Zebra ZD42042-C0EW02EZ User Manual
ZD620 and ZD420
Desktop Printers with Link-OS
®
User’s Guide
212485-002 Rev.B
Copyright
© 2017 ZIH Corp and/or its affiliates. All rights reserved. ZEBRA and the stylized Zebra
head are trademarks of ZIH Corp., registered in many jurisdictions worldwide. All other
trademarks are the property of their respective owners.
COPYRIGHTS AND TRADEMARKS: For complete copyright and trademark information, go to www.zebra.com/copyright
WARRANTY: For complete warranty information, go to www.zebra.com/warranty
END USER LICENSE AGREEMENT: For complete EULA information, go to www.zebra.com/eula
Terms of Use
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.
Product Improvements: Continuous improvement of products is a policy of Zebra
Technologies. All specifications and designs are subject to change without notice.
Liability Disclaimer: Zebra Technologies takes steps to ensure that its published
Engineering specifications and manuals are correct; however, errors do occur. Zebra
Technologies reserves the right to correct any such errors and disclaims liability resulting
therefrom.
Limitation of Liability: In no event shall Zebra Technologies 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 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.
2
About
This guide is for integrators and operators of Zebra Link-OS ZD620 and ZD420 desktop
printers. Use this guide to install, change configuration, operate, and physically support
these printers.
Other Online resources are available to support this printer include:
• “How To” videos
• ZD620 or ZD420 Desktop Printer Product page links for printer specifications
• Printer accessory, supplies, parts, and software links
• Various setup and configuration guides
• Programmer’s manuals,
• Printer Drivers (Windows, Apple, OPOS, etc.)
• Printer Firmware
• Printer Fonts
• Utilities
• Knowledge base and support contacts
• Printer warranty and repair links
Use these links to get to your Online printer support resources:
• ZD620 Thermal Transfer Printer — www.zebra.com/zd620t-info
• ZD620 Direct Thermal Printer — www.zebra.com/zd620d-info
• ZD420 Thermal Transfer Ribbon Cartridge Printer — www.zebra.com/zd420c-info
• ZD420 Thermal Transfer Printer — www.zebra.com/zd420t-info
• ZD420 Direct Thermal Printer — www.zebra.com/zd420d-info
3
Other Valuable Printer Resources
Zebra has a large suite of free and fee based software, Apps (applications), and other
technical resources for your Zebra Link-OS printer.
These are just some of the extensive software and resource areas available Online:
• Label Design software
• Printer Management tools
• Virtual Devices for legacy languages normally associated with other printer
brands
• Cloud based Enterprise printer management and printing
• XML and PDF format file printing
• Oracle and SAP support
• IoT data tools (Zatar)
• A suite of Link-OS Mobile Apps (applications for phones, tablets, etc.)
About
• Link-OS software development kit (SDK)
• Additional Operating Systems (OS) and Service platforms
See ZebraLink, Zebra Link-OS, and Zatar from this Online link: www.zebra.com/software
Zebra OneCare Printer Service and Support
For maximum productivity, we can help your business ensure its Zebra printers are Online
and ready for business. See the descriptions of the Zebra OneCare service and support
options available for your printers Online at this link: www.zebra.com/zebraonecare
Using This Document and Its Internally Attached Files
This document is best used with Adobe Reader or Adobe DC. This user’s guide includes
attached User Programming Example Files for sample printer operations.
Go to the Adobe Web site to load Adobe Reader (for free at the release time of this
publication): www.adobe.com
4
Document Conventions
The following graphic icons are used throughout the documentation set. These icons and
their associated meanings are described below.
Caution • If the precaution is not heeded, the user could receive minor or moderate injury.
Eye Injury Caution • If the precaution is not taken, the user’s eyes could be damaged. EXAMPLE:
Wear protective eyewear when installing or removing E-rings, C-clips, snap rings, springs, and
mounting buttons. These are under tension and could fly off.
Electrical Shock Caution • If the precaution is not taken, the user could receive an electrical shock.
