Load Ribbon

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

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

Transfer option installed in your printer.

Ribbon Coated Outside

(black ribbon spindle) Ribbon Coated Inside

(gray ribbon spindle)

a. Hold the ribbon with the loose end unrolling

clockwise. a. Hold the ribbon with the loose end unrolling

counterclockwise.

b. Place the roll of ribbon on the ribbon supply

spindle (1) and push it all the way back. b. Place the roll of ribbon on the ribbon supply

spindle (1) and push it all the way back.

c. Pull the end of the ribbon under the printhead

assembly (1) and out the front of the printer.

Extend the ribbon approximately 24 in.

(610 mm) out of the printer.

c. Pull the end of the ribbon under the printhead

assembly (1) and out the front of the printer.

Extend the ribbon approximately 24 in.

(610 mm) out of the printer.

1 1

Operations

Load Ribbon

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

4. Close the printhead assembly.

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

Ribbon Coated Outside

(black ribbon spindle) Ribbon Coated Inside

(gray ribbon spindle)

Operations

Load Ribbon

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Remove Used Ribbon

To remove used ribbon, complete these steps:

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

the same time, turn the ribbon take-up spindle release knob counterclockwise (2).

The tension blades collapse into the ribbon take-up spindle, loosening the ribbon.

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

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

damage the spindle.

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

Operations

Calibrate the Printer

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Calibrate the Printer

Auto Calibration

By default, the printer automatically calibrates on power up or when the printhead is closed.

During auto calibration, the printer determines the label length and sensor settings.

The results of the auto calibration are stored in the printer’s memory and are retained even if

printer power is removed. These parameters remain in effect until the next calibration is

performed.

Manual Calibration

Perform a media and ribbon sensor calibration to reset the sensitivity of the sensors so the

media and ribbon are detected more accurately. If you change the type of ribbon or media,

your printer may operate better if you perform this calibration.

For instructions, refer to Calibrate Media and Ribbon Sensor Sensitivity on page 74.

Note • If the control panel settings for MEDIA POWER UP or HEAD CLOSE are set to

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

Select Media Power-Up Option on page 80 or Select Head Close Option on page 80.

Operations

Adjust Printhead Pressure

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Adjust Printhead Pressure

You may need to adjust printhead pressure if printing is too light on one side, if you use thick

media, or if the media drifts from side to side during printing.

See Figure 10. The ZM400 pressure adjustment dials have four possible settings designated by

blocks of increasing size embossed on the print mechanism. The smallest block (fully

counterclockwise) is considered position 1, and the largest block (fully clockwise) is

considered position 4. The ZM600 dials have seven settings instead of four.

Figure 10 • Printhead Pressure Adjustment Dials

To set printhead pressure, complete these steps:

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

which printer you have.

1Outside dial

2Inside dial

Table 10 • ZM400 Printhead Pressure

Media Width Inside Dial Outside Dial

1 in. (25.4 mm) 31

2 in. (51 mm) 41

3 in. (76 mm) 32

3.5 in. and up (89 mm and up) 33

Operations

Adjust Printhead Pressure

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

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

Table 11 • ZM600 Printhead Pressure

Media Width Inside Dial Outside Dial

2 in. (50 mm) 6 1

3 in. (75 mm) 6 2

4 in. (100 mm) 7 3

5 in. (125 mm) 7 4

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

If the media... Then...

Requires higher pressure to

print well Increase both dials one position.

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

decrease the inside dial setting one position.

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

decrease the outside dial setting one position.

Prints too lightly on the left side

of the label. Increase the inside dial setting one position.

Prints too lightly on the right

side of the label. Increase the outside dial setting one position.

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Configuration

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

operation.

Contents

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Enter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Default Password Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Print a Configuration Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Print a Network Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

How to View or Modify Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Additional Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Standard Printer Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Configuration

Setup Mode

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Setup Mode

After you have installed the media and ribbon and the Power-On Self Test (POST) is complete,

the control panel displays PRINTER READY. You may now set printer parameters for your

application using the control panel display and the buttons directly below it. If it becomes

necessary to restore the initial printer defaults, see FEED and PAUSE Self Test on page 119.

Enter Setup Mode

To enter Setup Mode, complete these steps:

1. Press SETUP/EXIT.

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

3. Press SELECT to select and deselect the parameters.

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

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

limited to):

• printing at high speeds

• peeling the media

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

Because these and other factors affect print quality, run tests to determine the best

combination of printer settings and media for your application. A poor match may limit print

quality or print rate, or the printer may not function properly in the desired print mode.

Note • If the printer is operating on an IP network, you can change the printer’s parameters

in these additional ways:

• with ZebraLink™ WebView (ZebraNet 10/100 PrintServer, PSII, or Wireless Print Server

required). For information, see the appropriate print server user guide.

• with the SetWLAN configuration utility or the ZebraNet Bridge Wireless Setup Wizard

(ZebraNet Wireless Print Server required). For information, see the ZebraNet Wireless

Print Server User Guide.

Configuration

Setup Mode

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Exit Setup Mode

To leave Setup mode, complete these steps:

1. Press SETUP/EXIT.

The LCD displays SAVE CHANGES.

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

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

When the configuration and calibration sequence is done, PRINTER READY displays.

LCD Description

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

TEMPORARY Saves the changes until power is turned off.

CANCEL Cancels all changes made since you entered Setup mode,

except for changes made to the darkness and tear-off settings,

which go into effect as soon as they are made.

LOAD DEFAULTS Restores all parameters other than the network settings back to

the factory defaults. Use care when loading defaults because

you will need to reload all settings that you changed manually.

Note • Loading factory defaults causes the printer to

auto-calibrate.

LOAD LAST SAVE Loads values from the last permanent save.

DEFAULT NET Restores the wired and wireless network settings back to

factory defaults.

Configuration

Change Password-Protected Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Change Password-Protected Parameters

Certain parameters, including the communication parameters, are password-protected by

factory default.

The first time that you attempt to change a password-protected parameter, the printer displays

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

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

again unless you leave Setup mode by pressing SETUP/EXIT or by turning off (O) the printer.

To enter a password for a password-protected parameter, complete

these steps:

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

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

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

3. After entering the password, press SELECT.

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

you can change the value.

Default Password Value

The default password value is 1234. The password can be changed using the Zebra

Programming Language (ZPL) command ^KP (Define Password) or using the printer’s web

pages (ZebraNet® 10/100 Print Server, or Wireless Plus Print Server required).

Disable the Password Protection Feature

You can disable the password protection feature so that it no longer prompts you for a

password by setting the password to 0000 via the ^KP ZPL command. To re-enable the

password-protection feature, send the ZPL command ^KPx, where x can be any number from

1 to 9999.

