Zebra ZD421, ZD422 User Manual
ZD421 and
ZD621 Series
Link-OS® Printers
User Guide
P1123730-01EN
ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corporation, registered in
many jurisdictions worldwide. All other trademarks are the property of their respective owners.
© 2021 Zebra Technologies Corporation and/or its affiliates. All rights reserved.
Information in this document is subject to change without notice. The software described in this document
is furnished under a license agreement or nondisclosure agreement. The software may be used or copied
only in accordance with the terms of those agreements.
For further information regarding legal and proprietary statements, please go to:
SOFTWARE:zebra.com/linkoslegal
COPYRIGHTS:zebra.com/copyright
WARRANTY:zebra.com/warranty
END USER LICENSE AGREEMENT: 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.
Publication Date
March 24, 2021
2
Contents
About ................................................................................................................................................. 11
Printer Resources .......................................................................................................... 11
Zebra OneCare Printer Service and Support ................................................................. 12
Icon Conventions ........................................................................................................... 12
Introduction....................................................................................................................................... 13
Link-OS 4 inch Desktop Thermal Printers...................................................................... 13
Common Desktop Link-OS Printer Features .......................................................... 14
Link-OS 4 inch Desktop Printer Options................................................................. 15
Zebra Label Printing Solution........................................................................................ 17
Modes of Printing.................................................................................................... 17
What’s in the Box? ........................................................................................................ 18
Unpack and Inspect the Printer .............................................................................. 18
Printer Features ................................................................................................................................ 20
Inside the ZD421 Dual Capacity Ribbon Roll Printer.............................................. 22
Inside the ZD621 Dual Capacity Ribbon Roll Printer.............................................. 23
Inside the ZD421 Direct Thermal Printers .............................................................. 26
Inside the ZD621 Direct Thermal Printers .............................................................. 27
Inside the ZD421 Ribbon Cartridge Printer ............................................................ 28
Label Dispenser Option (field installable) - All Models ........................................... 30
Cutter Option (field installable) - All Models ........................................................... 30
Linerless Media Tear-Off Option (Direct Thermal Models Only) ............................ 31
Linerless Cutter Option (Direct Thermal Models Only)........................................... 31
Identifying Platen Drive Rollers Types.................................................................... 32
Printer Power Supply Options ................................................................................ 33
ZD621 Direct Thermal Locking Printer Features .................................................... 35
Zebra Print Touch ......................................................................................................... 36
3
Contents
Controls and Indicators ................................................................................................................... 37
User Interface.................................................................................................................37
Standard Interface Controls.................................................................................... 38
Meaning of the Indicator Light Patterns ........................................................................ 41
Status - Typical Operating Conditions .................................................................... 41
Status - Printhead Operation .................................................................................. 43
Status - Bluetooth Low Energy (BTLE) Option ....................................................... 44
Status - Ethernet (LAN) Option............................................................................... 44
Status - Wi-Fi (WLAN) Option ................................................................................ 45
Battery Indicators and Controls...................................................................................... 45
Install Hardware Options ................................................................................................................. 47
Field Installable printer Accessories and Options .......................................................... 47
Printer Connectivity Modules ........................................................................................ 49
Accessing the Connectivity Module Slot................................................................. 49
Installing the Serial Port Module............................................................................. 50
Installing the Internal Ethernet (LAN) Module......................................................... 51
Installing the Wireless Connectivity Module ........................................................... 53
Media Handling Options................................................................................................ 56
Removing the Standard Bezel................................................................................ 56
Installing the Label Dispenser ................................................................................ 57
Installing the Standard Media Cutter ...................................................................... 58
Installing the Linerless Media Cutter ...................................................................... 59
Installing the Linerless Media ‘Tear-Off’ Bezel ....................................................... 60
Media Roll Core Size Adapters .............................................................................. 61
Print Resolution Upgrade Kits ................................................................................ 63
Installing the Attached Power Supply Base Options .............................................. 64
Installing the Attached Battery Base Options ......................................................... 66
Installing the Battery into the Attached Power Base............................................... 67
Color Touch Display and Controls.................................................................................................. 68
Color Touch Display Printer Controls............................................................................. 69
Home Screen ................................................................................................................. 70
Printer Status.......................................................................................................... 70
Printer Info .............................................................................................................. 71
Printer Wizards ....................................................................................................... 72
User Menus ............................................................................................................ 74
System Menu ................................................................................................................ 75
System > Language................................................................................................ 76
System > Program Language > Diagnostic Mode.................................................. 77
4
Contents
System > Program Language > Virtual Device .................................................. 78