EXAMPLE: Turn off (O) the printer and disconnect it from the power source before performing the
following procedure.
Hot Surface Caution • If the precaution is not taken, the user could be burned. EXAMPLE: The
About
printhead may be hot and could cause sever burns. Allow the printhead to cool.
Product Damage Caution • If the precaution is not taken, the product could be damaged.
EXAMPLE: Unplugging the computer without properly shutting it down may corrupt the data on your
hard drive.
ESD Caution • If the precaution is not taken, the product electronics could be damaged by an
electrostatic discharge. EXAMPLE: Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
Important • The text here indicates information that is important for the user to know. EXAMPLE:
Run the setup.exe file for the product BEFORE connecting the product to your printer.
Note • The text here indicates information that is supplemental for the user to know and that is not
required to complete a task. EXAMPLE: Refer to zebra.com for complete information on product
warranties.
5
Contents
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Terms of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
• About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
• Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
• Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Link-OS 4 inch Desktop Thermal Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Zebra Label Printing Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
What’s in the Box? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Other Valuable Printer Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Zebra OneCare Printer Service and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Using This Document and Its Internally Attached Files . . . . . . . . . . . . . . . . . . . . . .4
Common Desktop Link-OS Printer Features:. . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Link-OS 4 inch Desktop Printer Options: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Modes of Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Open the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Closing the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
• Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Inside the ZD620 Dual Capacity Ribbon Roll Printer . . . . . . . . . . . . . . . . . . . . . . .29
Dual Capacity Ribbon Chassis - Ribbon Roll Holders . . . . . . . . . . . . . . . . . . . . . .30
Media Dancer - ZD620 Printer Models Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Inside the ZD620 and ZD420 Direct Thermal Printers . . . . . . . . . . . . . . . . . . . . . .31
Inside the ZD420 Ribbon Cartridge Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6
Contents
Accessing the Printhead of the Ribbon Cartridge Printer. . . . . . . . . . . . . . . . . . . .33
Label Dispenser Option (field installable) - All Models. . . . . . . . . . . . . . . . . . . . . .34
Cutter Option (field installable) - All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Linerless Media Tear-Off Option (Direct Thermal Models Only) . . . . . . . . . . . . . .35
Linerless Cutter Option (Direct Thermal Models Only). . . . . . . . . . . . . . . . . . . . . .35
Identifying Platen Drive Rollers Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Printer Power Supply Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Attached Power Supply Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Battery Power Base and Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
ZD620 and ZD420 Locking Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Zebra Print Touch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
• Install Hardware Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Field Installable printer Accessories and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Printer Connectivity Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Media Handling Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Power Base Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Printer Connectivity Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Power Failure Recovery Mode Jumper (OFF by Default) . . . . . . . . . . . . . . . . . . .42
Accessing the Connectivity Module Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Installing the Serial Port Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Installing the Internal Ethernet (LAN) Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Removing Printer Connectivity Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Media Handling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Removing the Standard Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Installing the Label Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Installing the Standard Media Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Installing the Linerless Media Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Installing the Linerless Media ‘Tear-Off’ Bezel. . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Media Roll Core Size Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Installing Media Roll Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Print Resolution Upgrade Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Installing the Printhead Resolution Upgrade Kits . . . . . . . . . . . . . . . . . . . . . . . . . .53
Installing the Attached Power Supply Base Options . . . . . . . . . . . . . . . . . . . . . . . . . .54
• Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Standard Interface Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
LCD User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Meaning of the Indicator Light Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Status - Typical Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Printer Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Media Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
7
Contents
Ribbon Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Ribbon Low (Ribbon Cartridge Printers Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Ribbon In (Ribbon Cartridge Printers Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Transferring Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Data Transfers Paused . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Out of Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Cover Open/Printhead (PH) Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Cut Error (Binding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Cartridge Authentication Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Status - Printhead Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Printhead Over Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Printhead Under Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Printhead Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Printhead Resolution Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Unauthorized Printhead Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Status - Bluetooth Low Energy (BTLE) Option. . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Bluetooth LE Paired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Bluetooth LE Failed to Pair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Status - Ethernet (LAN) Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Ethernet (LAN) No Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Ethernet (LAN) 100base Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Ethernet (LAN) 10base Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Ethernet (LAN) Link Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Status - Wi-Fi (WLAN) Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Wi-Fi Connecting to WLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Wi-Fi (WLAN) 100base Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Wi-Fi (WLAN) 10base Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Wi-Fi (WLAN) Link Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Display Controls and Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Navigating through Menu Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Idle Display (Default Start-up Screen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Home Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
