Zebra ZE511, ZE521 User Guide

ZE511/ZE521

Industrial Print Engine

User Guide

P1117212-01EN

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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.

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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

June 24, 2021

Introduction ........................................................................................................................................... 7

Print Engine Orientation................................................................................................... 8

Print Engine Components ............................................................................................... 9

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

Home Screen ................................................................................................................ 11

Print Status Tab...................................................................................................... 11

Printer Info Tab....................................................................................................... 12

Other Tabs.............................................................................................................. 13

Preparing to Print................................................................................................................................ 14

Ordering Supplies and Accessories............................................................................... 14

Label Software......................................................................................................... 14

Cables .................................................................................................................... 14

Media...................................................................................................................... 14

Ribbon .................................................................................................................... 15

Specifying the Media Handling Method.......................................................................... 16

Ribbon and Media Loading ........................................................................................... 17

Loading Ribbon ...................................................................................................... 17

Loading Media ........................................................................................................ 21

Calibrating the Ribbon and Media Sensors.................................................................... 26

Running the Print Wizard and Printing a Test Label ...................................................... 27

Printer Configuration and Adjustment ................................................................................................. 29

Changing Printer Settings .............................................................................................. 30

System Menu.......................................................................................................... 31

Connection Menu ................................................................................................... 38

Print Menu .............................................................................................................. 49

RFID Menu ............................................................................................................. 60

Storage Menu ......................................................................................................... 64

Contents

Toggle Positioning and Printhead Pressure Adjustment................................................ 66

Changing the Toggle Position ................................................................................ 66

Adjusting the Printhead Pressure ........................................................................... 69

Routine Maintenance.......................................................................................................................... 72

Cleaning Schedule and Procedures............................................................................... 72

Cleaning the Exterior, the Media Compartment, and the Sensors................................ 73

Cleaning the Printhead and Rollers ............................................................................... 73

Removing Used Ribbon ................................................................................................. 77

Replacing Print Engine Components ............................................................................. 78

Ordering Replacement Parts .................................................................................. 78

Recycling Print Engine Components ...................................................................... 78

Storing the Print Engine ................................................................................................. 78

Lubrication...................................................................................................................... 78

Troubleshooting .................................................................................................................................. 79

Judging Barcode Quality................................................................................................ 80

Configuration Labels ...................................................................................................... 82

PAUSE Self-Test........................................................................................................... 83

Printing and Interpreting a Sensor Profile ..................................................................... 84

Media Sensor Profile .............................................................................................. 84

Ribbon Sensor Profile............................................................................................. 85

Using Communication Diagnostics Mode ..................................................................... 86

Loading Defaults or Last Saved Values........................................................................ 87

Alert and Error States..................................................................................................... 88

Alerts and Error Messages ..................................................................................... 89

Indicator Lights ....................................................................................................... 93

Troubleshooting ............................................................................................................. 96

Printing or Print Quality Issues ............................................................................... 96

Ribbon Issues....................................................................................................... 100

RFID Issues.......................................................................................................... 102

Communications Issues ....................................................................................... 104

Miscellaneous Issues ........................................................................................... 105

Servicing the Printer..................................................................................................... 108

Shipping the Printer...................................................................................................... 108

Using USB Host Ports and Print Touch/NFC.................................................................................... 109

USB Host Ports............................................................................................................ 109

File Naming .......................................................................................................... 109

Contents

Print Touch/Near Field Communication (NFC) ............................................................ 109

Related SGD Commands for Advanced Users........................................................... 110

Items Required for the Exercises................................................................................ 111

Exercises..................................................................................................................... 113

Exercise 1: Copying Files to a USB Flash Drive and Performing USB Mirror ...... 113

Exercise 2: Printing a Label Format from a USB Flash Drive............................... 114

Exercise 3: Copying Files to/from a USB Flash Drive .......................................... 115

Exercise 4: Entering Data for a Stored File with a USB Keyboard

and Printing a Label.............................................................................................. 116

Exercise 5: Entering Data for a Stored File with a Phone or Tablet

and Printing a Label .................................................................................................... 117

Specifications.................................................................................................................................... 119

General Specifications ................................................................................................. 119

Power Specifications................................................................................................... 120

Power Cord Specifications.......................................................................................... 121

Communication Interface Specifications..................................................................... 122

Standard Connections .......................................................................................... 122

Optional Connections ........................................................................................... 125

Wireless Specifications......................................................................................... 126

Printing Specifications................................................................................................. 127

Ribbon Specifications................................................................................................... 127

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

Dimensions and Clearance Needs.............................................................................. 129

Front View (Right-Hand Print Engine Shown) ...................................................... 129

Rear View ............................................................................................................. 130

Top View—Electronics Enclosure Clearance ....................................................... 131

Side View—ZE511 Print Engine........................................................................... 132

Side View—ZE521 Print Engine........................................................................... 133

Print Engine Installation .................................................................................................................... 134

Requirements............................................................................................................... 134

Inspect the Contents of the Box................................................................................... 135

Install the Print Engine in an Applicator ...................................................................... 136

Applicator Interface Board Overview........................................................................... 137

Energy Star Effect on the Applicator Interface Board........................................... 138

Change the Applicator Interface Board Jumper Configuration ............................. 139

Applicator Interface Pin Configuration .................................................................. 142

Applicator Signals................................................................................................. 145

Contents

Connecting the Printer to a Device ................................................................................................... 147

Connecting to a Phone or Tablet ................................................................................. 147

Connecting to a Windows-Based Computer ............................................................... 148

Installing and Running Zebra Setup Utilities......................................................... 148

Connecting a Computer to the Printer’s USB Port...................................................... 150

Connecting a Computer to the Printer’s Serial or Parallel Port.................................... 153

Connecting to Your Network through the Printer’s Ethernet Port................................ 160

Connecting the Printer to Your Wireless Network....................................................... 168

Glossary............................................................................................................................................ 174

Introduction

This section provides a high-level overview of the printer and its components.

Print Engine Orientation

The ZE511 and ZE521 print engines are available in a left-hand configuration (the print mechanism is on the left) and a right-hand configuration (the print mechanism is on the right).

Left-hand (LH) print engine

Introduction

Power switch location

Control panel

Media cover

Right-hand (RH) print engine

Print Engine Components

The following shows the components inside the media compartment of a right-hand (RH) print engine. A left-hand (LH) unit contains a mirror image of these components. Familiarize yourself with these components before continuing.

Introduction

Ribbon take-up spindle

Ribbon supply spindle

Printhead-release latch

Printhead assembly (shown open)

Peel bar

Platen roller

910 7

Peel roller assembly (hidden when closed)

Peel roller latch

Media guide

Pinch roller assembly

Lower guide post

Upper guide post

Control Panel

All controls and indicators for the print engine are located on the control panel.

Introduction

1 2 4

Power switch Toggles the print engine on/off.

Display Shows the print engine’s operating status and allows the user to navigate

the menu system. For more information, see Home Screen on page 11.

NFC logo Used for the Print Touch feature. For more information, see Print

Touch/Near Field Communication (NFC) on page 109.

USB host ports Allows you to connect USB devices such as memory sticks, keyboards, or

handheld scanners to the printer. For more information, see USB Host

Ports on page 109.

PAUSE button Starts or stops print engine operation when pressed.

FEED button Forces the print engine to feed one blank label each time the button is

pressed.

CANCEL button Cancels print jobs when the print engine is paused.

Indicator lights Communicate the printer’s status. For more information, see Indicator

Lights on page 93.

Home Screen

IMPORTANT: If the background color of the Home screen is yellow or red, the printer is in an alert or error state and may need user intervention. For more information, see Alert and Error States on page 88.

Print Status Tab

The Print Status tab on the Home screen provides the current status (such as Idle). On this screen, touching the left or right arrow rotates the image of the printer so that you can view it from any angle.

Introduction

NOTE: Depending on how your print engine is configured, the screens may display horizontally or vertically. See System > Settings > Display Orientation on page 35 for options.

Printer Info Tab

The Printer Info tab on the Home screen provides connectivity and firmware data. To scroll in a screen that does not display everything at one time, such as the horizontal Printer Info screen, touch the screen and drag upward.

Introduction

NOTE: Depending on how your print engine is configured, the screens may display horizontally or vertically. See System > Settings > Display Orientation on page 35 for options.

Other Tabs

The following tabs are available on the Home screen:

Menu Allows you to access the user menus, where you can view or change the printer settings. See Changing

Printer Settings on page 30.

Wizards Allows you to change printer settings by going through prompts. For more information about individual parameters that are set by any of the wizards, see Changing Printer Settings on page 30.

IMPORTANT: When using the Wizards, do not send data to the print engine from the host. For best results, use full-width media running the Print or Set All Wizards. If the media is shorter than an image to be printed, the image may be truncated or print across multiple labels.

Introduction

Set All Wizard—runs all of the Wizards in sequence.

System—sets up non-print related operating system settings.

Connection—configures the printer’s connectivity options.

Print—configures key printing parameters and features. See

Running the Print Wizard and Printing a Test Label on page 27.

RFID—sets up the RFID subsystem operations.

Shortcuts Allows you to quickly access the most recent menu items and to save your favorites.The Print Station and Calibrate menu items also appear in the shortcuts.

1. Touch the dark heart icon next to a menu item to save it to your list of favorites.

A red heart icon (1) indicates a saved item.

2. Access saved items by touching Favorites (1).

Preparing to Print

Ordering Supplies and Accessories

The following required items do NOT come with the printer:

• Label design software

• Communication/network cables (such as USB, serial, parallel, wired Ethernet)

• Media

• Ribbon (if your printer has a thermal transfer option)

Label Design Software

Select and install the software that you will use to create label formats for your printer. One option is ZebraDesigner, which you can download from zebra.com

Cables

Media

See Communication Interface Specifications on page 122 for more information.