System > Program Language > ZBI ....................................................................... 79
System > Settings > Display Time Format ............................................................. 80
System > Settings > Password Level ..................................................................... 81
System > Settings > Set Password ........................................................................ 82
System > Settings > Power Up Action.................................................................... 83
System > Settings > Head Close Action................................................................. 84
System > Settings > Screen Calibration................................................................. 85
System > Settings > Restore Defaults.................................................................... 86
System > Settings > Print: System Settings ........................................................... 87
System > Energy Saving > Energy Star ................................................................. 88
Connection Menu.......................................................................................................... 89
Connection > Networks > Reset Network............................................................... 90
Connection > Networks > Primary Network............................................................ 91
Connection > Networks > IP Port ........................................................................... 92
Connection > Networks > IP Alternate Port............................................................ 93
Connection > Networks > Print: Network Info......................................................... 94
Connection > Networks > Visibility Agent............................................................... 95
Connection > Wired > Wired IP Protocol................................................................ 96
Connection > Wired > Wired IP Address................................................................ 97
Connection > Wired > Wired Gateway ................................................................... 98
Connection > Wired > Wired Mac Address ............................................................ 99
Connection > WLAN > WLAN IP Protocol............................................................ 100
Connection > WLAN > WLAN IP Address............................................................ 101
Connection > WLAN > WLAN Subnet .................................................................. 102
Connection > WLAN > WLAN Gateway ............................................................... 103
Connection > WLAN > WLAN Mac Address ........................................................ 104
Connection > WLAN > ESSID .............................................................................. 105
Connection > WLAN > WLAN Security ................................................................ 106
Connection > WLAN > WLAN Band ..................................................................... 107
Connection > WLAN > WLAN Country Code ....................................................... 108
Connection > Bluetooth > Bluetooth..................................................................... 109
Connection > Bluetooth > Bluetooth Discovery .................................................... 110
Connection > Bluetooth > Friendly Name............................................................. 111
Connection > Bluetooth > Minimum Security Mode ............................................. 112
Connection > Bluetooth > Specification Version .................................................. 113
Connection > Bluetooth > MAC Address.............................................................. 114
Connection > Bluetooth > Bluetooth Auth. PIN .................................................... 115
Connection > Bluetooth > Bluetooth Bonding....................................................... 116
Print Menu................................................................................................................... 117
Print > Print Quality > Darkness ........................................................................... 118
5
Contents
Print > Print Quality > Print Speed........................................................................ 119
Print > Print Quality > Print Type .......................................................................... 120
Print > Print Quality > Label Type......................................................................... 121
Print > Print Quality > Label Length...................................................................... 122
Print > Print Quality > Label Width (Dots)............................................................. 123
Print > Label Position > Collection Method........................................................... 124
Print > Label Position > Tear Line Offset.............................................................. 125
Print > Label Position > Horizontal Label Offset................................................... 126
Print > Label Position > Vertical Label Offset ....................................................... 127
Print > Sensors > Manual Calibration................................................................... 128
Print > Sensors > Label Sensor............................................................................ 129
Print > Sensors > Sensor Type ............................................................................ 130
Print > Sensors > Print: Sensor Profile................................................................. 131
Print > Print Station............................................................................................... 132
Print > Applicator > Applicator Port Mode ............................................................ 133
Print > Applicator > Start Print Mode .................................................................... 134
Print > Applicator > Error on Pause...................................................................... 135
Print > Applicator > Applicator Reprint ................................................................. 136
RFID Menu.................................................................................................................. 137
RFID > RFID Status.............................................................................................. 138
RFID > RFID Test................................................................................................. 139
RFID > RFID Calibrate ......................................................................................... 140
RFID > Read Power ............................................................................................. 141
RFID > Write Power.............................................................................................. 142
RFID > RFID Antenna .......................................................................................... 143
RFID > RFID Valid Count ..................................................................................... 144
RFID > RFID Void Count ...................................................................................... 145
RFID > RFID Program Position ............................................................................ 146
RFID > Read RFID Data....................................................................................... 147
Storage Menu.............................................................................................................. 148
Storage > USB > Copy: Files to USB ................................................................... 149
Storage > USB > Copy: Files to Printer................................................................ 150
Storage > USB > Copy: Configuration to USB ..................................................... 151
Storage > USB > Print: From USB ....................................................................... 152
Storage > Print Asset Lists ................................................................................... 153
Storage > USB > Print from E: ............................................................................. 154
Setup................................................................................................................................................ 155