• Printer Configuration Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Adjust Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
User Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
8
Contents
SETTINGS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
DARKNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
PRINT SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
MEDIA TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
PRINT METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
TEAR OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
PRINT WIDTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
PRINT MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
LABEL TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
LEFT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
REPRINT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
LABEL LENGTH MAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
TOOLS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
PRINT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
IDLE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
POWER UP ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
HEAD CLOSE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
LOAD DEFAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
MEDIA/RIBBON CAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
ZBI ENABLED? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
RUN ZBI PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
STOP ZBI PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
PRINT USB FILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
COPY USB FILE TO E: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
STORE E: FILE TO USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
PRINT STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
PASSWORD PROTECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
PRINT TEST FORMAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
9
Contents
NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
ACTIVE PRINT SERVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
PRIMARY NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
WIRED IP ADDRESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
WIRED SUBNET MASK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
WIRED GATEWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
WIRED IP PROTOCOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
WIRED MAC ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
WLAN IP ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
WLAN SUBNET MASK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
WLAN GATEWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
WLAN IP PROTOCOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
WLAN MAC ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
ESSID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
CHANNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
IP PORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
IP ALTERNATE PORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
RESET NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
VISIBILITY AGENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
BATTERY Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
BATTERY STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
LANGUAGE Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
COMMAND LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
COMMAND CHAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
CONTROL CHAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
DELIMITER CHAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
ZPL MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
VIRTUAL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
SENSOR TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
LABEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
TAKE LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
BAUD RATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
DATA BITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
PARITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
HOST HANDSHAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
WML. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
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Contents
BLUETOOTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
BLUETOOTH ADDRESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
DISCOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
CONNECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
BT SPEC VERSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
MIN SECURITY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
• Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Printer Setup Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Select a Location for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Install Printer Options and Connectivity Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Attaching Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Getting Ready to Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Preparing and Handling Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Media Storage Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Loading Roll Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Setting Media Sensing by Media type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Instructions for media loading: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Using the Movable Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Loading Roll Media (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Loading Thermal Transfer Roll Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Loading Zebra Transfer Roll Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Loading Non-Zebra 300 Meter Transfer Ribbon . . . . . . . . . . . . . . . . . . . . . . . . .161
Loading the ZD420 Ribbon Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Run a SmartCal Media Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
SmartCal Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Test Printing with the Configuration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Detecting a Media Out Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Detecting a Ribbon Out Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Connecting your Printer to a Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
®
Pre-install Windows