Caution • Do not change password-protected parameters unless you have a complete

understanding of the parameters’ functions. If the parameters are set incorrectly, the printer

may function unpredictably.

Configuration

Print a Configuration Label

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Print a Configuration Label

A configuration label lists the printer settings that are stored in configuration memory. After

you load the media, print a configuration label as a record of your printer’s current settings.

Keep the label to use when troubleshooting printing problems.

To print a configuration label, complete these steps:

1. On the control panel, press SETUP/EXIT.

2. Press or to scroll through the parameters until you reach LIST SETUP.

3. Press SELECT to select the parameter.

4. Press PLUS (+) to confirm printing.

A configuration label prints (Figure 11).

Figure 11 • Configuration Label

Configuration

Print a Network Configuration Label

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Print a Network Configuration Label

If you are using a print server, you can print a network configuration label after the printer is

connected to the network.

To print a network configuration label, complete these steps:

1. On the control panel, press SETUP/EXIT.

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

LIST NETWORK.

3. Press SELECT to select the parameter.

4. Press PLUS (+) to confirm printing.

A network configuration label prints (Figure 12). An asterisk designates whether the

wired or wireless print server is active. If no wireless print server is installed, the wireless

portion of the label does not print.

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

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Control Panel Parameters

Use the LCD on the control panel to view and adjust printer settings.

How to View or Modify Parameters

While viewing parameters, press PLUS (+) to continue to the next parameter, or press

MINUS (-) to return to the previous parameter in the cycle. Press SELECT when you want to

modify a parameter or view its options. When a parameter is changed, an asterisk (*) appears

in the upper left corner of the display to indicate that the value is different from the one

currently active in the printer.

Additional Parameters

Additional parameters appear in the following situations.

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

ZebraNet 10/100 Print Server User and Reference Guide

• When a wireless print server is installed in the printer. Refer to the ZebraNet Wireless

Print Server and Wireless Plus Print Server User Guide.

• When a Radio Frequency Identification (RFID) reader is installed. Refer to the RFID

Programming Guide for more information.

Copies of these manuals are available at http://www.zebra.com/manuals or on the user CD that

came with your printer.

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

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

information.

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Standard Printer Parameters

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

after entering Setup mode.

Table 12 • Printer Parameters (Page 1 of 24)

Parameter Action/Explanation

ZPL and XML

EPL

Adjust Print Darkness

Darkness (burn duration) settings depend on a variety of factors, including

ribbon type, media type, and the condition of the printhead. You may adjust

the darkness for consistent high-quality printing.

Important • Set the darkness to the lowest setting that provides

good print quality. If the darkness is set too high, the ink may

smear, the ribbon may burn through, or the printhead may wear

prematurely.

If printing is too light or if there are voids in printed areas, increase the

darkness. If printing is too dark or if there is spreading or bleeding of

printed areas, decrease the darkness.

The FEED Self Test on page 116 can be used to determine the best darkness

setting. You may want to adjust darkness while performing the PAUSE Self

Test on page 115. Because the darkness setting takes effect immediately,

you can see the results on labels that are currently printing. Darkness

settings also may be changed by the driver or software settings.

Default Value (ZPL, XML): +10

Range (ZPL, XML): 00 to +30

Default Value (EPL): +7

Range (EPL): 00 to +15

To change the value shown:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to increase darkness.

3. Press MINUS (-) to decrease darkness.

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

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Adjust Print Speed

Adjusts the speed for printing a label (given in inches per second). Slower

print speeds typically yield better print quality. Print speed changes take

effect upon exiting Setup mode.

Default Value: 2 IPS

Range:

• 200 dpi: 2 to 10 IPS

• 300 dpi: 2 to 8 IPS

• 600 dpi: 1 to 4 IPS

To change the value shown:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to increase the value.

3. Press MINUS (-) to decrease the value.

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

Table 12 • Printer Parameters (Page 2 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Adjust the Tear-Off Position

This parameter establishes the position of the media over the

tear-off/peel-off bar after printing.

See Figure 13. Higher numbers move the media out (the tear line moves

closer to the leading edge of the next label), and lower numbers move the

media in (the tear line moves closer to the edge of the label just printed).

Figure 13 • Tear-Off Position Adjustment

Default Value: +0

Range: –120 to +120

To change the value shown:

1. Press SELECT to select the parameter.

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

position by four dot rows.

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

position by four dot rows.

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

Select Print Mode

This parameter tells the printer how printed labels will be removed. Make

sure that you select a print mode that is compatible with your printer and

printer options. For information about how the print modes work with

different printer options, see Print Modes and Printer Options on page 30.

Default Value: TEAR-OFF

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

LINERLESS-P, LINERLESS-R, REWIND

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Table 12 • Printer Parameters (Page 3 of 24)

Parameter Action/Explanation

1Media direction

2Factory-set tear line location at position 00

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Set Media Type

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

Types of Media on page 25 for more information). Selecting continuous

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

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

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

calculate label length (the distance between two recognized registration

points of the inter-label gap, webbing, or alignment notch or hole).

Default Value: GAP/NOTCH

Selections: GAP/NOTCH, MARK, CONTINUOUS

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Select Print Method

The print method parameter tells the printer the method of printing that you

want to use: direct thermal (no ribbon) or thermal transfer (using thermal

transfer media and ribbon).

Default Value: THERMAL TRANSFER

Range: THERMAL TRANSFER, DIRECT THERMAL

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Table 12 • Printer Parameters (Page 4 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Set Print Width

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

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

based on the printer model and the printhead resolution.

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

format not being printed on the media. Setting the width too wide

wastes formatting memory and can cause printing off of the label

and on the platen roller. This setting can affect the horizontal

position of the label format if the image was inverted using the

^POI ZPL II command.

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Table 12 • Printer Parameters (Page 5 of 24)

Parameter Action/Explanation

Table 13 • Print Width Ranges and Maximum Values

Printhead

Resolution

Printer

ZM400 ZM600

200 dpi Default Value: 832

Range: 2 to 832 dots

Default Value: 1344

Range: 2 to 1344 dots

300 dpi Default Value: 1248

Range: 2 to 1248 dots

Default Value: 1984

Range: 2 to 1984 dots

600 dpi Default Value: 2496

Range: 2 to 2496 dots

N/A

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Set Maximum Label Length

This parameter is used during the media portion of the calibration process.

Always set maximum label length to a value that is at least 1.0 in.