For optimal printing quality and proper printer performance across our product line, Zebra strongly recommends the use of Zebra Certified Supplies as part of the total solution. A wide range of paper, polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the printing capabilities of the print engine and to prevent premature printhead wear. To purchase supplies, go to

zebra.com/supplies.

The Glossary on page 174 includes terms associated with media, such as black mark media, gap/notch media, RFID media, fanfold media, and roll media. Use these terms to help determine which type of media is best for your needs.

Ribbon

Preparing to Print

Do I need to use ribbon? The media itself determines if you need to use ribbon. Thermal Transfer media requires ribbon while Direct Thermal media does not.

How can I tell if media is Direct Thermal or Thermal Transfer? The easiest way is to scratch the surface of the media rapidly with your fingernail. If a black mark appears where you scratched, the media is Direct Thermal, and you do not need to use ribbon.

What kind of ribbon can I use? Ribbon can be wound with the coated side on the inside or outside. This print engine can use either type. Contact your authorized Zebra reseller for ordering information.

Ink on the Outside Ink on the Inside

How can I tell which side of the ribbon is coated? Press a corner of the sticky side of a label to the outer surface of the roll of ribbon, and then peel the label off of the ribbon. If ink particles adhere to the label, the outer side of the roll is coated. Repeat this test with the inner surface if necessary to confirm the coated surface.

An alternate method is to unroll a short length of ribbon, place the outer surface against a piece of paper, and scratch the inner surface of the ribbon with your fingernail. Lift the ribbon and check for marks on the paper. If the ribbon left a mark, the outer side is coated.

Preparing to Print

Specifying the Media Handling Method

1. On the Home screen, touch Menu > Print > Image Adjust > Media Handling.

2. Select a media handling method that matches your media and setup.

Method Description

Tear Off The printer prints label formats as it receives them. The printer operator can

tear off the printed labels when the printer stops.

Peel Off The printer peels the label from the backing during printing and then pauses

until the label is removed.

Rewind The printer prints without pausing between labels. The media is wound onto a

core after printing.

Cutter The printer cuts between labels after each one is printed.

Delayed Cut The printer waits for a delayed cut ZPL command (

printed label.

Linerless Peel Not used. Reserved for future use.

Linerless Rewind

Linerless Tear

Applicator The printer prints when it receives a signal from the applicator. Refer to the

Advanced User Information section of the Maintenance Manual for additional information about the applicator interface.

Linerless Cut Not used. Reserved for future use.

Linerless Delayed Cut

Stream The printer prints a batch of labels with backfeed occurring only at the start

and end of the batch instead of between individual labels. This setting increases label throughput in batch printing.

~JK) before it cuts the last

3. Touch the home icon to return to the Home screen.

Ribbon and Media Loading

MEDIA SUPPLY

MEDIA BACKING

OPEN

SUPPLIES LOADING

PRESS

TO OPEN

WHEN OPEN

MEDIA BACKING

WHEN CLOSED

DETAIL VIEW

LABEL

www.zebra.com/ze511-info

Use the instructions in this section to load ribbon (if used) and media in a ZE511/ZE521 print engine.

NOTE: The majority of the graphics in this section show a right-hand (RH) unit with ribbon that is coated with ink on the outside. Graphics for other options are included in some places for clarity.

Preparing to Print

Loading Ribbon

Ribbon is used with thermal transfer labels. For direct thermal labels, do not load ribbon in the print engine. To determine if ribbon must be used with a particular media, see Do I need to use ribbon? on page 13. To order Zebra Certified ribbon or media, visit zebra.com/supplies.

1. Determine which side of the ribbon is coated with ink (see How can I tell which side of the ribbon is

coated? on page 13), and then position the ribbon roll with the loose end unrolling in the direction

shown.

2. If necessary, update the ribbon ink side setting (see Print > Print Quality > Ribbon Tension on page 51).

LH (ink side out)

RH (ink side in)

RH (ink side out)

LH (ink side in)

Open the media cover.

Preparing to Print

4. Release the printhead assembly.

Preparing to Print

Place the roll of ribbon on the ribbon supply spindle. Push the roll back as far as it will go.

LH (ink side out) RH (ink side out)

LH (ink side in) RH (ink side in)

6. Place an empty ribbon core on the ribbon take-up spindle. Push the core back as far as it will go.

Preparing to Print

CAUTION—HOT SURFACE: The printhead may be hot and could cause severe burns. Allow the printhead to cool.

7. Thread the ribbon under the lower ribbon guide roller (1), under the printhead assembly (2), and then

over the upper ribbon guide roller (3).

LH (ink side out)

RH (ink side out)

LH (ink side in) RH (ink side in)

Wind the ribbon around the core on the ribbon take-up spindle in the direction shown.

Loading Media

1. Load media on the media supply reel of the applicator (refer to the applicator’s documentation for more

information).

2. Press the release button on the pinch roller assembly. Allow the assembly to pivot upward.

Preparing to Print

RHLH

3. Slide the media guide all the way out.

Preparing to Print

Thread the media under the upper guide post (1), below the pinch roller assembly (2), and under the

printhead assembly (3).

LH RH

5. Extend approximately 30 in. (75 cm) of media past the peel bar. Remove and discard the labels from

the liner on this exposed media.

6. Slide in the media guide until it just touches the edge of the media.

Preparing to Print

Press down on the pinch roller assembly until it locks closed.

8. Raise the peel roller latch so that the peel roller assembly pivots downward.

LH RH

9. Thread the liner around the peel bar (1) and through the peel roller assembly (2).

IMPORTANT: If the applicator has an air tube, route the liner between the air tube and the peel bar. Do not thread the liner over the air tube.

LH RH

121 2

Preparing to Print

Lock the printhead assembly.

10.

11. Rotate the peel roller assembly up until it locks into the closed position.

LH RH

12. Thread the liner around the take-up spindle of the applicator (refer to the applicator’s documentation for

more information).

Close the media cover.

13.

Preparing to Print

14. If desired, perform the PAUSE Self-Test on page 83 to verify that your printer is able to print.

Preparing to Print

Calibrating the Ribbon and Media Sensors

Use the procedure in this section to calibrate the printer, which adjusts the sensitivity of the media and ribbon sensors.

IMPORTANT: Follow the calibration procedure exactly as presented.

To cancel the calibration process, press and hold CANCEL at any step in the procedure.

1. Touch Print > Sensors > Manual Calibration.

The printer prompts you to start calibration.

2. Touch Start Calibration.

3. Follow the steps in the calibration procedure.

4. When calibration is complete, press PAUSE to exit pause mode and enable printing.

Preparing to Print

Running the Print Wizard and Printing a Test Label

The Print Wizard configures the printer, prints test labels, and adjusts print quality based on the results of the test labels.

IMPORTANT: When using the Wizards, do not send data to the printer from the host. For best results, use full-width media running the Print Wizard or Set All Wizard. If the media is smaller

than an image to be printed, the results may be truncated or print across multiple labels.

After you have completed the printer setup procedures and run the printer setup wizard, use this section to print a test label. Printing this label allows you to see if your connection is working and if you need to adjust any of the print settings.

1. On the Home screen, touch Wizards > Print > Start Print.

2. Follow the prompts to specify the following information:

• print type (Thermal Transfer or Direct Thermal)

• media type (Continuous, Gap/Notch, or Mark)

• label width

• media handling method (tear off, peel-off, rewind, cutter, delayed cut, linerless peel, linerless rewind, linerless tear, or applicator)

After you have specified these, the wizard instructs you to load media and then to place a label over the media sensor.

3. If you have not already done so, load media, and then touch the check mark.

4. At the prompt, close the printhead, and then touch the next check mark.

The printer calibrates and then asks if you would like to print a test label.

5. Follow the prompts until the printer completes auto calibration.

6. When asked to print a test label, touch the check mark.

A test label similar to this one prints. If your labels are smaller than the image, only a portion of the test label prints.

Preparing to Print

Examine the position of the label over the tear bar. If necessary, shift the position of the media over the

tear-off bar after printing.

• If the space between labels falls on the tear bar, continue with the next step.

• If the space between labels does not fall directly on the tear bar, shift the position of the media over the tear bar after printing. Lower numbers move the media into the printer by the specified number of dots (the tear line moves closer to the edge of the label just printed). Higher numbers move the media out of the printer (the tear line moves closer to the leading edge of the next label).

8. Examine the quality of the image on the test label. Is the quality of the barcode and text on the test label

acceptable? See Judging Barcode Quality on page 80 for assistance.

• If yes, touch the check mark, and then continue with step 13.

• If no, adjust the print quality manually by changing darkness and speed settings through the printer’s menu system, or continue with this procedure to run the Print Quality Assistance wizard.

Print Quality Assistance Wizard

9. Touch Print Quality Assistance.

The printer prompts for the number of test labels to print. The more labels you choose to print, the more choices that you will have available to decide on label quality. In general, if your test label from the previous wizard was acceptable, a lower number of test labels in this step will probably suffice.

10. Select a number of test labels to print.

The printer prints the specified number of test labels and prompts you for the best test label.

11. Decide which test label is the best quality. See Judging Barcode Quality on page 80 for assistance. If

none of the labels are acceptable, use the arrow to back up a screen in the wizard, and select a larger number of test labels.

12. In the list on the display, select the identifier for the test label with the best quality, and then touch the

check mark.

The printer changes the darkness and speed to the levels used on the best test label.

13. If necessary, see Printing or Print Quality Issues on page 96 to see what other issues may be affecting

your print quality.

The print setup procedure is complete.

Printer Configuration and Adjustment

This section assists you with configuration of and adjustments to the print engine.

Printer Configuration and Adjustment

Changing Printer Settings

You can view or change the printer settings in a number of ways. In this section, the user menus are shown, and when other options for changing the same setting exist, they are included.