Interface Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
USB Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Ethernet (LAN, RJ-45) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Wi-Fi and Bluetooth Classic Wireless Connectivity Option . . . . . . . . . . . . . . . . . . . .178
Update Printer Firmware to Finish Option Installations . . . . . . . . . . . . . . . . . . . .178
Printer Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
• Setup for Windows® OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Windows to Printer Communication Setup (Overview). . . . . . . . . . . . . . . . . . . . . . . .179
®
Pre-install Windows
Setting Up the Wi-Fi Print Server Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Printer Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
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Contents
Configure Using the ZebraNet Bridge’s Connectivity Wizard . . . . . . . . . . . . . . . . . . .182
Using a Configuration Script. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Saving a Configuration Script. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Bluetooth Option Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
®
Connecting to a Windows XP
Connecting to a Windows Vista
Connecting the Printer to a Windows 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Connecting the Printer to a Windows 10 PC . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
After Your Printer is Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Testing Communications by Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
SP2 Master Device. . . . . . . . . . . . . . . . . . . . . . .192
®
SP2 or Windows 7® Master Device. . . . . . . . .193
• Print Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Thermal Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Determining Your Printer’s Configuration Settings. . . . . . . . . . . . . . . . . . . . . . . .202
Select a Print Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Adjusting the Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Darkness Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Adjusting the Print Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
Replacing Supplies while Using the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
Printing on Fan-Fold Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Printing with Externally Mounted Roll Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
Externally Mounted Roll Media Considerations:. . . . . . . . . . . . . . . . . . . . . . . . . .209
Using the Label Dispenser Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
Using the Linerless Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Linerless Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Sending Files to the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
Ribbon Cartridge Programming Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
Printer Fonts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Identifying Fonts in Your Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
Localizing the Printer with Code Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
Asian fonts and Other Large Font Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
Getting Asian Fonts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
EPL Line Mode - Direct Thermal Printers only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Zebra® ZKDU — Printer Accessory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
ZD620 and ZD420 Locking Printer Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
ZBI 2.0 ™ — Zebra Basic Interpreter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
Setting the Power Failure Recovery Mode Jumper . . . . . . . . . . . . . . . . . . . . . . . . . .223
• USB Host Port and Link-OS Demonstration Examples . . . . . . . . . . . . . . 225
USB Host . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Using USB Host for Firmware Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Flash Drive Preparation and Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . . .226
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Contents
USB Host and Printer Usage Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
Items Required for the USB Host Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
Files for Completing the Exercises. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
File 1:
File 2: SAMPLELABEL.TXT....................227
File 3:LOGO.ZPL .......................227
File 4: USBSTOREDFILE.ZPL...................228
File 5: VLS_BONKGRF.ZPL....................228
File 6: VLS_EIFFEL.ZPL.....................228
File 7: KEYBOARDINPUT.ZPL...................229
File 8: SMARTDEVINPUT.ZPL...................229
Exercise 1: Copy Files to a USB Flash Drive and Perform USB Mirror . . . . . . . .230
Exercise 2: Print a Label Format from a USB Flash Drive . . . . . . . . . . . . . . . . . .232
Exercise 3: Copy Files to/from a USB Flash Drive. . . . . . . . . . . . . . . . . . . . . . . .233
Exercise 4: Enter Data for a Stored File with a USB Keyboard and Print a Label235
Using the USB Hosts Port and the NFC Capabilities . . . . . . . . . . . . . . . . . . . . . . . . .236
Exercise 5: Enter Data for a Stored File with a Smart Device and Print a Label .237
ZEBRA.BMP.......................227
• Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
Cleaning Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
Recommended Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Standard Platen (Drive) Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Linerless Platen (Drive) Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Media Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Label Dispenser Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
Cleaning the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
ZD620 / ZD420 Direct Thermal Printers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
ZD620 / ZD420 Thermal Transfer Printers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
ZD420 Ribbon Cartridge Printers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
Media Path Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Lower Half of ZD60/ZD420 Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Upper Half of ZD620/ZD420 Direct Thermal Printers. . . . . . . . . . . . . . . . . . . . . .247
Upper Half of ZD620/420 Thermal Transfer Printers . . . . . . . . . . . . . . . . . . . . . .247
Upper Half of ZD420 Thermal Transfer Ribbon Cartridge Printers . . . . . . . . . . .248
Cleaning the Cutter and Label Dispenser Options . . . . . . . . . . . . . . . . . . . . . . . .249
Cutter Option Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
Label Dispenser Option Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
Sensor Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
13
Contents
Lower Half of ZD60/ZD420 Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
Upper Half of ZD620/ZD420 Direct Thermal Printers. . . . . . . . . . . . . . . . . . . . . .252
Upper Half of ZD620/ZD420 Thermal Transfer Printers. . . . . . . . . . . . . . . . . . . .252
Upper Half of ZD420 Ribbon Cartridge Printers. . . . . . . . . . . . . . . . . . . . . . . . . .253
Platen Cleaning and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
Removing the Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
Replacing the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