(25.4 mm) greater than the actual label length (Figure 14). If the value is set

to a smaller value than the label length, the printer assumes that continuous

media is loaded, and the printer cannot calibrate.

For example, if the label length is 5.0 inches (126 mm) including the

interlabel gap, set the parameter for 6.0 inches (152 mm). If the label length

is 7.5 inches (190 mm), set the parameter for 9.0 inches (229 mm).

Figure 14 • Label Length

Default Value: 39.0 inches (988 mm).

Selections: Values are adjustable in one-inch (25.4 mm) increments.

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Table 12 • Printer Parameters (Page 6 of 24)

Parameter Action/Explanation

1Label length (including interlabel gap)

2Interlabel gap

3Set maximum label length to approximately

this value

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Set Early Warning for Maintenance

When this feature is enabled, the printer provides warnings when the

printhead needs to be cleaned.

Default Value: MAINT. OFF

Selections: MAINT. OFF, MAINTENANCE ON

To change the Early Warning settings:

1. Press SELECT to select the parameter.

2. When the LCD displays EARLY WARNING MAINTENANCE, press

PLUS (+) or MINUS (-) to toggle between OFF and ON. (If you are

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

Change Password-Protected Parameters on page 58.)

3. Exit Setup mode and save changes to enable additional parameters

related to the early warning system.

4. Enter Setup mode again and go to the following parameters to enter the

printhead cleaning interval and the printhead life.

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

Set Printhead Cleaning Interval for Early Warning

This parameter appears only when Early Warning for Maintenance is

enabled. This value should correspond to the length of the media or ribbon

roll that you are using.

Default Value: 450 M/1476 FT

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

To change the value shown:

1. Press SELECT to select the parameter.

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

the desired number of inches of media or ribbon.

When the printhead reaches the set length, WARNING CLEAN

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

printer generates an alert.

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

Reset Printhead Cleaning Counter for Early Warning

This parameter appears only when Early Warning for Maintenance is

enabled.

To reset the printhead cleaning counter:

1. Press SELECT to select the parameter.

2. Did you clean the printhead?

• If you cleaned the printhead, press PLUS (+) to select YES.

• If you did not clean the printhead, press MINUS (-) to select NO.

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

Table 12 • Printer Parameters (Page 7 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Set Printhead Life for Early Warning

This parameter appears only when Early Warning for Maintenance is

enabled. Set this value to the number of inches of media that the printhead

is expected to print.

Default Value: 1,000,000 inches

Range: 100 to 1,000,000 inches

To change the value shown:

1. Press SELECT to select the parameter.

2. Press MINUS (-) to move the cursor.

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

When the printhead reaches the set length, WARNING REPLACE

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

generates an alert.

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

Reset Printhead Life Counter for Early Warning

This parameter appears only when Early Warning for Maintenance is

enabled.

To reset the printhead life counter:

1. Press SELECT to select the parameter.

2. Did you replace the printhead?

• If you replaced the printhead, press PLUS (+) to select YES.

• If you did not replace the printhead, press MINUS (-) to select NO.

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

View Non-Resettable Counter

This parameter displays the total length of media that the printer has

printed. You can use ZPL commands to change the unit of measure for this

counter. For the commands, refer to the ZPL Programming Guide.

View User-Controlled Counter 1

This parameter displays the total length of media that the printer has printed

since this parameter was last reset. You can use ZPL commands to change

the unit of measure and reset this counter. For the commands, refer to the

ZPL Programming Guide.

View User-Controlled Counter 2

This parameter displays the total length of media that the printer has printed

since this parameter was last reset. You can use ZPL commands to change

the unit of measure and reset this counter. For the commands, refer to the

ZPL Programming Guide.

Table 12 • Printer Parameters (Page 8 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Print Counter Readings

Prints a label that lists the odometer readings for the following:

• the non-resettable counter

• the two user-controlled counters

• the Early Warning for Maintenance counters, which indicate when the

printhead was last cleaned and the printhead life

If the Early Warning for Maintenance feature is disabled, the counters

related to it do not print.

To print a list of the odometer readings:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to print the odometer readings.

3. Press SELECT to deselect the parameter.

List Fonts

This option prints a label that lists the available fonts in the printer,

including standard printer fonts plus any optional fonts. Fonts may be

stored in RAM or Flash memory.

To print a list of the available fonts:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to select PRINT.

3. Press SELECT to deselect the parameter.

ZPL and XML only List Bar Codes

This option prints a label that lists the available bar codes in the printer. Bar

codes may be stored in RAM or Flash memory.

To print a list of the available bar codes:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to select PRINT.

3. Press SELECT to deselect the parameter.

List Images

This option prints a label that lists the available images stored in the

printer’s RAM, Flash memory, or optional memory card.

To print a list of the available images:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to select PRINT.

3. Press SELECT to deselect the parameter.

Table 12 • Printer Parameters (Page 9 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

List Formats

This option prints a label that lists the available formats stored in the

printer’s RAM, Flash memory, or optional memory card.

To print a list of the available formats:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to select PRINT.

3. Press SELECT to deselect the parameter.

List Setup

This option prints a configuration label (see Figure 11 on page 59), which

lists the current printer configuration.

To print a configuration label:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to select PRINT.

3. Press SELECT to deselect the parameter.

List Network Settings

This option prints a network configuration label (see Figure 12

on page 60), which lists the settings for any print server that is installed.

To print a network configuration label:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to select PRINT.

3. Press SELECT to deselect the parameter.

List All

This option prints labels that list the available fonts, bar codes, images,

formats, and the current printer and network configurations.

To print labels for all settings:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to select PRINT.

3. Press SELECT to deselect the parameter.

Table 12 • Printer Parameters (Page 10 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

ZPL and XML only Format Memory Card

This option erases all previously stored information from the optional

64 MB flash chip on the Wireless Plus option board. This parameter

appears only when a Wireless Plus option board with the flash chip

populated is installed.

Caution • This option completely erases the flash chip.

To format a memory card:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to select A:.

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

the password.

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

Parameters on page 58.

4. Press the appropriate button again to select the desired card.

The display shows ARE YOU SURE?.

5. Do you want to continue?

• Press MINUS (-) to select NO to cancel the request and return to

FORMAT CARD prompt.

• Press PLUS (+) to select YES and begin initialization.

When initialization is complete, the control panel displays

FORMATTING CARD COMPLETED.

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

initialization may take up to 5 minutes to complete.

6. Press SELECT to deselect the parameter.

Table 12 • Printer Parameters (Page 11 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Initialize Flash Memory

This option erases all previously stored information from Flash memory.

Caution • This option completely erases the Flash memory.