• User menus—See the following sections:

• System Menu on page 31

• Connection Menu on page 38

• Print Menu on page 49

• RFID Menu on page 60

• Storage Menu on page 64

• Control panel key(s)—Some actions can be initiated through control panel key combinations.

• ZPL and Set/Get/Do (SGD) commands—Many parameters can be set through these commands. See

the Zebra Programming Guide for ZPL, ZBI, Set-Get-Do, Mirror, and WML at zebra.com/manuals for more information.

• Printer web pages—These are available when the printer has an active wired or wireless print server connection. See the ZebraNet Wired and Wireless Print Servers User Guide at zebra.com/manuals for more information.

Printer Configuration and Adjustment

System Menu

System > Language

If necessary, change the language that the printer displays. This change affects the words shown on the following:

• the Home screen

• the user menus

• error messages

• for some languages, the printer configuration label, the network configuration label, and other labels that you can select to print through the user menus

Accepted values:

English

Spanish

French

German

Italian

Norwegian

Portuguese

Swedish

Danish

Dutch

Related ZPL command(s): SGD command used: display.language

Printer web page:

^KL

Finnish

Japanese

Korean

Simplified Chinese

Traditional Chinese

Russian

Polish

Czech

Romanian

View and Modify Printer Settings > General Setup > Language

Printer Configuration and Adjustment

System > Program Language > Diagnostic Mode

Enabling this diagnostics tool causes the printer to output the hexadecimal values for all data received by the printer. The hexadecimal data is saved or printed based on the selection. For more information, see Using Communication Diagnostics Mode on page 86.

Accepted values:

• Print

• E: Drive

• USB Host

• Off

System > Program Language > Virtual Device

If any Virtual Device apps are installed on your printer, you may view or enable/disable them from this user menu. For more information about Virtual Devices, go to the User Guide for the appropriate Virtual Device, or contact your local reseller.

Printer Configuration and Adjustment

System > Program Language > ZBI

Zebra Basic Interpreter (ZBI 2.0™) is a programming option that may be installed on your printer. If you would like to acquire this option, contact your Zebra reseller for more information.

If ZBI programs have been downloaded to your printer, you may select one to run using this menu item. If no program exists on your printer, NONE is listed.

When ZBI programs have been downloaded but none are running, the printer lists all available programs. To run one of them, touch Run (highlighted in white) under the program name.

After a program is running, only that program is listed. Touch Stop (highlighted in white) to end the program.

SGD command used:

System > Settings > Display Time Format

Select the time format used by the printer.

Accepted values:

• 12-Hour

• 24-Hour

System > Settings > Password Level

Select the level of password protection for user menu items.

Accepted values:

• Selected

• All

• None

zbi.key (identifies if the ZBI 2.0 option is enabled or disabled on the printer)

Related ZPL command(s):

^KP (to change the printer password)

Printer Configuration and Adjustment

System > Settings > Set Password

Set a new printer password for menu items protected by the previous parameter. The default printer password is

Accepted values: Numerals 0–9

Related ZPL command(s):

^KP

System > Settings > Power Up Action

Set the action for the printer to take during the power-up sequence.

Accepted values:

• CALIBRATE—Adjusts sensor levels and thresholds, determines

the label length, and feeds the media to the next web.

• FEED—Feeds the labels to the first registration point.

1234.

• LENGTH—Determines the label length using current sensor

values, and feeds the media to the next web.

• NO MOTION—Tells the printer not to move the media. You must

manually ensure that the web is positioned correctly, or press FEED to position the next web.

• SHORT CAL—Sets the media and web thresholds without adjusting sensor gain, determines the label length, and

feeds the media to the next web.

Related ZPL command(s):

SGD command used:

^MF

ezpl.power_up_action

Printer web page:

View and Modify Printer Settings > Calibration

Printer Configuration and Adjustment

System > Settings > Head Close Action

Set the action for the printer to take when you close the printhead.

Accepted values:

• CALIBRATE—Adjusts sensor levels and thresholds, determines

the label length, and feeds the media to the next web.

• FEED—Feeds the labels to the first registration point.

• LENGTH—Determines the label length using current sensor

values, and feeds the media to the next web.

• NO MOTION—Tells the printer not to move the media. You must

manually ensure that the web is positioned correctly, or press FEED to position the next web.

• SHORT CAL—Sets the media and web thresholds without adjusting sensor gain, determines the label length, and

feeds the media to the next web.

Related ZPL command(s):

SGD command used:

^MF

ezpl.head_close_action

Printer web page:

View and Modify Printer Settings > Calibration

System > Settings > Display Orientation

Select the angle at which the control panel displays.

Accepted values:

• 0—Horizontal display (default)

• 90—Vertical display, rotated right

• 180—Horizontal display, upside-down

• 270—Vertical display, rotated left

SGD command used:

display.orientation

System > Settings > Screen Calibration

Touch each crosshair to calibrate the screen.

Printer Configuration and Adjustment

System > Settings > Restore Defaults

Restore specific printer, print server, and network settings back to the factory defaults. Use care when loading defaults because you will need to reload all settings that you changed manually.

Accepted values:

• PRINTER—Restores all printer settings other than the network

settings back to the factory defaults.

• NETWORK—Reinitializes the printer’s wired or wireless print

server. With a wireless print server, the printer also reassociates with your wireless network.

• LAST SAVED—Loads settings from the last permanent save.

Related ZPL command(s):

• PRINTER—

• NETWORK— ^JUN

• LAST SAVED— ^JUR

Control panel key(s):

• PRINTER—Hold FEED + PAUSE during printer power-up to reset the printer parameters to factory values.

• NETWORK—Hold CANCEL + PAUSE during printer power-up to reset the network parameters to factory values.

• LAST SAVED—N/A

Printer web page:

• PRINTER—View and Modify Printer Settings > Restore Default Configuration

• NETWORK—Print Server Settings > Reset Print Server

• LAST SAVED—View and Modify Printer Settings > Restore Saved Configuration

^JUF

Printer Configuration and Adjustment

System > Settings > Print: System Settings

Prints a printer configuration label. The following is a sample label.

Related ZPL command(s):

Control panel key(s):

Do one of the following:*

• Hold CANCEL during printer power-up. (Formerly called a CANCEL self-test.)

• Hold FEED + CANCEL for 2 seconds when the printer is in the Ready state.

Printer web page:

View and Modify Printer Settings > Print Listings on Label *

* Prints a printer configuration label and a network configuration label.

~WC

Printer Configuration and Adjustment

System > Energy Saving > Energy Star

When Energy Star mode is enabled, the printer goes into a “sleep” mode after a timeout period, thereby lowering power consumption. Press any button on the control panel to bring the printer back to an active state.

Accepted values:

• ON

• OFF

SGD command used:

•

power.energy_star.enable

•

power.energy_star_timeout

(to set the amount of idle time before Energy Star is invoked)

Connection Menu

Connection > Networks > Reset Network

IMPORTANT: You must reset the print server to allow changes to the network settings to take effect.

This option resets the wired or wireless print server and saves any changes that you made to any network settings.

Related ZPL command(s):

SGD command used:

Printer web page:

Print Server Settings > Reset Print Server

Connection > Networks > Primary Network

View or modify whether the wired or wireless print server is considered primary. You may select which one is primary.

Accepted values:

• Wired

• Wi-Fi

Related ZPL command(s):

SGD command used:

~WR

device.reset

^NC

ip.primary_network

Printer Configuration and Adjustment

Connection > Networks > IP Port

This printer setting refers to the internal wired print servers port number that the TCP print service is listening on. Normal TCP communications from the host should be directed to this port.

SGD command used:

•

internal_wired.ip.port

•

wlan.ip.port

Printer web page:

View and Modify Printer Settings > Network Communications Setup > TCP/IP Settings

Connection > Networks > IP Alternate Port

NOTE: Print servers supporting this command monitor both the primary port and the alternate port for connections at the same time.

This command sets the port number of the alternate TCP port.

SGD command used:

•

internal_wired.ip.port_alternate

•

wlan.ip.port_alternate

Printer web page:

View and Modify Printer Settings > Network Communications Setup > TCP/IP Settings

Printer Configuration and Adjustment

Connection > Networks > Print: Network Info

Prints the settings for any print server or Bluetooth device that is installed. The following is a sample label.

Related ZPL command(s):

Control panel key(s):

Do one of the following:*

• Hold CANCEL during printer power-up. (Formerly called a CANCEL self-test.)

• Hold FEED + CANCEL for 2 seconds when the printer is in the Ready state.

Printer web page:

View and Modify Printer Settings > Print Listings on Label *

* Prints a printer configuration label and a network configuration label.

~WL

Printer Configuration and Adjustment

Connection > Networks > Visibility Agent

When the printer is connected to a wired or wireless network, it attempts to connect to Zebra’s Asset Visibility Service via the Cloud-based Zebra Printer Connector using an encrypted, certificate-authenticated web socket connection. The printer sends Discovery Data and Settings and Alerts Data. Data printed via any label formats is NOT transmitted.

To opt out of this feature, disable this setting. For more information, see the “Opting Out of the Asset Visibility Agent” application note at

zebra.com.

Accepted values:

• On

• Off

SGD command used:

weblink.zebra_connector.enable

Printer web page:

View and Modify Printer Settings > Network Configuration > Cloud Connect Settings

Connection > Wired > Wired IP Protocol

IMPORTANT: You must reset the print server to allow changes to the network settings to take effect. See

Connection > Networks > Reset Network on page 38.

This parameter indicates if the user (permanent) or the server (dynamic) selects the wired print server’s IP address. When a dynamic option is chosen, this parameter tells the method(s) by which this print server receives the IP address from the server.

