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ZD42H42-T0EW02EZ
User Manual
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Product Data Sheet
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Zebra ZD42H42-T0EW02EZ User Manual

ZD620 and ZD420
Link-OS 4 inch Desktop Printers
User’s Guide
212485-003 Rev. A
Copyright 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.
For further information regarding legal and proprietary statements, please go to:
COPYRIGHTS:www.zebra.com/copyright WARRANTY:www.zebra.com/warranty END USER LICENSE AGREEMENT: www.zebra.com/eula SOFTWARE:www.zebra.com/linkoslegal

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

August 2018
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
• 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
About
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 printhead may be hot and could cause sever burns. Allow the printhead to cool.
About
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

Terms of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Proprietary Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Product Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Liability Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Publication Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
• About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Other Valuable Printer Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Zebra OneCare Printer Service and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Using This Document and Its Internally Attached Files . . . . . . . . . . . . . . . . . . . . . .4
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
• Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
• Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Link-OS 4 inch Desktop Thermal Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Common Desktop Link-OS Printer Features:. . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Link-OS 4 inch Desktop Printer Options: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Zebra Label Printing Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Modes of Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
What’s in the Box? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6
Contents
• Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Inside the ZD620 Dual Capacity Ribbon Roll Printer . . . . . . . . . . . . . . . . . . . . . . .23
Inside the ZD620 and ZD420 Direct Thermal Printers . . . . . . . . . . . . . . . . . . . . . .25
Inside the ZD420 Ribbon Cartridge Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Label Dispenser Option (field installable) - All Models . . . . . . . . . . . . . . . . . . . . . .28
Cutter Option (field installable) - All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Linerless Media Tear-Off Option (Direct Thermal Models Only) . . . . . . . . . . . . . .29
Linerless Cutter Option (Direct Thermal Models Only). . . . . . . . . . . . . . . . . . . . . .29
Identifying Platen Drive Rollers Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Printer Power Supply Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
ZD620 Locking Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Zebra Print Touch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
• Install Hardware Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Field Installable printer Accessories and Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Printer Connectivity Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Accessing the Connectivity Module Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Installing the Serial Port Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Installing the Internal Ethernet (LAN) Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Media Handling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Removing the Standard Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Installing the Label Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Installing the Standard Media Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Installing the Linerless Media Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Installing the Linerless Media ‘Tear-Off’ Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Media Roll Core Size Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Print Resolution Upgrade Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Installing the Attached Power Supply Base Options . . . . . . . . . . . . . . . . . . . . . . .49
Installing the Attached Battery Base Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Installing the Battery into the Attached Power Base . . . . . . . . . . . . . . . . . . . . . . .52
User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Standard Interface Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
LCD User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Meaning of the Indicator Light Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Status - Typical Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Status - Printhead Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Status - Bluetooth Low Energy (BTLE) Option . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Status - Ethernet (LAN) Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Status - Wi-Fi (WLAN) Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Display Controls and Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Navigating through Menu Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Battery Indicators and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
7
Contents
• Printer Configuration Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Adjust Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
User Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
SETTINGS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
DARKNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
PRINT SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
MEDIA TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
PRINT METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
TEAR OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
PRINT WIDTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
PRINT MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
LABEL TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
LEFT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
REPRINT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
LABEL LENGTH MAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
TOOLS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
PRINT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
IDLE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
POWER UP ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
HEAD CLOSE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
LOAD DEFAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
MEDIA/RIBBON CAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
CONFIG INFO TO USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
ZBI ENABLED? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
RUN ZBI PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
STOP ZBI PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
PRINT USB FILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
COPY USB FILE TO E: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
STORE E: FILE TO USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
PRINT STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
PASSWORD PROTECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
PRINT TEST FORMAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
8
Contents
NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
ACTIVE PRINT SERVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
PRIMARY NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
WIRED IP ADDRESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
WIRED SUBNET MASK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
WIRED GATEWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
WIRED IP PROTOCOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
WIRED MAC ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
WLAN IP ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
WLAN SUBNET MASK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
WLAN GATEWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
WLAN IP PROTOCOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
WLAN MAC ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
ESSID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
CHANNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
IP PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
IP ALTERNATE PORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
RESET NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
VISIBILITY AGENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
BATTERY Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
BATTERY STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
LANGUAGE Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
COMMAND LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
COMMAND CHAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
CONTROL CHAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
DELIMITER CHAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
ZPL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
VIRTUAL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
SENSOR TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
LABEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
TAKE LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
BAUD RATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
DATA BITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
PARITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
HOST HANDSHAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
WML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
9
Contents
BLUETOOTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
BLUETOOTH ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
DISCOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
CONNECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
BT SPEC VERSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
MIN SECURITY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
• Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Printer Setup Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Select a Location for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Install Printer Options and Connectivity Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Attaching Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Getting Ready to Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Preparing and Handling Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Media Storage Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Loading Roll Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Setting Media Sensing by Media type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Instructions for media loading: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Loading Thermal Transfer Roll Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Loading Zebra Transfer Roll Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Loading the ZD420 Ribbon Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Run a SmartCal Media Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
SmartCal Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Test Printing with the Configuration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Detecting a Media Out Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Detecting a Ribbon Out Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Connecting your Printer to a Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Interface Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Wi-Fi and Bluetooth Classic Wireless Connectivity Option . . . . . . . . . . . . . . . . . . . .151
• Setup for Windows® OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Windows to Printer Communication Setup (Overview). . . . . . . . . . . . . . . . . . . . . . . .152
®
Pre-install Windows
Setting Up the Wi-Fi Print Server Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Configure Using the ZebraNet Bridge’s Connectivity Wizard . . . . . . . . . . . . . . . . . . .154
Using a Configuration Script. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Bluetooth Option Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Connecting to a Windows XP
Connecting to a Windows Vista® SP2 or Windows 7® Master Device. . . . . . . . .165
Connecting the Printer to a Windows 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Connecting the Printer to a Windows 10 PC . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
After Your Printer is Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
Printer Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
®
SP2 Master Device. . . . . . . . . . . . . . . . . . . . . . .164
10
Contents
• Print Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Thermal Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Determining Your Printer’s Configuration Settings. . . . . . . . . . . . . . . . . . . . . . . .174
Select a Print Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Adjusting the Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Darkness Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Adjusting the Print Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Replacing Supplies while Using the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Printing on Fan-Fold Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Printing with Externally Mounted Roll Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Externally Mounted Roll Media Considerations:. . . . . . . . . . . . . . . . . . . . . . . . . .180
Using the Label Dispenser Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Using the Linerless Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Linerless Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Sending Files to the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Ribbon Cartridge Programming Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Printing with the Attached Battery Base and Battery Option . . . . . . . . . . . . . . . . . . .187
Printer Fonts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Identifying Fonts in Your Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Localizing the Printer with Code Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Asian fonts and Other Large Font Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
EPL Line Mode - Direct Thermal Printers only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
ZD620 and ZD420 Locking Printer Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Zebra® ZKDU — Printer Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
ZBI 2.0 ™ — Zebra Basic Interpreter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Setting the Power Failure Recovery Mode Jumper . . . . . . . . . . . . . . . . . . . . . . . . . .192
• USB Host Port and Link-OS Usage Examples . . . . . . . . . . . . . . . . . . . . . 193
USB Host . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
Using USB Host for Firmware Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
USB Host and Printer Usage Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Items Required for the USB Host Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Files for Completing the Exercises. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Exercise 1: Copy Files to a USB Flash Drive and Perform USB Mirror . . . . . . . .198
Exercise 2: Print a Label Format from a USB Flash Drive . . . . . . . . . . . . . . . . . .200
Exercise 3: Copy Files to/from a USB Flash Drive. . . . . . . . . . . . . . . . . . . . . . . .201
Exercise 4: Enter Data for a Stored File with a USB Keyboard and Print a Label203
Using the USB Hosts Port and the NFC Capabilities . . . . . . . . . . . . . . . . . . . . . . . . .204
Exercise 5: Enter Data for a Stored File with a Smart Device and Print a Label .205
11
Contents
• Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Cleaning Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Recommended Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
Cleaning the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
Media Path Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
Sensor Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
Platen Cleaning and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
ZD620 and ZD420 Direct Thermal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
ZD620 and ZD420 Thermal Transfer Ribbon Roll . . . . . . . . . . . . . . . . . . . . . . . .231
ZD420 Thermal Transfer Ribbon Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
Updating Printer Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Other Printer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
RTC Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
• Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Resolving Alerts and Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
Alert: Printhead Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
Alert: Media Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
Alert: Ribbon In (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . . . . .245
Alert: Ribbon Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Alert: Ribbon Low (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . . .247
Alert: CUT ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
Alert: PRINTHEAD OVER TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
Alert: PRINTHEAD SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
Alert: PRINTHEAD UNDER TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
Alert: OUT OF MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
Resolving Print Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
Issue: General Print Quality Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
Issue: No Print on the Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252
Issue: Labels Are Distorted in Size or Print Area Start Position Varies . . . . . . . .253
Communication Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
Issue: Label Job Sent, No Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
Issue: Label Job Sent, Skips Labels or Prints Bad Content . . . . . . . . . . . . . . . . .254
Issue: Label Job Sent, Data Transfers, But No Print . . . . . . . . . . . . . . . . . . . . . .255
Miscellaneous Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
Issue: Settings are Lost or Ignored . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
Issue: Non-continuous labels act as Continuous labels. . . . . . . . . . . . . . . . . . . .257
Issue: Printer Locks-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
Issue: Erroneous Ribbon Cartridge Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
Issue: Battery has a Red Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
12
Contents
• Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
SmartCal Media Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Configuration Report (CANCEL Self Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
Printer Network (and Bluetooth) Configuration Report . . . . . . . . . . . . . . . . . . . . .262
Print Quality Report (FEED self test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
Reset Printer Factory Defaults (PAUSE + FEED Self Test). . . . . . . . . . . . . . . . .266
Reset Network Factory Defaults (PAUSE + CANCEL Self Test) . . . . . . . . . . . . .266
Reset Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
Communication Diagnostics Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
Sensor Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
Advanced Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271
Manual Media Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271
Manual Print Width Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272
Manual Print Darkness Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273
Factory Test Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
Universal Serial Bus (USB) Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
Serial Port Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Connecting the Printer to a DTE Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Connecting the Printer to a DCE Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
ZD620 / ZD420 Thermal Transfer Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
ZD620 / ZD420 Ribbon Cartridge Thermal Transfer Models . . . . . . . . . . . . . . . . . . .287
ZD620 / ZD420 Direct Thermal Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
• Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Types of Thermal Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
Determining Thermal Media Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
General Media and Print Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
• ZPL Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Managing the ZPL Printer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
Configuration Setting to Command Cross-reference . . . . . . . . . . . . . . . . . . . . . . . . .309
Printer Memory Management and Related Status Reports . . . . . . . . . . . . . . . . . . . .312
ZPL Programming for Memory Management . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
13