ZD620 and ZD420 Direct Thermal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Removing the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Replacing the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
ZD620 and ZD420 Thermal Transfer Ribbon Roll . . . . . . . . . . . . . . . . . . . . . . . .265
Removing the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265
Replacing the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
ZD420 Thermal Transfer Ribbon Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
Printhead Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
Updating Printer Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
Other Printer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
RTC Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
• Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Resolving Alerts and Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Alert: Printhead Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Alert: Media Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Possible Cause - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Possible Cause - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
Possible Cause - 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
Alert: Ribbon In (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . . . . .279
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
Alert: Ribbon Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280
Possible Cause - 2 (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . .280
Possible Cause - 3 (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . .280
Possible Cause - 4 (Standard Roll - Thermal Transfer Printers) . . . . . . . . . . . . .280
Alert: Ribbon Low (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . . .281
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281
Alert: CUT ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282
14
Contents
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282
Alert: PRINTHEAD OVER TEMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
Alert: PRINTHEAD SHUTDOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284
Alert: PRINTHEAD UNDER TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
Alert: OUT OF MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .286
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .286
Resolving Print Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Issue: General Print Quality Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Possible Cause - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Possible Cause - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Possible Cause - 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288
Issue: No Print on the Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288
Issue: Labels Are Distorted in Size or Print Area Start Position Varies . . . . . . . .289
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
Possible Cause - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
Communication Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
Issue: Label Job Sent, No Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
Possible Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
Issue: Label Job Sent, Skips Labels or Prints Bad Content . . . . . . . . . . . . . . . . .290
Possible Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
Issue: Label Job Sent, Data Transfers, But No Print . . . . . . . . . . . . . . . . . . . . . .291
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291
Miscellaneous Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
Issue: Settings are Lost or Ignored . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . .
Possible Cause - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
Issue: Non-continuous labels act as Continuous labels. . . . . . . . . . . . . . . . . . . .293
. . . . . . . . . . . . . . . . . . . . . . . . .292
15
Contents
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293
Issue: Printer Locks-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
Issue: Erroneous Ribbon Cartridge Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
Possible Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
• Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
SmartCal Media Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
Configuration Report (CANCEL Self Test). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
Printer Network (and Bluetooth) Configuration Report. . . . . . . . . . . . . . . . . . . . .298
Print Quality Report (FEED self test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298
Reset Printer Factory Defaults (PAUSE + FEED Self Test). . . . . . . . . . . . . . . . .302
Reset Network Factory Defaults (PAUSE + CANCEL Self Test). . . . . . . . . . . . .302
Reset Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
Communication Diagnostics Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304
Sensor Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
Advanced Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
Manual Media Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308
Manual Print Width Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309
Manual Print Darkness Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310
Factory Test Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311
• Interface Connector Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
Universal Serial Bus (USB) Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
Serial Port Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313
Connecting the Printer to a DTE Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313
Connecting the Printer to a DCE Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314
• Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315
ZD620 / ZD420 Thermal Transfer Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316
ZD620 / ZD420 Ribbon Cartridge Thermal Transfer Models . . . . . . . . . . . . . . . . . . .323
ZD620 / ZD420 Direct Thermal Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330
• Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335
Types of Thermal Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336
Determining Thermal Media Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336
General Media and Print Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337
Label Dispenser (Peeler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338
Standard (Media) Cutter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
Linerless (Media) Cutter - Direct Thermal only. . . . . . . . . . . . . . . . . . . . . . . . . . .339
16
Contents
• ZPL Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
Managing the ZPL Printer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
ZPL Printer Configuration Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343
Configuration Setting to Command Cross-reference . . . . . . . . . . . . . . . . . . . . . . . . .344
Printer Memory Management and Related Status Reports . . . . . . . . . . . . . . . . . . . .347
ZPL Programming for Memory Management. . . . . . . . . . . . . . . . . . . . . . . . . . . .347
17
Introduction
This section introduces the award winning Zebra® Link-OS 4-inch desktop thermal label
printers, the ZD620 and ZD420. It has an overview of the Link-OS printer’s features and
options, and what ships with your new printer.