Accepted values:

• ALL

• GLEANING ONLY

• RARP

• BOOTP

• DHCP

• DHCP & BOOTP

• PERMANENT

Related ZPL command(s):

SGD command used:

^ND

internal_wired.ip.protocol

Printer web page:

View and Modify Printer Settings > Network Communications Setup > TCP/IP Settings

Printer Configuration and Adjustment

Connection > Wired > Wired IP Address

NOTE: To save changes to this setting, set Connection > Wired > Wired IP Protocol on page 41 to PERMANENT, and then reset the print server (see Connection > Networks > Reset Network on page 38).

View and, if necessary, change the printer’s wired IP address.

Accepted values: 000 to 255 for each field

Related ZPL command(s):

^ND

SGD command used:

internal_wired.ip.addr

Printer web page:

View and Modify Printer Settings > Network Communications Setup > TCP/IP Settings

Connection > Wired > Wired Subnet

NOTE: To save changes to this setting, set Connection > Wired > Wired IP Protocol on page 41 to PERMANENT, and then reset the print server (see Connection > Networks > Reset Network on page 38).

View and, if necessary, change the wired subnet mask.

Accepted values: 000 to 255 for each field

Related ZPL command(s):

SGD command used:

^ND

internal_wired.ip.netmask

Printer web page:

View and Modify Printer Settings > Network Communications Setup > TCP/IP Settings

Connection > Wired > Wired Gateway

NOTE: To save changes to this setting, set Connection > Wired > Wired IP Protocol on page 41 to PERMANENT, and then reset the print server (see Connection > Networks > Reset Network on page 38).

View and, if necessary, change the default wired gateway.

Accepted values: 000 to 255 for each field

Related ZPL command(s):

SGD command used:

^ND

internal_wired.ip.gateway

Printer web page:

View and Modify Printer Settings > Network Communications Setup > TCP/IP Settings

Printer Configuration and Adjustment

Connection > Wired > Wired Mac Address

View the Media Access Control (MAC) address of the wired print server. This value cannot be modified.

SGD command used:

Printer web page:

View and Modify Printer Settings > Network Communications Setup > TCP/IP Settings

Connection > Wi-Fi > Wi-Fi IP Protocol

IMPORTANT: You must reset the print server to allow changes to the network settings to take effect. See

Connection > Networks > Reset Network on page 38.

This parameter indicates if the user (permanent) or the server (dynamic) selects the wireless print server’s IP address. When a dynamic option is chosen, this parameter tells the method(s) by which this print server receives the IP address from the server.

Accepted values:

internal_wired.mac_addr

• ALL

• GLEANING ONLY

• RARP

• BOOTP

• DHCP

• DHCP & BOOTP

• PERMANENT

Related ZPL command(s):

SGD command used:

^ND

wlan.ip.protocol

Printer web page:

View and Modify Printer Settings > Network Communications Setup > Wireless Setup

Printer Configuration and Adjustment

Connection > Wi-Fi > Wi-Fi IP Address

NOTE: To save changes to this setting, set Connection > Wired > Wired IP Protocol on page 41 to PERMANENT, and then reset the print server (see Connection > Networks > Reset Network on page 38).

View and, if necessary, change the printer’s wireless IP address.

Accepted values: 000 to 255 for each field

Related ZPL command(s):

SGD command used:

•

ip.addr

•

wlan.ip.addr

Printer web page:

View and Modify Printer Settings > Network Communications Setup > Wireless Setup

Connection > Wi-Fi > Wi-Fi Subnet

NOTE: To save changes to this setting, set Connection > Wired > Wired IP Protocol on page 41 to PERMANENT, and then reset the print server (see Connection > Networks > Reset Network on page 38).

^ND

View and, if necessary, change the wireless subnet mask.

Accepted values: 000 to 255 for each field

Related ZPL command(s):

SGD command used:

^ND

wlan.ip.netmask

Printer web page:

View and Modify Printer Settings > Network Communications Setup > Wireless Setup

Connection > Wi-Fi > Wi-Fi Gateway

NOTE: To save changes to this setting, set Connection > Wired > Wired IP Protocol on page 41 to PERMANENT, and then reset the print server (see Connection > Networks > Reset Network on page 38).

View and, if necessary, change the default wireless gateway.

Accepted values: 000 to 255 for each field

Related ZPL command(s):

SGD command used:

^ND

wlan.ip.gateway

Printer web page:

View and Modify Printer Settings > Network Communications Setup > Wireless Setup

Printer Configuration and Adjustment

Connection > Wi-Fi > Wi-Fi Mac Address

View the Media Access Control (MAC) address of the wireless print server. This value cannot be modified.

SGD command used:

Printer web page:

View and Modify Printer Settings > Network Communications Setup > Wireless Setup

Connection > Wi-Fi > ESSID

The Extended Service Set Identification (ESSID) is an identifier for your wireless network. Specify the ESSID for the current wireless configuration.

Accepted values: 32-character alphanumeric string (default 125)

SGD command used:

wlan.mac_addr

wlan.essid

Printer web page:

View and Modify Printer Settings > Network Communications Setup > Wireless Setup

Connection > Wi-Fi > Wi-Fi Security

Select the security type being used on your wireless network.

Related ZPL command(s):

SGD command used:

^WX

wlan.security

Printer web page:

View and Modify Printer Settings > Network Communications Setup > Wireless Encryption Setup

Connection > Wi-Fi > Wi-Fi Band Set a preferred band to connect with via Wi-Fi.

Accepted values:

• 2.4

• 5

• All

SGD command used:

wlan.band_preference

Printer web page:

View and Modify Printer Settings > Network Communications Setup > Wireless Setup

Printer Configuration and Adjustment

Connection > Wi-Fi > Wi-Fi Country Code

IMPORTANT: The list of country codes is specific to each printer and depends on the printer model and its wireless radio configuration. The list is subject to change, addition, or deletion with any firmware update, at any time, without notice.

The country code defines the regulatory country for which the wireless radio is currently configured.

To determine the country codes available on your printer, issue the

! U1 getvar "wlan" command to return all commands related to Wi-Fi

settings. Locate the view the country codes available for your printer.

SGD command used:

Connection > Bluetooth > Bluetooth

Select if Bluetooth is enabled.

Accepted values:

wlan.country.code command in the results and

wlan.country_code

• On—Enables the Bluetooth radio.

• Off—Disables the Bluetooth radio.

SGD command used:

bluetooth.enable

Connection > Bluetooth > Bluetooth Discovery

Select if the printer is “Discoverable” for Bluetooth device pairing.

Accepted values:

• On—Enables Bluetooth discoverable mode.

• Off—Disables Bluetooth discoverable mode.

SGD command used:

bluetooth.discoverable

Printer Configuration and Adjustment

Connection > Bluetooth > Friendly Name

This command sets the friendly name, which is used during service discovery. For changes to take effect, you must power cycle the printer or issue the

Reset Network on page 38).

If you do not set a friendly name, this setting defaults to the printer serial number.

Accepted values: 17-character text string

SGD command used:

Connection > Bluetooth > Minimum Security Mode

This printer setting defines the minimum level of security that the printer requires for a Bluetooth connection. Connections attempting to use a lower level are refused.

Accepted values: 1–4

SGD command used:

device.reset command (see Connection > Networks >

bluetooth.friendly_name

bluetooth.minimum_security_mode

Connection > Bluetooth > Specification Version

This parameter displays the Bluetooth library version number.

SGD command used:

bluetooth.version

Connection > Bluetooth > MAC Address

This parameter displays the Bluetooth device address.

SGD command used:

bluetooth.address

Printer Configuration and Adjustment

Connection > Bluetooth > Bluetooth Auth. PIN

Set the PIN used when Bluetooth authentication is enabled (Bluetooth

2.0 and earlier).

SGD command used:

•

bluetooth.bluetooth_pin (to set the PIN)

•

bluetooth.authentication (to enable authentication)

Connection > Bluetooth > Bluetooth Bonding

Select if the printer should retain details from previously completed Bluetooth pairings.

Accepted values:

• On—Enables Bluetooth bonding so that the information is

retained.

• Off—Disables Bluetooth bonding.

SGD command used:

bluetooth.bonding

Printer Configuration and Adjustment

Print Menu

Print > Print Quality > Darkness

Set the print darkness to the lowest setting that provides good print quality. If you set the darkness too high, the label image may print unclearly, barcodes may not scan correctly, the ribbon may burn through, or the printhead may wear prematurely.

Accepted values: 0.0 to 30.0

Related ZPL command(s):

•

^MD

•

~SD

SGD command used:

Printer web page:

View and Modify Printer Settings > General Setup > Darkness

Print > Print Quality > Print Speed

Select the speed, in inches per second (ips), for printing a label. Slower print speeds typically yield better print quality.

Accepted values:

• ZE511 203 dpi = 2 to 18

• ZE511 300 dpi = 2 to 14

• ZE511 600 dpi = 2 to 6

• ZE521 203 dpi = 2 to 14

• ZE521 300 dpi = 2 to 12

Related ZPL command(s):

SGD command used:

Printer web page:

View and Modify Printer Settings > General Setup > Print Speed

print.tone

^PR

media.speed

Printer Configuration and Adjustment

Print > Print Quality > Print Type

Specify if the printer needs to use ribbon for printing. If you need assistance, see Do I need to use ribbon? on page 13.

Accepted values:

• Thermal Transfer—Uses ribbon and thermal transfer media.

• Direct Thermal—Uses direct thermal media and no ribbon.

Related ZPL command(s):

SGD command used:

^MT

ezpl.print_method

Printer web page:

View and Modify Printer Settings > Media Setup > Print Method

Print > Print Quality > Ribbon Ink Side

Select whether your ribbon is coated on the inside or the outside. To determine which side of the ribbon is coated, see How can I tell which

side of the ribbon is coated? on page 13.