Printer Setup Overview ................................................................................................ 155
Select a Location for the Printer................................................................................... 155
Install Printer Options and Connectivity Modules......................................................... 156
6
Contents
Attaching Power........................................................................................................... 156
Getting Ready to Print.................................................................................................. 157
Preparing and Handling Media ............................................................................. 157
Media Storage Tips .............................................................................................. 158
Loading Roll Media ...................................................................................................... 158
Setting Media Sensing by Media type .................................................................. 158
Instructions for media loading:.............................................................................. 159
Loading Thermal Transfer Roll Ribbon ........................................................................ 165
Loading Zebra Transfer Roll Ribbon .................................................................... 166
Loading the ZD421 Ribbon Cartridge ......................................................................... 176
Run a SmartCal Media Calibration.............................................................................. 177
SmartCal Procedure ............................................................................................. 177
Test Printing with the Configuration Report ................................................................. 178
Detecting a Media Out Condition ................................................................................ 179
Detecting a Ribbon Out Condition............................................................................... 180
Connecting your Printer to a Computer....................................................................... 181
Interface Cable Requirements.............................................................................. 181
Wi-Fi and Bluetooth Classic Wireless Connectivity Option .......................................... 185
Setup for Windows® OS................................................................................................................. 186
Windows to Printer Communication Setup (Overview) ................................................ 186
Pre-install Windows® Printer Drivers ........................................................................... 186
Setting Up the Wi-Fi Print Server Option ..................................................................... 187
Configure Using the ZebraNet Bridge Connectivity Wizard ......................................... 187
Using a Configuration Script................................................................................. 194
Bluetooth Option Configuration.................................................................................... 195
Connecting to a Windows XP® SP2 Central Device............................................. 198
Connecting to a Windows Vista® SP2 or Windows 7® Central Device ................ 199
Connecting the Printer to a Windows 8 ................................................................ 202
Connecting the Printer to a Windows 10 PC ........................................................ 203
After Your Printer is Connected ................................................................................... 205
Print Operations.............................................................................................................................. 208
Thermal Printing........................................................................................................... 208
Determining Your Printer’s Configuration Settings ............................................... 208
Select a Print Mode or Collection Method.................................................................... 208
Adjusting the Print Quality............................................................................................ 209
Adjusting the Print Width.............................................................................................. 209
Replacing Supplies while Using the Printer.......................................................... 210
Printing on Fan-Fold Media.......................................................................................... 210
7
Contents
Printing with Externally Mounted Roll Media................................................................ 213
Externally Mounted Roll Media Considerations:................................................... 213
Using the Label Dispenser Option ............................................................................... 214
Using the Linerless Options ......................................................................................... 217
Linerless Printing .................................................................................................. 218
Sending Files to the Printer.......................................................................................... 218
Ribbon Cartridge Programming Commands ................................................................ 218
Printing with the Attached Battery Base and Battery Option........................................ 219
Printer Fonts................................................................................................................ 220
Identifying Fonts in Your Printer ........................................................................... 220
Localizing the Printer with Code Pages................................................................ 220
Asian fonts and Other Large Font Sets ................................................................ 221
EPL Line Mode - Direct Thermal Printers only............................................................ 222
ZD621 and ZD421 Locking Printer Option ................................................................... 222
Zebra® ZKDU — Printer Accessory ........................................................................... 223
ZBI 2.0 ™ — Zebra Basic Interpreter........................................................................... 223
Setting the Power Failure Recovery Mode Jumper...................................................... 224
USB Host Port and Link-OS Usage Examples ............................................................................. 225
USB Host ..................................................................................................................... 225
Using USB Host for Firmware Updates ................................................................ 226
USB Host and Printer Usage Examples...................................................................... 227
Items Required for the USB Host Exercises......................................................... 227
Files for Completing the Exercises....................................................................... 227
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 ............................................... 234
Exercise 4: Enter Data for a Stored File with a USB Keyboard and Print a Label 236
Using the USB Hosts Port and the NFC Capabilities................................................... 237
Exercise 5: Enter Data for a Stored File with a Smart Device andPrintaLabel.. 238
Maintenance.................................................................................................................................... 240
Cleaning.......................................................................................................................240
Cleaning Supplies................................................................................................. 240
Recommended Cleaning Schedule ...................................................................... 241
Cleaning the Printhead ......................................................................................... 243