This document covers the following ZD-series desktop printer models:
• ZD620 Thermal Transfer Printer — www.zebra.com/zd620t-info
• ZD620 Direct Thermal Printer — www.zebra.com/zd620d-info
• ZD420 Thermal Transfer Ribbon Cartridge Printer — www.zebra.com/zd420c-info
• ZD420 Thermal Transfer Printer — www.zebra.com/zd420t-info
• ZD420 Direct Thermal Printer — www.zebra.com/zd420d-info
Link-OS 4 inch Desktop Thermal Printers
The Zebra® Link-OS 4 inch Desktop printers are compact label printers with a wide range
of features and options.
• Direct Thermal and Thermal Transfer printer models available.
• Includes ZD420 Healthcare printer models with plastics that withstand common
hospital cleaning chemicals and include a medical grade power supply.
• ZD620 printers can support printing speeds* up to 203.4 mm/s per second (8 ips inches per second) for 203 dpi (dots per inch print density) printers and
152.4 mm/s (6 ips) for 300 dpi version printers.
• ZD420 printers can support printing speeds* up to 152.4 mm/s per second (6 ips)
for 203 dpi printers and 101.6 mm/s (4 ips) for 300 dpi version printers.
• These printers support ZPL™ and EPL Zebra printer programming languages and
a wide variety of other printer control languages via Link-OS Virtual Devices.
* -Maximum print speeds vary by model, print resolution, and the type of media in use.
18
Introduction
Common Desktop Link-OS Printer Features:
• OpenAccess ™ design for simplified media loading.
• Color-coded “touch points” for operator controls and media guides.
• Enhanced user interface featuring three buttons and five status indicators.
• Easy, field installable media handling options.
• Media roll support:
• Outer Diameter (O.D.): Up to 127 mm (5 inch) and
• Inner Diameter (I.D.) roll cores:12.7 mm (0.5 inch), 25.4 mm (1 inch) and
additional core sizes with optional media core adapters.
• Movable Sensor provides compatibility with the widest range of media types:
• Compatible with full or partial width black mark media.
• Compatible with notched or slotted media.
• Multi-center position transmissivity sensor for use with label gap/web media.
• Universal Serial Bus (USB) Host Port that can be used for easy firmware
upgrades.
• Universal Serial Bus (USB) 2.0 interface
• Modular Connectivity Slot for field installable 10/100 Ethernet (802.3 RJ-45) or
Serial (RS-232 DB-9) interface options.
• On–the–fly OpenType and TrueType font scaling and import, Unicode, resident
scalable font (Swiss 721 Latin 1 font), and a selection of resident bitmap fonts.
• Backwards compatibility focused technology eases printer replacement:
• Drop in replacement of legacy Zebra desktop printers. The printer accepts
both EPL and ZPL programming languages.
• Supports Link-OS virtual devices to interpret non-Zebra printer programming
languages.
• XML-Enabled printing—allows XML communications for barcode label printing,
eliminating license fees and print server hardware and lowering customization and
programming costs.
• Zebra ™ Global Printing Solution – supports Microsoft Windows keyboard
encoding (and ANSI), Unicode UTF-8 and UTF 16 (Unicode Transformation
Formats), XML, ASCII (7 and 8 bit used by legacy programs and systems), basic
single and double byte font encoding, JIS and Shift-JIS (Japanese International
Standards), Hexadecimal encoding, and custom character mapping (DAT table
creation, font linking, and character remapping).
• Supports printer configuration via a setup utility running on mobile devices.
• Zebra’s Print Touch (Near Field Communication - NFC) ‘tap’ to pair devices,
access printer information, and access mobile applications.
• Zebra’s Link-OS - an open platform that connects operating systems for smart
Zebra devices with powerful software apps (applications), making the devices
easy to integrate, manage and maintain from any location.
19
Introduction
• Printhead maintenance reporting enabled and customizable by the user.
• Easy tool-less replacement of printhead and platen (driver) roller.