Accepted values:

• Ink Side Out

• Ink Side In

SGD command used:

ribbon.coating

Printer Configuration and Adjustment

Print > Print Quality > Ribbon Tension

Select the ribbon tension setting that is appropriate for the width or type of media being printed. High can be used for most media. The correct setting is determined by a combination of the ribbon width and the ribbon length. If necessary, use a lower value for narrow media or for glossy media.

Ribbon Width

76 to 127 mm (3 to 5 in.)

102 to 152 mm (4 to 6 in.)

127 to 180 mm (5 to 7.1 in.)

Accepted values:

• Low

• Medium

• High

Related ZPL command(s):

300 Meters 450 Meters 600 Meters

Low Low Low

Low Low or Medium Low or Medium

Low or Medium Medium Medium

Ribbon Length

or High

^JW

Printer Configuration and Adjustment

Print > Print Quality > Media Type

Select the type of media that you are using.

Accepted values:

• Continuous—With continuous media, you must include a label length in your label format (

• Gap/Notch—With gap/notch media, you may need to adjust the position of the transmissive media sensor, which finds “start of label” indicators, such as notches or holes in the media or interlabel gaps.

On the pinch roller assembly (1), slide the sensor position indicator (2) to move the sensor.

^LL if you are using ZPL).

• If the media uses interlabel gaps, position the sensor approximately at the center of the media width.

• If the media has notches or holes between labels, align the sensor with the notch or hole in the media.

• Mark—Some types of media have black marks printed on the underside of the media liner, which act as “start of label” indicators. The reflective media sensor senses these black marks. The position of this sensor is not adjustable. If you use this type of media, refer to Media Specifications on page 128 for information about black mark requirements.

Related ZPL command(s):

SGD command used:

^MN

ezpl.media_type

Printer web page:

View and Modify Printer Settings > Media Setup > Media Type

Printer Configuration and Adjustment

Print > Print Quality > Label Length (Dots)

For continuous media, specify the length of the labels being used, in dots. For non-continuous media, this value is determined during media calibration and cannot be modified.

Accepted values: 1 to 32000, (in dots) not to exceed the maximum label length

Related ZPL command(s):

^LL

SGD command used:

zpl.label_length

Print > Print Quality > Label Width (Dots)

NOTE: Setting the width too narrow can result in portions of a label format not being printed on the media. Setting the width too wide wastes formatting memory and can cause the printer to print off of the label and onto the platen roller. This setting can affect the horizontal position of the label format if the image was inverted using the

ZPL II command.

Specify the width of the labels being used, in dots. The default value is the maximum width for the printer, based on the printhead dpi (dots per inch) value.

Accepted values:

• ZE511 203 dpi = 0002 to 832

• ZE511 300 dpi = 0002 to 1228

• ZE511 600 dpi = 0002 to 2456

• ZE521 203 dpi = 0002 to 1344

• ZE521 300 dpi = 0002 to 1984

Related ZPL command(s):

^PW

^POI

SGD command used:

ezpl.print_width

Printer web page:

View and Modify Printer Settings > Media Setup > Print Width

Printer Configuration and Adjustment

Print > Image Adjust > Media Handling

Select a media handling method that is compatible with the options available on your printer. See the Zebra Programming Guide at

zebra.com/manuals for more information.

Accepted values:

Tear Off, Peel Off, Rewind, Cutter, Delayed Cut, Linerless Peel, Linerless Rewind, Linerless Tear, Applicator, Linerless Cut, Linerless

Delayed Cut, Stream

Related ZPL command(s):

SGD command used:

^MM

ezpl.print_mode

Printer web page:

View and Modify Printer Settings > General Setup > Print Mode

Print > Image Adjust > Tear Line Offset If necessary, shift the position of the media over the tear-off bar after

printing.

• Lower numbers move the media into the printer by the specified number of dots (the tear line moves closer to the edge of the label just printed).

• Higher numbers move the media out of the printer (the tear line moves closer to the leading edge of the next label).

Accepted values: –120 to +120

Related ZPL command(s):

~TA

SGD command used: ezpl.tear_off

Printer web page:

View and Modify Printer Settings > General Setup > Tear Off

Printer Configuration and Adjustment

Print > Image Adjust > Horizontal Label Offset

If necessary, shift the position of the image horizontally on the label.

• Negative numbers move the left edge of the image toward the left edge of the label by the number of dots selected.

• Positive numbers move the edge of the image toward the right edge of the label.

Accepted values: –9999 to 9999

Related ZPL command(s):

^LS

SGD command used:

zpl.left_position

Printer web page:

View and Modify Printer Settings > Advanced Setup > Left Position

Print > Image Adjust > Vertical Label Offset

If necessary, shift the position of the image vertically on the label.

• Lower numbers move the image higher on the label (toward the printhead).

• Higher numbers move the image farther down on the label (away from the printhead) by the specified number of dots.

Accepted values: –120 to +120

Related ZPL command(s):

^LT

Printer web page:

View and Modify Printer Settings > General Setup > Label Top

Printer Configuration and Adjustment

Print > Image Adjust > Invert Label

When this option is enabled, the image prints inverted on the media.

Accepted values:

• On

• Off

SGD command used: print.invert_label

Print > Sensors > Calibrate

This option adjusts sensor levels and thresholds, determines the label length, and feeds the media to the next web. This option is disabled when Media Type is set to Continuous and Head Close Action is set to Calibrate.

Printer web page: Calibration cannot be initiated through the web pages. See the following web page for settings that are set during sensor calibration:

View and Modify Printer Settings > Calibration

Print > Sensors > Manual Calibration

This option adjusts the sensitivity of the media and ribbon sensors, adjusts sensor levels and thresholds, determines the label length, and feeds the media to the next web.

Related ZPL command(s):

SGD command used:

Control panel key(s):

Hold PAUSE + FEED + CANCEL for 2 seconds to initiate calibration.

Printer web page: Calibration cannot be initiated through the web pages. See the following web page for settings that are set during sensor calibration:

View and Modify Printer Settings > Calibration

~JC

ezpl.manual_calibration

Printer Configuration and Adjustment

Print > Sensors > Label Sensor

IMPORTANT: This value is set during sensor calibration. Do not change these settings unless you are told to do so by Zebra Technical Support or by an authorized service technician.

Set the sensitivity of the label sensor.

Accepted values: 0 to 255

SGD command used:

Printer web page:

View and Modify Printer Settings > Calibration

Print > Sensors > Sensor Type

Select the media sensor that is appropriate for the media that you are using. The reflective sensor typically is used only for black mark media. The transmissive sensor typically is used for other media types.

Accepted values:

ezpl.label_sensor

• Transmissive

• Reflective

Related ZPL command(s):

SGD command used:

^JS

device.sensor_select

Printer web page:

View and Modify Printer Settings > Media Setup

Print > Sensors > Print: Sensor Profile

Shows the sensor settings compared to actual sensor readings. To interpret the results, see Printing and Interpreting a Sensor Profile on

page 84.

Related ZPL command(s):

~JG

Control panel key(s):

Hold FEED + CANCEL during printer power-up.

Printer web page:

View and Modify Printer Settings > Print Listings on Label

Printer Configuration and Adjustment

Print > Print Station

Use this menu item to fill in variable fields in a label format and print the label using a Human Input Device (HID), such as a USB keyboard, scale, or barcode scanner. A suitable label format must be stored on the E: drive of the printer to use this option. See the exercises in Using USB

Host Ports and Print Touch/NFC on page 109 for an exercise using this

capability.

When you plug an HID into one of the printer’s USB host ports, use this user menu to select a form on the printer’s E: drive. After you have been prompted to fill in each variable

the desired quantity of labels to print.

For more information about using the Programming Guide at zebra.com/manuals.

* This menu item can be used only if a USB device is connected to a USB host port on the printer.

SGD command used:

•

usb.host.keyboard_input (must be set to ON)

•

usb.host.template_list

field on the form, you can specify

^FN

^FN command or the SGD commands related to this feature, see the Zebra

•

usb.host.fn_field_list

•

usb.host.fn_field_data

•

usb.host.fn_last_field

•

usb.host.template_print_amount

Print > Applicator > Applicator Port Mode

Controls the way in which the applicator port’s “End Print” signal functions.

Accepted values:

• Off

• 1 = End Print signal normally high, and low only when the printer

is moving the label forward.

• 2 = End Print signal normally low, and high only when the printer

is moving the label forward.

• 3 = End Print signal normally high, and low for 20 ms when a label

has been printed and positioned.

• 4 = End Print signal normally low, and high for 20 ms when a label has been printed and positioned.

Related ZPL command(s):

^JJ

SGD command used:

device.applicator.end_print

Printer Configuration and Adjustment

Print > Applicator > Start Print Mode

Determines if the applicator port’s “Start Print” signal is in level mode or pulse mode.

Accepted values:

• Pulse Mode—Start Print signal must be deasserted before it can

be asserted for the next label.

• Level Mode—Start Print signal does not need to be deasserted to

print the next label. As long as the Start Print signal is low and a label is formatted, a label prints.

Related ZPL command(s):

SGD command used:

^JJ

device.applicator.start_print

Print > Applicator > Error on Pause

Determines how applicator port errors are treated by the printer. Enabling this feature also causes the “Service Required” pin to be asserted.

Accepted values:

• Enabled

• Disabled

SGD command used:

device.applicator.error_on_pause

Printer web page:

View and Modify Printer Settings > Advanced Setup > Error on Pause

Print > Applicator > Applicator Reprint

Specifies if a high or low value is required for an applicator to reprint a label.

Enables or disables the

~PR command, which when enabled reprints the

last printed label. It also enables the Reprint button on the Home screen.

Related ZPL command(s):

•

^JJ

•

~PR

SGD command used:

device.applicator.reprint

Printer Configuration and Adjustment

RFID Menu

RFID > RFID Status

Display the status of the RFID subsystem of the printer.