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.
14
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 updates.
• 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).
• Factory installed network models support printer configuration via a setup utility running on mobile devices.
• Use the printer’s optional Bluetooth Low Energy (LE) feature for short range communication to a
variety of 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.
• 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) ro
• A minimum of 64 MB of internal (E:\) printer memory for storing forms, fonts, and graphics.
ller.
15
Introduction

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.
• Factory Installed Wired and Wireless options:
• Bluetooth Low Energy (LE) wireless connectivity
• Wi-Fi (802.11ac – includes a/b/g/n), Bluetooth Classic 4.X (3.X compatible), and Bluetooth Low
Energy (LE) wireless connectivity.
• Factory installed Internal Ethernet Print Server (LAN, RJ-45 connector) — supports 10Base-T,
100Base-TX and fast Ethernet 10/100 auto-switching networks for wired connectivity. The factory installed option includes Bluetooth Low Energy (LE) wireless connectivity.
• 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.
• 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.
• 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.
• 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.
16
Introduction
• 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.
17

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 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:
Introduction
• 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.
• 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.
18

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

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.
®
reseller.
19
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.
20

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
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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
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 ZD620 Dual Capacity Ribbon Roll Printer

23
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.
24
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
Media Dancer
(ZD620 Only)

Inside the ZD620 and ZD420 Direct Thermal Printers

25
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 ZD420 Ribbon Cartridge Printer

26
Printer Features
Backside of
Printhead
Printhead
Actuator Arm
PRINTHEAD ACCESS
1. Pull both release arms out (green highlighted black parts).
2. Ribbon drive transport drops down.
3. Lift printhead actuator arm up to access the printhead
Printhead
Ribbon Cartridge
Authentication and Status
Interface
Ribbon Sensor
Ribbon Sensor’s
Reflector
Accessing the Printhead of the Ribbon Cartridge Printer
27
Printer Features
Door Latch
Label Taken
Sensor
Label Peel Bar
Peel Roll
Dispenser Door
Label Liner
Exit Area
Media Exit Slot
Cutter Module

Label Dispenser Option (field installable) - All Models

Cutter Option (field installable) - All Models

28
Printer Features
Label Taken
Sensor
Label Taken
Sensor
Cut Label Landing
Area

Linerless Media Tear-Off Option (Direct Thermal Models Only)

Linerless Cutter Option (Direct Thermal Models Only)

29
Printer Features
203 dpi Standard Platen (black)
300 dpi Standard Platen (gray)
203 dpi Linerless Platen (reddish-brown)
300 dpi Linerless Platen (brown)

Identifying Platen Drive Rollers Types

The platen (drive) rollers are colored differently to identify the platen type and print resolution of your printer (and the platen). Do not exchange platen types unless instructed to by an upgrade procedure or Zebra technical support. The printer will not operate correctly and may cause a variety of problems requiring maintenance.
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