To initialize Flash memory:

1. Press SELECT to select the parameter.

2. If prompted for a password, enter the printer password. For

instructions, see Change Password-Protected Parameters on page 58.

The display shows INITIALIZE FLASH?

3. Press PLUS (+) to select YES.

The display shows ARE YOU SURE?.

4. Do you want to continue?

• Press MINUS (-) to select NO to cancel the request and return to the

INITIALIZE FLASH prompt.

• Press PLUS (+) to select YES and begin initialization.

When initialization is complete, the control panel displays

INITIALIZING MEMORY COMPLETED.

Note • Depending on the amount of free FLASH memory,

initialization may take up to 1 minute to complete.

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

Print Sensor Profile

A sensor profile shows sensor settings compared to actual sensor readings.

This label (which will extend across several actual labels or tags) can be

used to troubleshoot printing problems. To interpret the results of the

sensor profile, see Sensor Profile on page 121.

To print a sensor profile:

1. Press SELECT to select the parameter.

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

media sensor profile.

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

Media and Ribbon Sensor Sensitivity on page 74.

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

Table 12 • Printer Parameters (Page 12 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Calibrate Media and Ribbon Sensor Sensitivity

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

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

steps must be performed even if only one of the sensors requires

adjustment. You may press MINUS (-) at any step in this procedure

to cancel the process.

To perform a media and ribbon sensor calibration:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to start the calibration procedure.

The LOAD BACKING prompt displays.

3. Open the printhead.

4. Remove approximately 8 in. (203 mm) of labels from the backing, and

pull the media into the printer so that only the backing is between the

media sensors.

5. Leave the printhead open.

6. Press PLUS (+) to continue.

The REMOVE RIBBON prompt displays.

7. Remove the ribbon (if used).

8. Close the printhead.

9. Press PLUS (+) to continue.

The message CALIBRATING PLEASE WAIT displays.

The printer adjusts the scale (gain) of the signals that it receives from

the media and ribbon sensors based on the specific media and ribbon

combination being used. On the sensor profile, this essentially

corresponds to moving the peak of the graph up or down to optimize

the readings for your application.

When calibration is complete, RELOAD ALL displays.

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

positioned under the media sensor.

11. Reload the ribbon (if used).

12. Close the printhead.

13. Press PLUS (+) to continue.

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

printer checks the readings for the media and ribbon based on the new

scale established, determines the label length, and determines the print

mode. To see the new readings on the new scale, print a sensor profile.

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

Table 12 • Printer Parameters (Page 13 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Set Parallel Communications

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

computer.

Default Value: BIDIRECTIONAL

Selections: BIDIRECTIONAL, UNIDIRECTIONAL

To change the value shown:

1. Press SELECT to select the parameter.

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

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

ZPL and XML only Set Serial Communications

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

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

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

RS422/485 operation.

Default Value: RS232

Selections: RS232, RS485 MULTIDROP

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Set Baud

This setting applies only when the serial port is used. The baud setting of

the printer must match the baud setting of the host computer for accurate

communications to take place. Select the value that matches the one being

used by the host computer.

Default Value: 9600

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

28800, 38400, 57600, 115200

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

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Table 12 • Printer Parameters (Page 14 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Set Data Bits

This setting applies only when the serial port is used. The data bits of the

printer must match the data bits of the host computer for accurate

communications to take place. Set the data bits to match the setting being

used by the host computer.

Default Value: 8BITS

Selections: 7BITS, 8BITS

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Set Parity

This setting applies only when the serial port is used. The parity of the

printer must match the parity of the host computer for accurate

communications to take place. Select the parity that matches the one being

used by the host computer.

Default Value: NONE

Selections: EVEN, ODD, NONE

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Set Host Handshake

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

protocol of the printer must match the handshake protocol of the host

computer for communication to take place. Select the handshake protocol

that matches the one being used by the host computer.

Default Value (ZPL, XML): XON/XOFF

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

Default Value (EPL): DTR & XON/XOFF

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

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Table 12 • Printer Parameters (Page 15 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

ZPL and XML only Set Protocol

Protocol is a type of error checking system. Depending on the selection, an

indicator may be sent from the printer to the host computer signifying that

data has been received. Select the protocol that is requested by the host

computer. Further details on protocol can be found in the ZPL

Programming Guide.

Default Value: NONE

Selections: NONE, ZEBRA, ACK_NAK

Note • ZEBRA is the same as ACK_NAK, except that ZEBRA

response messages are sequenced. If ZEBRA is selected, the printer

must use DSR/DTR for host handshake protocol.

To change the value shown:

1. Press SELECT to select the parameter.

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

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

ZPL and XML only Set Network ID

This parameter assigns a unique number to the printer when the printer is

operating in an RS422/485 multi-drop network environment (an external

RS422/485 adapter is required). This gives the host computer the means to

address a specific printer. This does not affect TCP/IP or IPX networks.

Default Value: 000

Range: 000 to 999

To change the value shown:

1. Press SELECT to select the parameter.

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

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

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

Set Communications Mode

The communication diagnostics mode is a troubleshooting tool for

checking the interconnection between the printer and the host computer.

For more information, see Communications Diagnostics Test on page 120.

Default Value: NORMAL MODE

Selections: NORMAL MODE, DIAGNOSTICS

To select communication diagnostics mode:

1. Press SELECT to select the parameter.

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

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

Table 12 • Printer Parameters (Page 16 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

ZPL and XML only Set Control Prefix Character

The printer looks for this two-digit hex character to indicate the start of a

ZPL/ZPL II control instruction.

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

delimiter character. The printer must see different characters to

work properly.

Default Value: 7E ~

Range: 00 to FF

To change the value shown:

1. Press SELECT to select the parameter.

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

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

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

ZPL and XML only Set Format Prefix Character

The format prefix is a two-digit hex value used as a parameter place marker

in ZPL/ZPL II format instructions. The printer looks for this hex character

to indicate the start of a ZPL/ZPL II format instruction. See the ZPL

Programming Guide for more information.

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

delimiter character. The printer must see different characters to

work properly.

Default Value: 5E ^

Range: 00 to FF

To change the value shown:

1. Press SELECT to select the parameter.

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

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

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

Table 12 • Printer Parameters (Page 17 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

ZPL and XML only Set Delimiter Character

The delimiter character is a two-digit hex value used as a parameter place

marker in ZPL/ZPL II format instructions. See the ZPL Programming

Guide for more information.

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

delimiter character. The printer must see different characters to

work properly.