Related ZPL command(s): SGD command used: rfid.error.response

RFID > RFID Test

During the RFID test, the printer attempts to read and write to a transponder. No printer movement occurs with this test.

1. Position the RFID label with its transponder over the RFID antenna array.

^HL or ~HL

2. Touch Start.

The results of the test are shown below the Start button.

SGD command used:

rfid.tag.test.execute

RFID > RFID Calibrate

NOTE: Before running this command, load the printer with RFID media, calibrate your printer, close the printhead, and feed at least one label to make sure that tag calibration begins from the correct position.

Leave all transponders before and after the tag that is being calibrated. This allows the printer to determine RFID settings which do not encode the adjacent tag. Allow a portion of media to extend out the front of the printer to allow for backfeed during the tag calibration procedure.

Initiate tag calibration for RFID media. (Not the same as media and ribbon calibration.) During the process, the printer moves the media, calibrates the RFID tag position, and determines the optimal settings for the RFID media being used. These settings include the programming position, the antenna element to use, and the read/write power level to use. See the RFID Programming Guide 3 for more information.

Related ZPL command(s):

SGD command used:

rfid.tag.test.content and

^HR

rfid.tag.calibrate

Printer Configuration and Adjustment

RFID > Read Power

If the desired read power is not achieved through RFID tag calibration, a value may be specified.

Accepted values: 0 to 30

Related ZPL command(s):

^RW

SGD command used:

rfid.reader_1.power.read

Printer web page:

View and Modify Printer Settings > RFID Setup > RFID READ PWR

RFID > Write Power

If the desired write power is not achieved through RFID tag calibration, a value may be specified.

Accepted values: 0 to 30

Related ZPL command(s):

SGD command used:

^RW

rfid.reader_1.power.write

Printer web page:

View and Modify Printer Settings > RFID Setup > RFID WRITE PWR

RFID > RFID Antenna

If the desired antenna is not achieved through RFID tag calibration, a value may be specified.

Accepted values:

A1, A2, A3, A4, A5, A6, A7

B1, B2, B3, B4, B5, B6, B7

Related ZPL command(s):

SGD command used:

^RW

rfid.reader_1.antenna_port

Printer web page:

View and Modify Printer Settings > RFID Setup > RFID ANTENNA

Printer Configuration and Adjustment

RFID > RFID Valid Count

Resets the RFID valid label counter to zero.

Related ZPL command(s):

SGD command used:

odometer.rfid.valid_resettable

RFID > RFID Void Count

Resets the RFID void label counter to zero.

Related ZPL command(s):

SGD command used:

odometer.rfid.void_resettable

~RO

RFID > RFID Program Position

If the desired programming position (read/write position) is not achieved through RFID tag calibration, a value may be specified.

Accepted values:

• F0 to Fxxx (where xxx is the label length in millimeters or 999,

whichever is less)—The printer feeds the label forward for the specified distance and then begins programming.

• B0 to B30—The printer backfeeds the label for the specified

distance and then begins programming. To account for the backfeed, allow empty media liner to extend out of the front of the printer when using a backward programming position.

Related ZPL command(s):

SGD command used:

^RS

rfid.position.program

Printer web page:

View and Modify Printer Settings > RFID Setup > PROGRAM POSITION

Printer Configuration and Adjustment

RFID > Read RFID Data

Read and return the specified tag data from the RFID tag located over the RFID antenna. No printer movement occurs while tag data is being read. The printhead can be open or closed.

1. Position the RFID label with its transponder over the RFID antenna.

2. Touch Read RFID Data.

The results of the test are shown on the display.

Related ZPL command(s):

^RF

SGD command used:

•

rfid.tag.read.content

•

rfid.tag.read.execute

RFID > RFID Country Code

sets the RFID reader country code. The country code is restricted based on the region code assigned to the reader and, in some instances, cannot be modified. Only the countries available for your region are listed.

SGD command used:

rfid.country_code

Printer Configuration and Adjustment

Storage Menu

Storage > USB > Copy: Files to USB

Select files from the printer to store on a USB Flash drive.

1. Insert a USB flash drive into the printer’s USB host port.

The printer lists available files.

2. Touch the box next to the desired files. Select All is also available.

3. Touch the check mark to copy the selected files.

SGD command used:

Storage > USB > Copy: Files to Printer

Select files to copy to the printer from a USB Flash drive.

1. Insert a USB flash drive into the printer’s USB host port.

The printer lists available files.

2. Touch the box next to the desired files. Select All is also available.

3. Touch the check mark to copy the selected files.

SGD command used:

Storage > USB > Copy: Configuration to USB

Use this function to copy the printer’s configuration information to a USB mass storage device, such as a USB Flash drive, that is plugged into one of the printer’s USB host ports. This makes the information accessible without having to print physical labels.

Related ZPL command(s): information returned to the host computer.

Printer web page:

usb.host.write_list

usb.host.read_list

^HH—Returns the printer configuration

• Printer Home Page > View Printer Configuration

(to view printer configuration information on your web browser)

• View and Modify Printer Settings > Print Listings on Label

(to print the configuration information on labels)

Printer Configuration and Adjustment

Storage > USB > Print: From USB

Select files to print from a USB Flash drive.

1. Insert a USB flash drive into the printer’s USB host port.

The printer lists available files.

2. Touch the box next to the desired files. Select All is also available.

3. Touch the check mark to print the selected files.

SGD command used:

Storage > Print Asset Lists

Print the specified information on one or more labels.

Accepted values:

• Formats—Prints the available formats stored in the printer’s RAM,

Flash memory, or optional memory card.

• Images—Prints the available images stored in the print engine’s

RAM, Flash memory, or optional memory card.

• Fonts—Prints the available fonts in the print engine, including

standard print engine fonts plus any optional fonts. Fonts may be stored in RAM or Flash memory.

• Barcodes—Prints the available barcodes in the print engine. Barcodes may be stored in RAM or Flash memory.

• All—Prints the previous labels plus the printer configuration label and the network configuration label.

Related ZPL command(s):

Printer web page:

View and Modify Printer Settings > Print Listings on Label

usb.host.read_list

^WD

Storage > Print from E:

Select files to print from the printer’s E: drive.

1. Touch Print from E:.

The printer lists available files.

2. Touch the box next to the desired files. Select All is also available.

3. Touch the check mark to print the selected files.

Printer Configuration and Adjustment

Toggle Positioning and Printhead Pressure Adjustment

The printhead pressure toggles can be adjusted to create more or less pressure, as needed. They can also be moved from side to side to adjust the pressure in certain areas.

If the toggles are not positioned correctly or adjusted to apply the correct pressure, the following types of issues may result:

• media and ribbon may slip

• ribbon may wrinkle

• media may move from side to side during printing

• printing may be too light or too dark on one side of the media

Use the lowest printhead pressure necessary to produce good print quality. Higher pressures may cause premature wear on the printhead elements.

Changing the Toggle Position

NOTE: The graphics shown in this section depict a right-hand (RH) model. The graphics for a left-hand (LH) model would be a mirror image.

1. Release the printhead assembly to lessen the pressure on the toggles.

Printer Configuration and Adjustment

Loosen the locking nut at the top of the toggle to be moved.

3. Reposition the toggle as necessary to provide even pressure on the media. For extremely narrow

media, position the inner toggle over the center of the media, and decrease the pressure on the outer toggle.

Printer Configuration and Adjustment

Tighten the locking nut.

5. Lock the printhead assembly.

Printer Configuration and Adjustment

Adjusting the Printhead Pressure

If positioning the toggles properly does not solve a print quality or other issue, try adjusting the printhead pressure. Maximize printhead life by using the lowest pressure that produces the desired print quality.

NOTE: The graphics shown in this section depict a right-hand (RH) model. The graphics for a left-hand (LH) model would be a mirror image.

Inner toggle (closest to the body of the printer)

Outer toggle (farthest from the body of the printer)

1. Are you experiencing either of the following issues?

If the media... Then...

Requires higher pressure overall to print well

Requires lower pressure overall to print well

2. If overall pressure is not an issue, initiate a PAUSE Self-Test on page 83.

3. While printing labels, use the control panel to lower the darkness setting until the labels are printing

Increase the pressure on both toggles. Continue with step 5 on

page 70.

Decrease the pressure on both toggles. Continue with step 5

on page 70.

gray instead of black. (See Print > Print Quality > Darkness on page 49.)

Printer Configuration and Adjustment

Are you experiencing any of the following issues?

If the media...

Prints too lightly on the left side of the label.

Prints too lightly on the right side of the label.

Increase the pressure on the inner toggle.

Increase the pressure on the outer toggle.

Then for right-hand (RH)

print engines...

Shifts left while printing Increase the pressure on the outer

toggle.

Decrease the pressure on the inner toggle.

Shifts right while printing Increase the pressure on the inner

toggle.

Decrease the pressure on the outer toggle.

5. To make adjustments to the printhead pressure:

a. Loosen the upper knurled nut on the toggle to be adjusted.

Then for left-hand (LH)

print engines...

Increase the pressure on the outer toggle.

Increase the pressure on the inner toggle.

Decrease the pressure on the outer toggle.

Increase the pressure on the outer toggle.

Decrease the pressure on the inner toggle.

b. Increase or decrease the pressure by rotating the lower nut.

Increase pressure Decrease pressure

Printer Configuration and Adjustment

Hold the lower nut in place and tighten the upper knurled nut.

6. If necessary, reinitiate a PAUSE Self-Test on page 83.

7. While printing labels, use the control panel to raise the darkness setting until the labels are again

printing black instead of gray. (See Print > Print Quality > Darkness on page 49.)

8. Check the print quality, and if necessary, repeat this procedure until the printhead pressure is

adequate.

Routine Maintenance

Routine preventive maintenance is a crucial part of normal printer operation. By taking good care of your printer, you can minimize the potential problems that you might have with it and help to achieve and to maintain your standards for print quality.

