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It sounds like your labelling software is re-sending the entire print job each time. Do some research with your software and see if you can change the defaults so that everything BUT the serial number is stored inside the printer, and only the new serial number is sent. It's difficult to be more specific because every software package is different...
The serial number is located on the guide for the print head holder. Open the cover, as if your going to change the ink. To the right of the print head holder (where the ink goes), on the guide that moves the holder back and forth, there is a white label with the serial number. The number starts with four letters and ends with five numbers.
Make sure the label size is correct, if the print encounters a gap before it is complete; it will re-print the same label. In MS Word make sure the page size is set to the correct size including any headers and footers and Width etc.
Sounds like you chose print to file for the port in the driver instead of what it should be set for. comm for serial cables. lpt1 for parallel, usb for usb. by having it set the way you do it is told to save the code. goto printers and faxes and right click on the zdesigner print driver and chose properties. then click the ports tab and chose the correct port.
if you are using the free software that came with the printer, it does not print serialized numbers very well past about 160 or so... to stop the pausing uncheck the "Print bar code as a graphic" box and check the "Auto font scaling" box.
Eventually you HAVE to give the printer a break, during inventory times at work, we have to print 50K+ labels, and in order to prevent either serial number skipping or other issues, I print in 250 batches, yes; there is a time gap but it's better than to restart a series of prints because a few numbers were skipped. Try printing 200 and 200 sets to prevent errors or skips.
The printer shouldn't print the same barcode twice. As long as the data is exactly the same, and the supplies are exactly the same, these two printers should be acting the same.
Are you using a 3rd party software application or driver? If so, you may need to contact them to help you adjust the issue, but longoftheshort, if the printer details are exact, like above, then the printer is duplicating, likely, because it is being told to do it. Since the printer cannot arbitrarily reprint a label, it must be told to do it. That is either done through data, or it is done because it didn't finish the job on the previous label and may do it on the followup label.
Generally the ZM 400 can cope with printing at the lower speeds when printing barcoedes that are the same. You may get pauses if the barcodes are sequential numbers or are all different, then the data to be transfered to the printer cannot cannot keep up with the printer and pauses while it gets more data. We have found that if you can select in your labelling software to print the barcode as a graphic, then it speed up quite a lot. It is a matter of matching your print speed and quality to match your expectations, sometimes you will just have to put up with the pauses.