Media Path Cleaning ............................................................................................ 246
Sensor Cleaning ................................................................................................... 251
Platen Cleaning and Replacement ....................................................................... 255
Replacing the Printhead.............................................................................................. 259
8
Contents
ZD621 and ZD421 Direct Thermal ....................................................................... 260
ZD621 and ZD421 Thermal Transfer Ribbon Roll................................................ 264
ZD421 Thermal Transfer Ribbon Cartridge .......................................................... 269
Updating Printer Firmware .......................................................................................... 273
Other Printer Maintenance........................................................................................... 273
RTC Battery ................................................................................................................. 273
Fuses ........................................................................................................................... 273
Troubleshooting ............................................................................................................................. 274
Resolving Alerts and Errors ......................................................................................... 274
Alert: Printhead Open ........................................................................................... 274
Alert: Media Out.................................................................................................... 275
Alert: Ribbon In (ZD421 Cartridge Printer only).................................................... 277
Alert: Ribbon Out .................................................................................................. 278
Alert: Ribbon Low (ZD421 Cartridge Printer only) ................................................ 279
Alert: CUT ERROR............................................................................................... 280
Alert: PRINTHEAD OVER TEMP ......................................................................... 281
Alert: PRINTHEAD SHUTDOWN ......................................................................... 282
Alert: PRINTHEAD UNDER TEMP....................................................................... 283
Alert: OUT OF MEMORY ..................................................................................... 284
Resolving Print Issues................................................................................................. 285
Issue: General Print Quality Issues ...................................................................... 285
Issue: No Print on the Label ................................................................................. 286
Issue: Labels Are Distorted in Size or Print Area Start Position Varies................ 287
Communication Issues................................................................................................ 288
Issue: Label Job Sent, No Data Transfer ............................................................. 288
Issue: Label Job Sent, Skips Labels or Prints Bad Content ................................. 288
Issue: Label Job Sent, Data Transfers, But No Print............................................ 289
Miscellaneous Issues.................................................................................................. 290
Issue: Settings are Lost or Ignored....................................................................... 290
Issue: Non-continuous labels act as Continuous labels. ...................................... 291
Issue: Printer Locks-Up ........................................................................................ 291
Issue: Erroneous Ribbon Cartridge Faults ........................................................... 291
Issue: Battery has a Red Indicator ....................................................................... 292
Tools ................................................................................................................................................ 293
Printer Diagnostics ....................................................................................................... 293
Power-On Self Test .............................................................................................. 293
SmartCal Media Calibration.................................................................................. 293
Configuration Report (CANCEL Self Test) ........................................................... 294
9
Contents
Printer Network (and Bluetooth) Configuration Report ......................................... 295
Print Quality Report (FEED self test).................................................................... 296
Reset Printer Factory Defaults (PAUSE + FEED Self Test) ................................. 299
Reset Network Factory Defaults (PAUSE + CANCEL Self Test) ......................... 299
Reset Button......................................................................................................... 300
Communication Diagnostics Test ......................................................................... 301
Sensor Profile ....................................................................................................... 302
Advanced Mode ........................................................................................................... 303
Manual Media Calibration..................................................................................... 303
Manual Print Width Adjustment ............................................................................ 304
Manual Print Darkness Adjustment ...................................................................... 305
Factory Test Modes ..................................................................................................... 306
Interface Wiring............................................................................................................................... 307
Universal Serial Bus (USB) Interface ........................................................................... 307
Serial Port Interface ..................................................................................................... 308
Connecting the Printer to a DTE Device............................................................... 308
Connecting the Printer to a DCE Device .............................................................. 309
Dimensions ..................................................................................................................................... 310
ZD621 / ZD421 Thermal Transfer Models ................................................................... 311
ZD421 Ribbon Cartridge Thermal Transfer Models ..................................................... 319
ZD621 / ZD421 Direct Thermal Models ....................................................................... 327
Media................................................................................................................................................ 334
Types of Thermal Media .............................................................................................. 334
Determining Thermal Media Types ...................................................................... 334
General Media and Print Specifications ............................................................... 335
ZPL Configuration ......................................................................................................................... 339
Managing the ZPL Printer Configuration...................................................................... 339
Configuration Setting to Command Cross-reference .................................................. 341
Printer Memory Management and Related Status Reports ......................................... 344
ZPL Programming for Memory Management ....................................................... 344
10
About
This guide is for integrators and operators of Zebra Link-OS ZD421 desktop printers. Use this guide to
install, change configuration, operate, and physically support these printers.