Default Value: 2C ,

Range: 00 to FF

To change the value shown:

1. Press SELECT to select the parameter.

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

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

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

ZPL and XML only Select ZPL Mode

The printer remains in the selected mode until it is changed by this

parameter or by using a ZPL/ZPL II command. The printer accepts label

formats written in either ZPL or ZPL II, eliminating the need to rewrite any

ZPL formats that already exist. See the ZPL Programming Guide for more

information on the differences between ZPL and ZPL II.

Default Value: ZPL II

Range: ZPL II, ZPL

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Table 12 • Printer Parameters (Page 18 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Select Media Power-Up Option

This parameter sets the action of the media when you turn on the printer.

Default Value: CALIBRATION

Selections: CALIBRATION, SHORT CAL, LENGTH, NO MOTION,

FEED

•Calibration adjusts sensor levels and thresholds, determines length,

and feeds the media to the next web.

•Short Cal sets media and web thresholds without adjusting sensor

gain, determines length, and feeds the media to the next web.

•Length determines label length using current sensor values, and feeds

the media to the next web.

•No Motion tells the printer not to move the media. You must

manually ensure that the web is positioned correctly, or press feed to

position the next web.

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

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Select Head Close Option

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

Default Value: CALIBRATION

Selections: CALIBRATION, SHORT CAL, LENGTH, NO MOTION,

FEED

•Calibration adjusts sensor levels and thresholds, determines length,

and feeds the media to the next web.

•Short Cal sets media and web thresholds without adjusting sensor

gain, determines length, and feeds the media to the next web.

•Length determines label length using current sensor values, and feeds

the media to the next web.

•No Motion tells the printer not to move the media. You must

manually ensure that the web is positioned correctly, or press feed to

position the next web.

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

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Table 12 • Printer Parameters (Page 19 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Select Backfeed Sequence

This parameter sets when label backfeed occurs after a label is removed in

some print modes. It has no effect in Rewind mode. This setting is

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

Programming Guide for more information).

Default Value: DEFAULT (90%)

Selections: DEFAULT, AFTER, OFF, BEFORE, 10%, 20%, 30%, 40%,

50%, 60%, 70%, 80%

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Adjust Label Top Position

This parameter adjusts the print position vertically on the label. Positive

numbers adjust the label top position farther down the label (away from the

printhead) by the specified number of dots. Negative numbers adjust the

position up the label (toward the printhead).

Default Value: +000

Range: –120 to +120 dots

To change the value shown:

1. Press SELECT to select the parameter.

2. Press PLUS (+) to increase the value.

3. Press MINUS (-) to decrease the value.

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

Adjust Left Position

This parameter adjusts the print position horizontally on the label. Positive

numbers adjust printing to the left by the specified number of dots.

Negative numbers shift printing to the right.

Default Value: 0000

Range: –9999 to +9999 dots

To change the value shown:

1. Press SELECT to select the parameter.

2. Press MINUS (-) to move the cursor.

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

digit. For a negative value, enter the value before changing to the

minus sign.

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

Table 12 • Printer Parameters (Page 20 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

ZPL and XML only Set Reprint Mode

When reprint mode is enabled, you can reprint the last label printed either

by issuing the ~PR ZPL command or by pressing MINUS (-) on the control

panel.

Default Value: DISABLED

Selections: ENABLED, DISABLED

To change the value shown:

1. Press SELECT to select the parameter.

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

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

See next column View Sensor Settings

These parameters are automatically set during the calibration procedure

and should be changed only by a qualified service technician. Refer to the

ZPL II Programming Guide for information on these parameters.

To skip these parameters:

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

Table 12 • Printer Parameters (Page 21 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

ZPL and XML only Select Format Convert

Selects the bitmap scaling factor. The first number is the original dots per

inch (dpi) value; the second, the dpi to which you would like to scale.

Default Value: NONE

Selections: NONE, 150 → 300, 150 → 600, 200 → 600, 300 → 600

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Select Idle Display

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

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

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

Default Value: FIRMWARE (FW) VERSION

Selections: MM/DD/YY (24HR), MM/DD/YY (12HR), DD/MM/YY

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

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Table 12 • Printer Parameters (Page 22 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Set Real-Time Clock (RTC) Date

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

in IDLE DISPLAY.

To change the value shown:

1. Press SELECT to select the parameter.

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

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

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

Set RTC Time

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

in IDLE DISPLAY.

To change the value shown:

1. Press SELECT to select the parameter.

2. Press the left oval MINUS (-) to move to the next digit position.

3. Press the right oval PLUS (+) to change the value of the digit.

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

Specify Password Level

This parameter allows you to select whether certain factory-selected menu

items or all menu items are password protected.

Default Value: SELECTED ITEMS

Selections: SELECTED ITEMS, ALL ITEMS

1. Press SELECT to select the parameter.

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

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

Table 12 • Printer Parameters (Page 23 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Select the Display Language

This parameter changes the language displayed on the LCD. Each language

selection is displayed in the language itself.

Default Value: ENGLISH

Selections: ENGLISH, SPANISH, FRENCH, GERMAN, ITALIAN,

NORWEGIAN, PORTUGUESE, SWEDISH, DANISH, SPANISH 2,

DUTCH, FINNISH, JAPANESE, KOREAN, SIMPLIFIED CHINESE,

TRADITIONAL CHINESE

To change the value shown:

1. Press SELECT to select the parameter.

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

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

Table 12 • Printer Parameters (Page 24 of 24)

Parameter Action/Explanation

Configuration

Control Panel Parameters

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Notes • ___________________________________________________________________

__________________________________________________________________________

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Routine Maintenance

This section provides routine cleaning and maintenance procedures.

Contents

Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Cleaning Schedule and Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Clean the Printhead and Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Clean the Media Compartment and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Clean the Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Routine Maintenance for the Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Remove Printed Labels or Liner from the Rewind Spindle . . . . . . . . . . . . . . . . . . . . . 96

Adjust Media Alignment for Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Routine Maintenance

Replacing Printer Components

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Replacing Printer Components

Some printer components, such as the printhead and platen roller, may wear out over time and

can be replaced easily. Regular cleaning may extend the life of some of these components. See

Cleaning Schedule and Procedures on page 89 for the recommended cleaning intervals.

Ordering Replacement Parts

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

strongly recommends the use of genuine Zebra™ supplies as part of the total solution.

Specifically, the ZM400 and ZM600 are designed to work only with genuine Zebra™

printheads, thus maximizing safety and print quality.

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

on page 3 for contact addresses and telephone numbers.

Recycling Printer Components

Lubrication

No lubrication is needed for this printer.

The majority of this printer’s components are recyclable. The printer’s main logic board

includes a battery that you should dispose of properly.