• A minimum of 64 MB of internal (E:\) printer memory for storing forms, fonts, and
graphics.
Link-OS 4 inch Desktop Printer Options:
• A Color LCD User Interface for easy setup, print configuration, printing, and a
range of Link-OS features.
• Healthcare printer models:
• Healthcare wipe-able plastics for disinfecting and cleaning.
• IEC 60601-1 certified power supply.
• Wi-Fi (802.11ac – includes a/b/g/n) and Bluetooth Classic 4.1 (3.X compatible)
wireless connectivity as a factory installed option.
• Thermal Transfer Printing - A choice of easy loading thermal transfer ribbon
cartridge or dual capacity ribbon roll (74 m and 300 m ribbons) models.
• ZD620 and select ZD420 printers have an factory installed, on-board Real Time
Clock (RTC) in printers that have Bluetooth Low Power (BTLE) or Wi-Fi with
Classic Bluetooth configurations.
• Field installable connectivity modules:
• Internal Ethernet Print Server (LAN, RJ-45 connector) — supports 10Base-T,
100Base-TX and fast Ethernet 10/100 auto-switching networks.
• Serial (RS-232 DB-9) Port
• Field installable media handling options:
• Label Dispenser (Peel-Off liner and present the label for the operator).
• General purpose media cutter.
• Linerless Label Tear-Off printing with a ‘Label Taken’ sensor.
• Linerless Label Cutter with a ‘Label Taken’ sensor.
20
Introduction
• Media Core Adapter kit include adapters for media rolls with Outer Diameters
(O.D.) up to 127 mm (5 inches):
• 38.1 mm (1.5 inch) I.D. media cores.
• 50.8 mm (2.0 inch) I.D. media cores.
• 76.2 (3.0 inch) I.D. media cores.
• Field upgrade kit to change printer resolution is available. Change your printer
from 203 dpi to 300 dpi - or - from 300 dpi to 203 dpi printing with these tool-less
upgrade kits.
• Asian Language support with printer configuration options for the large Simplified
and Traditional Chinese, Japanese, or Korean character sets.
• Printers sold in China have the Simplified Chinese SimSun font pre-installed.
• Zebra® ZBI 2.0 ™ (Zebra BASIC Interpreter) programming language. ZBI allows
you to create custom printer operations that can automate processes, use
peripherals (i.e. scanners, scales, keyboards, Zebra® ZKDU ™ , etc.) all without
being attached to a PC or network.
• Locking Media Cabinet for ZD620 Direct Thermal Healthcare printer models. This
special Healthcare model includes for additional security, Kensington ™ Slot for
Kensington locking devices to secure the printer.
21
Zebra Label Printing Solution
The printer is just one of three (3) parts of a printing solution. To print; you need a printer
(ZD620 or ZD420), compatible media (thermal transfer ribbon cartridge or rolls, and
thermal transfer media; or just direct thermal media), and software (driver, applications or
programming) to tell the printer what to do and print. The printer can print without being
connected to other devices or systems.
The media may be labels, tags, tickets, receipt paper, fan-fold stacks, tamper proof labels,
etc.
Zebra assists you with label design and print with the free label and form design software:
ZebraDesigner ™ for Windows PC operating systems.
Zebra provides a complete suite of free Link-OS software applications and drivers to
configure printer settings, print labels and receipts, get printer status, import graphics and
fonts, send programming commands, update firmware, and download files.
The Zebra web site or your reseller will be able to help you identify media for your desired
use case.
Introduction
22
Modes of Printing
You can operate this printer in many different modes and media configurations:
• Direct thermal printing (which uses heat sensitive media to print).
• Thermal transfer printing with easy to use thermal transfer ribbon cartridge or ribbon rolls (heat and pressure transfers ink from the ribbon to media).
• Standard Tear-Off mode allows you to tear off each label/receipt or batch print a
strip of labels and tear them off after it is printed.
• Label Dispense Mode: If an optional dispenser is installed, the backing material
can be peeled away from the label as it is printed. After this label is removed, the
next one is printed.