Over time, the movement of media or ribbon across the printhead wears through the protective ceramic coating, exposing and eventually damaging the print elements (dots). To avoid abrasion:

• Clean the printhead frequently.

• Minimize printhead pressure and burn temperature (darkness) settings by optimizing the balance between the two.

• When using Thermal Transfer mode, ensure that the ribbon is as wide or wider than the media to prevent exposing the printhead elements to the more abrasive label material.

IMPORTANT: Zebra is not responsible for damage caused by the use of cleaning fluids on this print engine.

Cleaning Schedule and Procedures

Specific cleaning procedures are provided in this section. Table 1 shows the recommended cleaning schedule. These intervals are intended as guidelines only. You may have to clean more often, depending upon your application and media.

Table 1 Recommended Cleaning Schedule

Area Method Interval

Printhead Solvent* Direct Thermal Mode: After every roll of media (or 500

Platen roller Solvent*

Pinch roller Solvent*

Peel roller Solvent*

Media sensors Air blow

Ribbon sensor Air blow

Media path Solvent*

Ribbon path Solvent*

Tear-off/peel-off bar Solvent*

*Zebra recommends using the Preventive Maintenance Kit (p/n 47362 or p/n 105950-035 - multipack). In place of this kit, you may use a clean swab dipped in 99.7% isopropyl alcohol.

feet of fanfold media).

Thermal Transfer Mode: After every roll of ribbon.

Routine Maintenance

Cleaning the Exterior, the Media Compartment, and the Sensors

Over time, dust, grime, and other debris may build up on the outside and inside of your printer, particularly in a harsh operating environment.

Printer Exterior

You may clean the exterior surfaces of the print engine with a lint-free cloth and a small amount of a mild detergent, if necessary. Do not use harsh or abrasive cleaning agents or solvents.

IMPORTANT: Zebra is not responsible for damage caused by the use of cleaning fluids on this print engine.

Media Compartment and Sensors

Brush, air blow, or vacuum any accumulated paper lint and dust away from the media and ribbon paths and the sensors.

Cleaning the Printhead and Rollers

Inconsistent print quality, such as voids in the barcode or graphics, may indicate a dirty printhead. For the recommended cleaning schedule, see Cleaning Schedule and Procedures on page 72.

CAUTION—ESD: Before touching the printhead assembly, discharge any built-up static electricity by touching the metal printer frame or by using an anti-static wriststrap and mat.

1. Turn Off (O) the print engine.

2. Open the media cover.

3. Remove the media and ribbon.

Release the printhead assembly.

Routine Maintenance

5. Press the release button on the upper pinch roller assembly, and allow the assembly to pivot upward.

CAUTION—HOT SURFACE: The printhead may be hot and could cause severe burns. Allow the printhead to cool.

6. Clean the printhead.

Routine Maintenance

Using the swab from the Preventive Maintenance Kit (p/n 47362 or p/n 105950-035 for a multipack),

wipe the print elements (gray strip) from end to end. In place of this kit, use a lint-free cloth dipped in

99.7% isopropyl alcohol.

b. Allow the solvent to evaporate.

7. Clean the rollers.

a. Use the swab or the lint-free cloth to clean the pinch roller (1), peel roller (2), and platen roller (3).

Rotate the rollers while cleaning them.

b. Allow the solvent to evaporate.

1 2 3

NOTE: If print quality does not improve after you perform this procedure, clean the printhead with Zebra’s Save-a-Printhead cleaning film. Call your authorized Zebra distributor for more information.

8. Reload the ribbon and media (if used).

9. Close the upper pinch roller assembly.

Lock the printhead assembly.

10.

11. Close the media cover.

Routine Maintenance

Removing Used Ribbon

Remove used ribbon from the ribbon take-up spindle each time you change the roll of ribbon.

1. Has the ribbon run out?

• Yes—Continue with step 2.

• No—Cut or break the ribbon before the ribbon take-up spindle.

Routine Maintenance

LH RH

2. Slide the core with the used ribbon off of the ribbon take-up spindle.

LH RH

3. Discard the used ribbon. Reuse the empty core from the ribbon supply spindle by moving it to the

ribbon take-up spindle.

Routine Maintenance

Replacing Print Engine Components

Some print engine components, such as the printhead and platen roller, may wear out over time and can be replaced easily. Regular cleaning may extend the life of some of these components. See Table 1 on

page 72 for the recommended cleaning intervals.

Ordering Replacement Parts

Zebra ™ printers are designed to work only with genuine Zebra printheads, thus maximizing safety and print quality. Contact your authorized Zebra reseller for part ordering information.

Recycling Print Engine Components

The majority of this print engine’s components are recyclable. The print engine’s main logic board may include a battery that you should dispose of properly.

Do not dispose of any print engine components in unsorted municipal waste. Please dispose of the battery according to your local regulations, and recycle the other print engine components according to your local standards. For more information, see zebra.com/environment.

Storing the Print Engine

If you are not placing the print engine into immediate operation, repackage it using the original packing materials. You may store the print engine under the following conditions:

• Temperature: –40°C to 60°C (–40° to 140°F)

• Relative humidity: 5% to 85% non-condensing

Lubrication

No lubrication is needed for this print engine.

CAUTION—PRODUCT DAMAGE: Some commercially available lubricants will damage the finish and the mechanical parts if used on this print engine.

Troubleshooting

This section provides information about errors that you might need to troubleshoot. Assorted diagnostic tests are included.

Judging Barcode Quality

Figure 1 shows how printer settings such as darkness and print speed can affect the quality of barcodes.

Set the print darkness to the lowest setting that provides good print quality. The Print Quality Assistant in

Running the Print Wizard and Printing a Test Label on page 27 can help you determine the best settings.

Figure 1 Barcode Darkness Comparison

Diagnostics and Troubleshooting

Too Dark

Labels that are too dark are fairly obvious. They may be readable but not in-spec.

• The normal barcode bars increase in size.

• The openings in small alphanumeric characters may fill in with ink.

• Rotated barcode bars and spaces run together.

Slightly Dark

Slightly dark labels are not as obvious.

• The normal barcode will be in-spec.

• Small character alpha numerics will be bold and could be slightly filled in.

• The rotated barcode spaces are small when compared to the in-spec code, possibly making the code unreadable.

In-Spec

A barcode that is “in-spec” (within specifications) can only be confirmed by a verifier, but it should exhibit some visible characteristics.

• The normal barcode will have complete, even bars and clear, distinct spaces.

• The rotated barcode will have complete, even bars and clear, distinct spaces. Although it may not look as good as a slightly dark barcode, the barcode is within specifications.

• In both normal and rotated styles, small alphanumeric characters look complete.

Slightly Light

Slightly light labels are, in some cases, preferred to slightly dark ones for barcodes.

• Both normal and rotated barcodes will be in spec.

• Small alphanumeric characters may not be complete.

Too Light

Labels that are too light are obvious.

Diagnostics and Troubleshooting

• Both normal and rotated barcodes have incomplete bars and spaces.

• Small alphanumeric characters are unreadable.

Configuration Labels

Some of the most commonly used diagnostic items are the printer configuration label and the network configuration label. Sample labels are shown in Figure 2. Analyzing the information on these labels can help you to troubleshoot potential issues.

To print a printer configuration label, touch Menu > Settings > Print: System Settings.

To print a network configuration label, touch Menu > Connection > Networks > Print: Network Info.

Figure 2 Sample Labels

Printer Configuration Label Network Configuration Label

Diagnostics and Troubleshooting

PAUSE Self-Test

Use this self-test to provide the test labels required when making adjustments to the print engine’s mechanical assemblies or to determine if any printhead elements are not working. Figure 3 shows a sample printout.

Figure 3 PAUSE Self-Test Label

1. Turn off (O) the print engine.

2. Press and hold PAUSE while turning on (I) the print engine. Hold PAUSE until the first control panel

light turns off.

Diagnostics and Troubleshooting

• The initial self-test prints 15 labels at the print engine’s slowest speed, and then automatically

pauses the print engine. Each time PAUSE is pressed, an additional 15 labels print.

• While the print engine is paused, pressing CANCEL alters the self-test. Each time PAUSE is

pressed, 15 labels print at 152 mm (6 in.) per second.

• While the print engine is paused, pressing CANCEL again alters the self-test a second time. Each

time PAUSE is pressed, 50 labels print at the print engine’s slowest speed

• While the print engine is paused, pressing CANCEL again alters the self-test a third time. Each time

PAUSE is pressed, 50 labels print at 152 mm (6 in.) per second.

• While the print engine is paused, pressing CANCEL again alters the self-test a fourth time. Each

time PAUSE is pressed, 15 labels print at the print engine’s maximum speed.

3. To exit this self-test at any time, press and hold CANCEL.

Diagnostics and Troubleshooting

Printing and Interpreting a Sensor Profile

Touch Menu > Print > Print Quality > Print: Sensor Profile to print a sensor profile image (which extends across several actual labels or tags). Use the sensor profile image to troubleshoot the following situations:

• The printer experiences difficulty in determining gaps (web) between labels.

• The printer incorrectly identifies preprinted areas on a label as gaps (web).

• The printer cannot detect ribbon.

Compare your results to the examples shown in this section. If the sensitivity of the sensors must be adjusted, calibrate the printer (see Calibrating the Ribbon and Media Sensors on page 26).

Media Sensor Profile

The line labeled MEDIA (1) on the sensor profile indicates the media sensor readings. The media sensor threshold settings is indicated by WEB (2). The media out threshold is indicated by OUT (3). The upward or downward spikes (4) indicate divisions between labels (the web, notch, or black mark), and the lines between the spikes (5) indicate where labels are located.

If you compare the sensor profile printout to a length of your media, the spikes should be the same distance apart as the gaps on the media. If the distances are not the same, the print engine may be having difficulty determining where the gaps are located.