Do not dispose of any printer components in unsorted municipal waste. Please dispose of the

battery according to your local regulations, and recycle the other printer components

according to your local standards. For more information, see

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

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

mechanical parts if used on this printer.

Routine Maintenance

Cleaning Schedule and Procedures

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Cleaning Schedule and Procedures

Specific cleaning procedures are provided on the following pages. Table 14 shows the

recommended cleaning schedule. These intervals are intended as guidelines only. You may

have to clean more often, depending upon your application and media.

Clean the Exterior

You may clean the exterior surfaces of the printer with a lint-free cloth and a small amount of a

mild detergent, if necessary. Do not use harsh or abrasive cleaning agents or solvents.

Important • Zebra is not responsible for damage caused by the use of cleaning fluids on this

printer.

Table 14 • Recommended Cleaning Schedule

Area Method Interval

Printhead Solvent* Direct Thermal Mode: After every roll of

media (or 500 feet of fanfold media).

Thermal Transfer Mode: After every roll of

ribbon or three rolls of media.

Platen roller Solvent*

Media sensors Air blow

Ribbon sensor Air blow

Media path Solvent*

Ribbon path Solvent*

Pinch roller (part of Peel-Off option) Solvent*

Cutter

module If cutting continuous,

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

depending upon your application and media).

If cutting tag stock or label

liner material Solvent* and

air blow After every two or three rolls of media.

Tear-off/peel-off bar Solvent* Once a month.

Take-label sensor Air blow Once every six months.

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

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

Routine Maintenance

Cleaning Procedures

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Clean the Printhead and Platen Roller

You can minimize printhead wear and maintain print quality with regular preventive measures.

Over time, the movement of media or ribbon across the printhead wears through the protective

ceramic coating, exposing and eventually damaging the print elements (dots). To avoid

abrasion:

• Clean the printhead frequently, and use well-lubricated thermal transfer ribbons with

backings optimized to reduce friction.

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

between the two.

• Ensure that the thermal transfer ribbon is as wide or wider than the label media to prevent

exposing the elements to the more abrasive label material.

For best results, clean the printhead after changing every roll of ribbon. Inconsistent print

quality, such as voids in the bar code or graphics, may indicate a dirty printhead.

Figure 15 • Location of the Printhead and Platen Roller

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

hanging necklaces, identification badges, or other metallic objects that could touch the

printhead. You are not required to turn off the printer power when working near an open

printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose

all temporary settings, such as label formats, and you must reload them before you resume

printing.

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

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

1Printhead assembly

2Platen roller

Routine Maintenance

Cleaning Procedures

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

To clean the printhead and platen roller, complete these steps:

1. Open the printhead assembly.

2. Remove the media and ribbon.

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

brown strip on the printhead assembly from end to end. In place of the Preventive

Maintenance Kit, you may use a clean swab dipped in a solution of isopropyl alcohol

(minimum 90%) and deionized water (maximum 10%). Allow the solvent to evaporate.

Caution • The printhead may be hot and could cause severe burns. Allow the printhead

to cool.

Caution • Before touching the printhead assembly, discharge any built-up static electricity

by touching the metal printer frame or by using an antistatic wriststrap and mat.

Routine Maintenance

Cleaning Procedures

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

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

solvent to evaporate.

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

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

printhead with Save-A-Printhead cleaning film. This specially coated material removes

contamination buildup without damaging the printhead. Call your authorized Zebra

reseller for more information.

Routine Maintenance

Cleaning Procedures

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Clean the Media Compartment and Sensors

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

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

paths.

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

Figure 16 • Cleaning the Sensors

1Take-label sensor

2Ribbon sensor

3Media sensor

Routine Maintenance

Cleaning Procedures

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Clean the Cutter Module

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

To clean the cutter module, complete these steps:

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

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

washer (2).

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

counterclockwise to lower the blade.

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

this procedure.

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

Routine Maintenance

Cleaning Procedures

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

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

wipe along the upper cutting surface (1) and the cutter blade (2). In place of the

Preventive Maintenance Kit, you may use a clean swab dipped in a solution of isopropyl

alcohol (minimum 90%) and deionized water (maximum 10%). Allow the solvent to

evaporate.

Figure 17 • Cleaning the Cutter Module

5. Replace the cutter shield.

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

The lower cutter blade returns to its correct operating position.

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

technician.

Routine Maintenance

Routine Maintenance for the Rewind Option

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Routine Maintenance for the Rewind Option

When you use the Rewind option, you will periodically need to remove printed labels or used

liner from the rewind spindle. You may also need to adjust the media alignment for the Rewind

option.

Remove Printed Labels or Liner from the Rewind Spindle

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

steps:

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

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

3. Loosen the thumbscrew on the rewind media guide.

Routine Maintenance

Routine Maintenance for the Rewind Option

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

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

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

Routine Maintenance

Routine Maintenance for the Rewind Option

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Adjust Media Alignment for Rewind Option

The instructions below apply only if the printer has a Rewind option. The liner should be

installed flush against the backplate of the rewind spindle to prevent the media/backing from

winding too loosely.

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

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

these steps:

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

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

backplate (2).

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Troubleshooting

This section provides information about errors that you might need to troubleshoot. Assorted

diagnostic tests are included.

Contents

Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Miscellaneous Printer Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Printer Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

FEED Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

FEED and PAUSE Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Communications Diagnostics Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Troubleshooting

Troubleshooting Checklists

100

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Troubleshooting Checklists

If an error condition exists with the printer, review this checklist:

Is there an error message on the LCD? If yes, see LCD Error Messages on page 101.

Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media

and Ribbon Sensor Sensitivity on page 74.

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

Media and Ribbon Sensor Sensitivity on page 74.

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

on page 105.

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

on page 109.

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

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

on page 25.

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

on page 66.

Review the label- and ribbon-loading illustrations in Load Media on page 33 and Load

Ribbon on page 47.

Does the printhead need to be adjusted? See Adjust Printhead Pressure on page 53for

more information.

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

on page 74 for more information.

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

Perform one or more of the self-tests given in Printer Diagnostics on page 113. Use the

results to help identify the problem.

If you are still having problems, see Contacts on page 3 for customer support information.

101

Troubleshooting

LCD Error Messages

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

LCD Error Messages

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

causes, and the recommended solutions.

Table 15 • LCD Error Messages

LCD Display/

Printer Condition Possible Cause Recommended Solution

The ERROR light flashes.

The printhead was replaced with

one that is not a genuine Zebra™

printhead..

Install a genuine Zebra™ printhead.

The printer stops; the

ERROR light flashes.