Information, support, and additional resources are available online to support this printer:
• ZD621 Thermal Transfer printer — zebra.com/
• ZD621 Direct Thermal printer — zebra.com/
• ZD421 Thermal Transfer Ribbon Cartridge printer — zebra.com/
• ZD421 Thermal Transfer printer — zebra.com/
• ZD421 Direct Thermal printer — zebra.com/
• ZD621R Thermal Transfer printer — zebra.com/
Printer Resources
Zebra has a large suite of technical resource for your Zebra Link-OS printer, as well as free and fee-based
software and Apps (applications), including:
• “How To” videos
• 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
ZD621t-info
ZD621d-info
ZD421c-info
ZD421t-info
ZD421d-info
ZD621r-info
• Utilities
• Knowledge base and support contacts
• Printer warranty and repair links
• 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
11
About
• Oracle and SAP support
• Zebra Savanna ™ Data Intelligence platform - turns raw data from devices (IoT) and sensors into
actionable intelligence for your business
• A suite of Link-OS Mobile Apps (applications for phones, tablets, etc.)
• Link-OS software development kit (SDK)
• Additional Operating Systems (OS) and Service platforms
Find out more about ZebraLink, Zebra Link-OS, and Zebra Savanna at 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. Refer to the descriptions of the Zebra OneCare service and support options available for your
printers at zebra.com/zebraonecare
.
Icon Conventions
The documentation set is designed to give the reader more visual clues. The following graphic icons are
used throughout the documentation set. These icons and their associated meanings are described below.
NOTE: The text here indicates information that is supplemental for the user to know and that is not
required to complete a task.
IMPORTANT: The text here indicates information that is important for the user to know.
CAUTION—EYE INJURY: Wear protective eyewear when performing certain tasks.
CAUTION—PRODUCT DAMAGE: If the precaution is not taken, the product could be damaged.
.
CAUTION: If the precaution is not heeded, the user could receive minor or moderate injury.
CAUTION—HOT SURFACE: Touching this area could result in burns.
CAUTION—ESD: Observe proper electrostatic safety precautions.
CAUTION—ELECTRIC SHOCK: Disconnect the printer power before performing certain procedures to
avoid the risk of electric shock.
WARNING: If danger is not avoided, the user CAN be seriously injured or killed.
DANGER: If danger is not avoided, the user WILL be seriously injured or killed.
NOTE: This is an icon for wired networking notes.
NOTE: This is an icon for wireless networking notes.
12
Introduction
This section introduces the Zebra Link-OS 4-inch desktop thermal label printers, the ZD621 and ZD421. 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:
• ZD621 Thermal Transfer Printer — zebra.com/
• ZD621 Direct Thermal Printer — zebra.com/
• ZD421 Thermal Transfer Ribbon Cartridge Printer — zebra.com/
• ZD421 Thermal Transfer Printer — zebra.com/
• ZD421 Direct Thermal Printer — zebra.com/
• ZD621R Thermal Transfer Printer — zebra.com/
ZD621d-info
ZD421d-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 some Healthcare printer model configurations with plastics that withstand common hospital
cleaning chemicals and include a medical grade power supply.