• Media Cutting: If an optional media cutter is installed, the printer can cut the label
liner between labels, receipt paper or tag stock.
• Linerless media printing with Cut or Tear-Off label options for easy pick and place
label applications.
• Stand-alone: The printer can print without being directly connected to a computer.
Introduction
• A printer with the color LCD display option can use menus to access and print
a label format/form.
• A Link-OS App connecting via Bluetooth (Wireless option).
• An auto running label format/form (programming based).
• A data input device connected to the printer’s USB Host port or serial port.
This mode accommodates data input devices, such as scanners, weigh
scales, a Zebra Keyboard Display Unit (ZKDU), etc.
• Shared network printing: Printers configured with Ethernet (LAN) and Wi-Fi
interface options include an internal print server.
23
What’s in the Box?
Documentation
and Software
USB CablePrinter
Power
Supply
Non-Zebra 300 Meter Ribbon
Adapters
Printer Documentation
Included with Thermal Transfer Printer (uses ribbon rolls)
Empty Starter Ribbon Cores
After unpacking, make sure you have all parts shown below. Follow the procedures for
inspecting the printer to familiarize yourself with printer parts so you can follow the
instructions in this book.
Introduction
24
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.
• Open the printer 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. Zebra
Technologies Corporation is not responsible for any damage to the printer
incurred during shipment, and will not cover the repair of this damage under its
warranty policy.
• Keep all packaging material for shipping company inspection.
• Notify your authorized Zebra
See the Zebra Web site for ‘How To’ videos on packing and unpacking your printer. See
About section for links to one of these 5 basic Link-OS printer variations.
Introduction
®
reseller.
25
Open the Printer
To access the media compartment, pull the release latches towards you and lift the cover.
Check the media compartment for loose or damaged components.
Introduction
ESD Caution • The discharge of electrostatic energy that accumulates on the surface of
the human body or other surfaces can damage or destroy the printhead and other
electronic components used in this device. You must observe static-safe procedures when
working with the printhead or the electronic components under the top cover.
Closing the printer
Lower the top cover. Press down in the middle of the cover in front until the cover snaps
closed.
26
Printer Features
This section will help you identify features of these Zebra® Link-OS 4-inch desktop thermal
label printers, the ZD620 and ZD420. ‘How to’ videos on the Zebra Web site include a
Printer Features video; as well as; other printer setup and task specific videos. Links to
these five (5) Link-OS 4- inch desktop printers are:
• ZD620 Thermal Transfer Printer — www.zebra.com/zd620t-info
• ZD620 Direct Thermal Printer — www.zebra.com/zd620d-info
• ZD420 Thermal Transfer Ribbon Cartridge Printer — www.zebra.com/zd420c-info
• ZD420 Thermal Transfer Printer — www.zebra.com/zd420t-info
• ZD420 Direct Thermal Printer — www.zebra.com/zd420d-info
27
Printer Features
Interface and Connectivity
Module Slot Access
User Interface
Release
Latch
DC Power
Receptacle
Power Button
Release
Latch
Fan-Fold Media
Entry Slot
For more details on printer controls, see Controls and Indicators
Printer Features
28
Printer Features
Movable Sensor
(Black Mark and Lower Web/Gap)
Media Guides
Head-Up Sensor
(inside)
Media Guide Stop
Adjustment
Platen (Drive) Roller
Roll Holders
Upper Web (Gap)
Array Sensor
(other side)
Ribbon Carriage
Printhead
Inside the ZD620 Dual Capacity Ribbon Roll Printer
29
Printer Features
Take Up Spindles
Supply Spindles (full ribbon rolls)
Media
Dancer
(ZD620 Only)
Dual Capacity Ribbon Chassis - Ribbon Roll Holders
Media Dancer - ZD620 Printer Models Only
The printer’s window is removed to show the Media Dancer (plate). the Media Dancer is
re-colored to make it easier to see. It is the same color as the dark gray parts adjacent to it.
30
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