In thermal transfer mode, ribbon is

not loaded or incorrectly loaded. Load ribbon correctly. See Load

Ribbon on page 47.

In thermal transfer mode, the

ribbon sensor is not detecting

ribbon that is loaded incorrectly.

1. Load ribbon correctly. See Load

Ribbon on page 47.

2. Calibrate the sensors. See

Calibrate Media and Ribbon

Sensor Sensitivity on page 74.

In thermal transfer mode, media is

blocking the ribbon sensor. 1. Load media correctly. See Load

Media on page 33.

2. Calibrate the sensors. See

Calibrate Media and Ribbon

Sensor Sensitivity on page 74.

In thermal transfer mode, the

printer did not detect the ribbon

even though it is loaded correctly.

1. Print a sensor profile. See Print

Sensor Profile on page 73. The

ribbon out threshold (marked by

the word RIBBON) is likely too

high, above the black area that

indicates where the ribbon is

detected.

2. Calibrate the sensors or load

printer defaults. See Calibrate

Media and Ribbon Sensor

Sensitivity on page 74 or LOAD

DEFAULTS on page 57.

ERROR CONDITION

INVALID HEAD

ERROR CONDITION

RIBBON OUT

Troubleshooting

LCD Error Messages

102

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

The ERROR light flashes.

Ribbon is loaded, but the printer is

set for direct thermal mode. Ribbon is not required with direct

thermal media. If you are using direct

thermal media, remove the ribbon. This

error message will not affect printing.

If you are using thermal transfer media,

which requires ribbon, set the printer

for Thermal Transfer mode. See Select

Print Method on page 65.

The printer stops; the

ERROR light flashes.

The media is not loaded or is

loaded incorrectly. Load media correctly. See Load Media

on page 33.

Misaligned media sensor. Check position of the media sensor.

The printer is set for

noncontinuous media, but

continuous media is loaded.

Install proper media type, or reset

printer for current media type and

perform calibration.

The printer stops; the

ERROR light flashes.

The printhead is not fully closed. Close printhead completely.

The head open sensor is not

working properly. Call a service technician.

The ERROR light flashes.

The printhead has a faulty

thermistor.. Call a service technician.

The printer stops; the

ERROR light is on; the

printer cycles through these

three messages.

Caution • An improperly connected printhead data or power cable

can cause these error messages. The printhead may be hot

enough to cause severe burns. Allow the printhead to cool.

The printhead data cable is not

properly connected. Caution • Turn off (O) the printer

before performing this procedure.

Failure to do so can damage the

printhead.

1. Turn off (O) the printer.

2. Disconnect and reconnect the data

cable to the printhead.

3. Ensure that the cable connector is

fully inserted into the printhead

connector.

4. Turn on (I) the printer.

The printhead has a faulty

thermistor. Call a service technician.

Table 15 • LCD Error Messages (Continued)

LCD Display/

Printer Condition Possible Cause Recommended Solution

WARNING

RIBBON IN

ERROR CONDITION

PAPER OUT

ERROR CONDITION

HEAD OPEN

THERMISTOR

FAULT

WARNING

HEAD COLD

THERMISTOR

FAULT

ERROR CONDITION

HEAD ELEMENT BAD

103

Troubleshooting

LCD Error Messages

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

The printer prints while the

ERROR light flashes.

Caution • An improperly connected printhead data or power cable

can cause this error message. The printhead may be hot enough to

cause severe burns. Allow the printhead to cool.

The printhead temperature is

approaching its lower operating

limit.

Continue printing while the printhead

reaches the correct operating

temperature. If the error remains, the

environment may be too cold for

proper printing. Relocate the printer to

a warmer area.

The printhead data cable is not

properly connected. Caution • Turn off (O) the printer

before performing this procedure.

Failure to do so can damage the

printhead.

1. Turn off (O) the printer.

2. Disconnect and reconnect the data

cable to the printhead.

3. Ensure that the cable connector is

fully inserted into the printhead

connector.

4. Turn on (I) the printer.

The printhead has a faulty

thermistor. Call a service technician.

The printer stops; the

ERROR light flashes.

Caution • The printhead may be hot enough to cause severe

burns. Allow the printhead to cool.

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

automatically resumes when the

printhead elements cool to an

acceptable operating temperature.

Table 15 • LCD Error Messages (Continued)

LCD Display/

Printer Condition Possible Cause Recommended Solution

WARNING

HEAD COLD

WARNING

HEAD TOO HOT

Troubleshooting

LCD Error Messages

104

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

The printer stops.

The printer is defragmenting

memory. Caution • Do NOT turn off the printer

power during defragmenting. Doing so

can damage the printer.

Allow the printer to finish

defragmenting. If you get this error

message frequently, check your label

formats. Formats that write to and erase

memory frequently may cause the

printer to defragment often. Using

properly coded label formats usually

minimizes the need for defragmenting.

If this error message does not go away,

contact Technical Support. The printer

requires service.

The printer stops; the

ERROR light flashes.

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

with your fingers.

The cutter blade is in the media

path. Turn off the printer power and unplug

the printer. Inspect the cutter module

for debris and clean as needed

following the cleaning instructions in

Clean the Cutter Module on page 94.

There is not enough memory to

perform the function specified on

the second line of the error

message.

Free up some of the printer’s memory

by adjusting the label format or printer

parameters. One way to free up

memory is to adjust the print width to

the actual width of the label instead of

leaving the print width set to the

default. See Set Print Width

on page 66.

Ensure that the data is not directed to a

device that is not installed or is

unavailable.

Refer to the Maintenance Manual for

more information about the specified

function.

Table 15 • LCD Error Messages (Continued)

LCD Display/

Printer Condition Possible Cause Recommended Solution

DEFRAGMENTING

ERROR CONDITION

CUTTER JAM

OUT OF MEMORY

(function)

105

Troubleshooting

Print Quality Problems

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Print Quality Problems

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

solutions.

Table 16 • Print Quality Problems

Problem Possible Cause Recommended Solution

General print quality

issues The printer is set at the

incorrect print speed. For optimal print quality, set the print speed to

the lowest possible setting for your application

via control panel, the driver, or the software. See

Adjust Print Speed on page 63. You may want to

perform the FEED Self Test on page 116.

You are using an incorrect

combination of labels and

ribbon for your application.

1. Switch to a different type of media or ribbon

to try to find a compatible combination.

2. If necessary, consult your authorized Zebra

reseller or distributor for information and

advice.

The printer is set at an incorrect

darkness level. For optimal print quality, set the darkness to the

lowest possible setting for your application via

the control panel, the driver, or the software. See

Adjust Print Darkness on page 62. You may

want to perform the FEED Self Test on page 116

to determine the ideal darkness setting.