• ZD621 printers can support printing speeds* up to 203 mm/s per second (8 ips - inches per second)
for 203 dpi (dots per inch print density) printers and 152 mm/s (6 ips) for 300 dpi version printers.
• ZD421 printers can support printing speeds* up to 152 mm/s per second (6 ips) for 203 dpi printers
and 102 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.
ZD621t-info
ZD421c-info
ZD421t-info
ZD621r-info
NOTE: Maximum print speeds vary by model, print resolution, and the type of media in use.
13
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 in.) and
• Inner Diameter (I.D.) roll cores:12.7 mm (0.5 in.), 25.4 mm (1 in.) 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 updates.
• Universal Serial Bus (USB) 2.0 interface
• ZD621 - The Modular Connectivity Slot has a Serial (RS-232 DB-9) Port and an Ethernet (LAN,
RJ-45 connector) with an Internal Print Server that supports 10Base-T, 100Base-TX and fast
Ethernet 10/100 auto-switching networks factory installed.
• ZD421 — Modular Connectivity Slot is available for ZD421 field installable 10/100 Ethernet (802.3
RJ-45) with an Internal Print Server 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 c
table creation, font linking, and character remapping).
• Support for printer configuration via a setup utility running on mobile devices.
ustom character mapping (DAT
• Use the printer’s Bluetooth Low Energy (BTLE) feature exclusively for Zebra Link-OS Setup
Apps using for short range communication to mobile devices. Bluetooth LE works with Zebra
mobile setup utility applications to assist in printer setup, perform media calibration, and
maximize print quality.
• Zebra’s Print Touch (Near Field Communication - NFC) tap- to- pair devices, access printer
information, and access mobile applications.
14
Introduction
• 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.
• An On-board Real Time Clock (RTC).
• 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 Touch User Interface for easy setup, print configuration, printing, and a range of Link-OS
features.
• Factory Installed RFID support with the Color Touch Display with ZD621R thermal transfer printer.
• Healthcare printer models:
• Healthcare wipe-able plastics for disinfecting and cleaning.
• IEC 60601-1 certified power supply.
• Factory Installed and Field Installable Wired and Wireless options:
• Wi-Fi (802.11ac – includes a/b/g/n), Bluetooth Classic 4.1, and Bluetooth Low Energy (LE) 5.0
wireless connectivity.
• Internal Ethernet Print Server (LAN, RJ-45 connector) — supports 10Base-T, 100Base-TX and
fast Ethernet 10/100 auto-switching networks for wired connectivity. This includes Bluetooth Low
Energy (LE) wireless connectivity.
• ZD621 printers include Internal Ethernet Print Server (LAN, RJ-45 connector) — supports
10Base-T, 100Base-TX and fast Ethernet 10/100 auto-switching networks, and Serial (RS-232
DB-9) Port.
• Thermal Transfer Printing - a choice of easy loading thermal transfer ribbon cartridge or dual
capacity ribbon roll (74 m and 300 m ribbons) models.
• The printer has a factory installed, on-board Real Time Clock (RTC).
• ZD421 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.
15
Introduction
• Media Core Adapter kit include adapters for media rolls with Outer Diameters (O.D.) up to 127 mm
(5 in.):
• 38.1 mm (1.5 in.) I.D. media cores.
• 50.8 mm (2.0 in.) I.D. media cores.
• 76.2 (3.0 in.) I.D. media cores.
• Attached Power Supply Base with internal power supply.
• Attached Battery Base with removable Battery.
• Attached Battery Base and Battery are sold separately.
• The battery provides a constant regulated 24 VDC until the battery shutdown for recharging to
maintain print quality. This keeps print from changing as the battery discharges with use.
• Includes a Shutdown Mode for shipping and storage.
• Includes battery charge and status indicators built into the battery.
• 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 ZD621 Direct Thermal Healthcare printer models. This special
Healthcare model includes for additional security, Kensington ™ Slot for Kensington locking devices
to secure the printer.
16
Zebra Label Printing Solution
The printer is just one of three parts of a printing solution. To print; you need a printer (ZD621 or ZD421),
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.