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

and Platen Roller on page 90.

Incorrect or uneven printhead

pressure. Set the printhead pressure to the minimum

needed for good print quality. See Adjust

Printhead Pressure on page 53.

The printhead is improperly

balanced. Call a service technician.

Long tracks of

missing print on

several labels

Print element damaged. Call a service technician.

Troubleshooting

Print Quality Problems

106

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Wrinkled ribbon Ribbon fed through the

machine incorrectly. See Load Ribbon on page 47.

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

good print quality. See Adjust Print Darkness

on page 62.

Incorrect or uneven printhead

pressure. Set the printhead pressure to the minimum

needed for good print quality. See Adjust

Printhead Pressure on page 53.

Media not feeding properly;

“walking” from side to side. Make sure that media is snug by adjusting the

media guide, or call a service technician.

The strip plate needs adjusting. Call a service technician.

The printhead needs vertical

adjustment. Call a service technician.

The printhead is improperly

balanced. Call a service technician.

The printhead and platen roller

need to be realigned. Call a service technician.

Printing too light or

too dark over the

entire label

The media or ribbon is not

designed for high-speed

operation.

Replace supplies with those recommended for

high-speed operation.

You are using an incorrect

combination of media and

ribbon for your application.

1. Switch to a different type of media or ribbon

to try to find a compatible combination.

2. If necessary, consult your authorized Zebra

reseller or distributor for information and

advice.

You are using ribbon with

direct thermal media. Direct thermal media does not require ribbon. To

check if you are using direct thermal media,

perform the label scratch test in When to Use

Ribbon on page 27.

Incorrect or uneven printhead

pressure. Set the pressure to the minimum needed. See

Adjust Printhead Pressure on page 53.

Smudge marks on

labels The media or ribbon is not

designed for high-speed

operation.

Replace supplies with those recommended for

high-speed operation.

Misregistration/skips

labels The printer is not calibrated. Recalibrate the printer.

Improper label format. Use correct label format.

Misregistration and

misprint of one to

three labels

The platen roller is dirty. See Clean the Printhead and Platen Roller

on page 90.

Media does not meet

specifications. Use media that meets specifications.

Table 16 • Print Quality Problems (Continued)

Problem Possible Cause Recommended Solution

107

Troubleshooting

Print Quality Problems

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Vertical drift in

top-of-form position The printer is out of calibration. Recalibrate the printer.

Vertical drift occurs during

normal printer operation.

Note • A vertical drift of

± 4 to 6 dot rows

(approximately 0.5 mm)

is within normal

tolerances.

Calibrate the printer.

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

and Platen Roller on page 90.

Vertical image or

label drift The printer is using

non-continuous labels but is

configured in continuous mode.

Configure the printer for non-continuous and run

calibration routine, if necessary.

The media sensor is positioned

incorrectly. Ensure that the media sensor is properly

positioned to read a single/consistent interlabel

gap.

The media sensor is calibrated

improperly. See Calibrate Media and Ribbon Sensor

Sensitivity on page 74.

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

and Platen Roller on page 90.

Improper printhead pressure

settings (toggles). Adjust the printhead pressure to ensure proper

functionality.

Improperly loaded ribbon or

media. Verify that the printer is loaded properly.

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

4 mm and consistently placed. Media must not

exceed minimum specifications for mode of

operation.

The bar code printed

on a label does not

scan.

The bar code is not within

specifications because the print

is too light or too dark.

Perform the FEED Self Test on page 116. Adjust

the darkness or print speed settings as necessary.

Not enough blank space around

the bar code. Leave at least 1/8 in. (3.2 mm) between the bar

code and other printed areas on the label and

between the bar code and the edge of the label.

Table 16 • Print Quality Problems (Continued)

Problem Possible Cause Recommended Solution

Troubleshooting

Calibration Problems

108

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Calibration Problems

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

solutions.

Table 17 • Calibration Problems

Problem Possible Cause Recommended Solution

Loss of printing

registration on labels.

Excessive vertical

drift in top-of-form

registration.

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

instructions in Clean the Printhead and Platen

Roller on page 90.

Media guides are positioned

improperly. Ensure that the media guides are properly

positioned.

The media type is set

incorrectly. Set the printer for the correct media type

(gap/notch, continuous, or mark). See Set Media

Type on page 65.

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

on page 33.

Auto Calibrate failed. Media or ribbon is loaded

incorrectly. Ensure that media and ribbon are loaded

correctly.

The sensors could not detect the

media or ribbon. Manually calibrate the printer. See Calibrate

Media and Ribbon Sensor Sensitivity on page 74.

The sensors are dirty or

positioned improperly. The

sensors are dirty, or media is

positioned improperly for the

sensors to detect.

Ensure that the sensors are clean and that media

is positioned properly.

109

Troubleshooting

Communications Problems

3/27/07 ZM400/ZM600 User Guide 79695L-001 Rev. A

Communications Problems

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

solutions.

Table 18 • Communications Problems

Problem Possible Cause Recommended Solution

A label format was sent to

the printer but was not

recognized. The DATA

light does not flash.

The communication

parameters are incorrect. Check the printer driver or software

communications settings (if applicable).

If you are using serial communication, check

the serial port setting in the control panel

menu. See Set Serial Communications

on page 75.

If you are using serial communication, make

sure you are using a null modem cable or a null

modem adapter.

Using the control panel controls, check the

protocol setting. It should be set to NONE. See

Set Protocol on page 77.

If a driver is used, check the driver

communication settings for your connection.

A label format was sent to

the printer. Several labels

print, then the printer

skips, misplaces, misses, or

distorts the image on the

label.

The serial communication

settings are incorrect. Ensure that the flow control settings match.

Check the communication cable length. See

Table 5 on page 19 for requirements.

Check the printer driver or software

communications settings (if applicable).

A label format was sent to

the printer but was not

recognized. The DATA

light flashes but no

printing occurs.

The prefix and delimiter

characters set in the printer

do not match the ones in the

label format.

Verify the prefix and delimiter characters. See

Set Format Prefix Character on page 78 and

Set Delimiter Character on page 79 for the

requirements.

Incorrect data is being sent

to the printer. Check the communication settings on the

computer. Ensure that they match the printer

settings.

If the problem continues, check the label

format.

Troubleshooting

Ribbon Problems

110

79695L-001 Rev. A ZM400/ZM600 User Guide 3/27/07

Ribbon Problems

Table 19 identifies problems that may occur with ribbon, the possible causes, and the

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