Modes of Printing
You can operate this printer in many different modes and media configurations:
• Direct thermal printing: uses heat sensitive media to print.
Introduction
• Thermal transfer printing: uses thermal transfer ribbon cartridge or ribbon rolls, where 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: allows for easy pick and place label
applications.
• Stand-alone: the printer can print without being directly connected to a computer.
• A printer with the color touch 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.
17
What’s in the Box?
USB Cable
Printer
Power Cord (varies by locale)
Non-Zebra 300 Meter Ribbon Adapters
Printer Documentation
Included with Thermal Transfer Printer (uses ribbon rolls)
Empty Starter Ribbon Cores
Power Supply
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
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
Refer to the Zebra Web site for ‘How To’ videos on packing and unpacking your printer. Go to About on
page 11 for links to one of the 5 basic Link-OS printer variations.
®
reseller.
18
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
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.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. Push down on the front of the printer to close. Push the center or both corners of the
printer firmly until both side latches lock.
19
Printer Features
This section will help you identify features of these Zebra® Link-OS 4-inch desktop thermal label printers,
the ZD621 and ZD421. ‘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:
• ZD621 Thermal Transfer Printer — zebra.com/
• ZD621 Direct Thermal Printer — zebra.com/
• ZD421 Thermal Transfer Ribbon Cartridge Printer — zebra.com/
• ZD421 Thermal Transfer Printer — zebra.com/
• ZD421 Direct Thermal Printer — zebra.com/
• ZD621R Thermal Transfer Printer — zebra.com/
ZD621t-info
ZD621d-info
ZD421t-info
ZD421d-info
ZD621r-info
ZD421c-info
20
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, go to Controls and Indicators on page 37.
Printer Features
21
Printer Features
Movable Sensor
(Black Mark and Lower Web/Gap)
Media
Guides
Head-Up Sensor
(inside)
Media Guide
Stop
Platen (Drive) Roller
Roll
Holders
Upper Web (Gap)
Array Sensor
(other side)
Ribbon
Carriage
Printhead
Inside the ZD421 Dual Capacity Ribbon Roll Printer
22
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 ZD621 Dual Capacity Ribbon Roll Printer
23
Printer Features
RFID Antenna Dome
Identifying the ZD621R RFID Antenna Location
The ZD621R printers antenna is located between the platen rollover and movable media sensor channel in
the center of the printer. This is the only visible RFID item other than the Color Touch Display when on and
the product branding and labeling.
24
Printer Features
Take Up Spindles
Supply Spindles (full ribbon rolls)
Media Dancer
(ZD621 Only)
Dual Capacity Ribbon Chassis - Ribbon Roll Holders
Media Dancer - ZD621 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 locate. It is the same color as the dark gray parts adjacent to it.
25
Printer Features
Movable Sensor
(Black Mark and Lower Web/Gap)
Media Guides
Head-Up Sensor
(inside)
Media Guide Stop
Platen (Drive) Roller
Roll Holders
Upper Web (Gap)
Array Sensor
Printhead
Inside the ZD421 Direct Thermal Printers
26
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
Printhead
Inside the ZD621 Direct Thermal Printers
27
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
Ribbon Cartridge
Shown Installed
(sold separately)
Upper Web (Gap)
Array Sensor
Release
Arms (2)
Ribbon Drive
Transport
Inside the ZD421 Ribbon Cartridge Printer
28
Printer Features
Backside of
Printhead
Printhead
Actuator Arm
Ribbon
Transport
Release
Arms
Printhead
Ribbon Cartridge
Authentication and Status
Interface
Ribbon Sensor
Ribbon Sensor’s
Reflector
Accessing the Printhead of the Ribbon Cartridge Printer
To access the printhead:
1. Pull both release arms out (lighter gray parts).
The ribbon drive transport drops down.
2. Lift printhead actuator arm up to access the printhead.
29
Printer Features
Door Latch
Label Taken
Sensor
Peel Roll
Dispenser Door
Label Liner
Exit Area
Label Peel Bar
Media Exit Slot
Cutter Module
Label Dispenser Option (field installable) - All Models
Cutter Option (field installable) - All Models
30
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