Figure 4 Media Sensor Profile (Gap/Notch Media)

Figure 5 Media Sensor Profile (Black Mark Media)

1 2

Ribbon Sensor Profile

The line labeled RIBBON (1) on the sensor profile indicates the ribbon sensor readings. The ribbon sensor threshold setting is indicated by OUT (2). If the ribbon readings are below the threshold value, the print engine does not acknowledge that ribbon is loaded.

Diagnostics and Troubleshooting

Using Communication Diagnostics Mode

The communication diagnostics test is a troubleshooting tool for checking the interconnection between the print engine and the host computer. When the printer is in diagnostics mode, it prints all data received from the host computer as straight ASCII characters with the hex values below the ASCII text. The print engine prints all characters received, including control codes such as CR (carriage return). Figure 6 shows a typical test label from this test.

Figure 6 Sample Communications Diagnostics Mode Label

1. Set the label width equal to or less than the actual media width being used for the test.

Touch Settings > Media Settings to access the label width setting.

2. Touch Menu > System > Program Language > Diagnostic Mode, and change the setting to Print.

The printer enters diagnostics mode and prints any data received from the host computer on a test label

NOTE: Other options for this mode include E:Drive for saving the output to the print engine’s hard drive and USB Host to save the output to a device that is connected to the USB host port.

3. Check the output for error codes. For any errors, check that your communication parameters are

correct.

Errors show on the test label as follows:

• FE indicates a framing error.

• OE indicates an overrun error.

• PE indicates a parity error.

• NE indicates noise.

4. To exit this self-test and return to normal operation, power cycle the printer or set the Diagnostic Mode

option to Off.

Diagnostics and Troubleshooting

Loading Defaults or Last Saved Values

Restoring the printer to default values or to the last saved values can help if things are not working as expected. Use care when loading defaults because you will need to reload all settings that you changed manually.

Touch Menu > System > Settings > Restore Defaults to see the available options.

• Restore Printer—Restores all printer settings other than the network settings back to the factory defaults.

• Restore Network—Reinitializes the printer’s wired or wireless print server. With a wireless print server, the printer also reassociates with your wireless network.

• Restore Last Saved—Loads settings from the last permanent save.

See System > Settings > Restore Defaults on page 36 for additional ways to restore these values.

Alert and Error States

If the background color of the Home screen changes, you may need to take an action to restore the printer to a Ready status. Red and yellow backgrounds typically halt printing until the issue is resolved. Informational messages with a green background usually disappear without user intervention, and printing continues as normal.

Diagnostics and Troubleshooting

Touch the icons in the bar at the top of the Home screen to view the error, alert, or informational message. See Alerts and Error Messages on page 89 for recommended actions.

Diagnostics and Troubleshooting

Alerts and Error Messages

Display/Indicator Lights Possible Causes Recommended Solutions

The printhead is not fully closed. Close the printhead completely.

Head Open

Printhead is open.

Close the printhead.

The printhead open sensor is not working properly.

Call a service technician to replace the sensor.

Media Out

Media is out.

Load additional media.

Paper Jam

Media jammed.

Check the media.

The media is not loaded or is loaded incorrectly.

Load media correctly. See Ribbon and

Media Loading on page 17.

Misaligned media sensor. Check the position of the media

sensor.

The printer is set for noncontinuous media, but continuous media is loaded.

1. Install the proper media type, or reset printer for the current media type.

2. Calibrate the printer. See

Calibrating the Ribbon and Media Sensors on page 26.

There is an issue with the media in the media path.

1. Check for media that is loaded incorrectly or stuck to components in the media path.

2. Check if media is wrapped around the platen roller. Carefully remove any labels.

3. If necessary, clean the platen roller to remove adhesive. See Cleaning

the Printhead and Rollers on page 73.

Diagnostics and Troubleshooting

Display/Indicator Lights Possible Causes Recommended Solutions

1. Load ribbon correctly. See Ribbon

and Media Loading on page 17.

2. Calibrate the printer. See

Calibrating the Ribbon and Media Sensors on page 26.

1. See Print > Sensors > Print:

Sensor Profile on page 57 to print a

sensor profile image (which extends across several actual labels or tags).The ribbon out threshold (1) is likely too high, above the line that indicates where the ribbon is detected (2).

Ribbon Out

Ribbon is out.

Replace the ribbon.

In thermal transfer mode:

• ribbon is not loaded

• ribbon is loaded incorrectly

• the ribbon sensor is not detecting ribbon

• media is blocking the ribbon sensor

In thermal transfer mode, the printer did not detect the ribbon even though it is loaded correctly.

Ribbon In

Ribbon was detected in

Direct Thermal mode.

Remove the ribbon.

If you are using direct thermal media, the printer is waiting for ribbon to be loaded because it is incorrectly set for thermal transfer mode.

Ribbon is loaded, but the printer is set for direct thermal mode.

2. Calibrate the printer (see

Calibrating the Ribbon and Media Sensors on page 26) or load

printer defaults (see System >

Settings > Restore Defaults on page 36).

Set the printer for Direct Thermal mode. See Print > Print Quality > Print

Type on page 50.

Ribbon is not required with direct thermal media. If you are using direct thermal media, remove the ribbon. This error message will not affect printing.

If the message persists with no ribbon in the printer, Calibrate the printer. See Calibrating the Ribbon and Media

Sensors on page 26.

If you are using thermal transfer media, which requires ribbon, set the printer for Thermal Transfer mode. See Print > Print Quality > Print Type

on page 50.

Diagnostics and Troubleshooting

Display/Indicator Lights Possible Causes Recommended Solutions

Head Identification Failed

Printhead is not a Zebra

Certified Product

Replace the Printhead

The printhead was replaced with one that is not a genuine Zebra printhead.

Install a genuine Zebra printhead.

Head Element Out

A printhead element failed.

The printhead may need to be replaced.

Replace Printhead

Replace the printhead.

Head Maintenance Needed

Clean the printhead.

Head Over Temp

Printhead is too hot.

All printing is halted.

Head Under Temp

Printhead is too cold. All printing is halted.

Head Thermistor Fault

Faulty thermistor detected.

Replace the printhead.

A printhead element is no longer working.

The printhead is nearing the end of its

If the location of the failed element affects printing, replace the printhead.

Replace the printhead.

life and should be replaced.

The printhead needs to be cleaned. Follow the cleaning instructions in

Cleaning the Printhead and Rollers on page 73.

CAUTION—HOT SURFACE: The printhead may be hot enough to cause severe burns. Allow the printhead to cool.

The printhead is over temperature. Allow the printer to cool. Printing

automatically resumes when the printhead elements cool to an acceptable operating temperature.

If this error persists, consider changing where the printer is located or using a slower print speed.

CAUTION—HOT SURFACE: An improperly connected printhead data or power cable can cause these error messages. The printhead may be hot enough to cause severe burns. Allow the printhead to cool.

The printhead data cable is not properly connected.

Make sure that the printhead is fully seated. If necessary, call a service technician to check the cable.

The printhead has a faulty thermistor. Replace the printhead.

The printer shows one of these messages or cycles between them.

Diagnostics and Troubleshooting

Display/Indicator Lights Possible Causes Recommended Solutions

CAUTION—HOT SURFACE: An improperly connected printhead data

Head Under Temp

Printhead is too cold. All printing is halted.

Out of Memory Storing XXX

XXX not stored.

Out of memory.

The printhead temperature is approaching its lower operating limit.

The printhead data cable is not properly connected.

The printhead has a faulty thermistor. Replace the printhead.

There is not enough memory to perform the function specified.

or power cable can cause this error message. The printhead may be hot enough to cause severe burns. Allow the printhead to cool.

Continue printing while the printhead reaches the correct operating temperature. If the error remains, the environment may be too cold for proper printing. Relocate the printer to a warmer area.

Make sure that the printhead is fully seated. If necessary, call a service technician to check the cable.

Free up some of the printer’s memory by adjusting the label format or printer parameters. One way to free up memory is to adjust the print width to the actual width of the label instead of leaving the print width set to the default.

Ensure that the data is not directed to a device that is not installed or is unavailable.

If the problem persists, call a service technician.

Indicator Lights

The indicator lights communicate the printer’s status.

Diagnostics and Troubleshooting

STATUS light

PAUSE light

DATA light

SUPPLIES light

NETWORK light

Table 2 Status of Printer As Shown by Indicator Lights

• STATUS light steady green (other lights steady yellow for 2 seconds during printer power-up)

The printer is ready.

• PAUSE light steady yellow.

The printer is paused.

• STATUS light steady red

• SUPPLIES light steady red

The media supply is out. The printer needs attention and cannot continue without user intervention.

• STATUS light steady red

• SUPPLIES light flashing red

The ribbon supply is out. The printer needs attention and cannot continue without user intervention.

Diagnostics and Troubleshooting

Table 2 Status of Printer As Shown by Indicator Lights (Continued)

• STATUS light steady yellow

• SUPPLIES light flashing yellow

The printer is in Direct Thermal mode, which does not require ribbon; however, ribbon is installed in the printer.

• STATUS light steady red

• PAUSE light steady yellow

The printhead is open. The printer needs attention and cannot continue without user intervention.

• STATUS light steady yellow

The printhead is over temperature.

CAUTION—HOT SURFACE: The printhead may be hot and could cause severe burns. Allow the printhead to cool.

• STATUS light flashing yellow

One of the following:

• The printhead is under temperature.

• The power supply is over temperature.

• The main logic board (MLB) is over temperature.

• STATUS light steady red

• PAUSE light steady red

• DATA light steady red

The printhead was replaced with one that is not a genuine Zebra ™ printhead. Install a genuine Zebra ™ printhead to continue.

• STATUS light flashing red

The printer is unable to read the dpi setting of the printhead.

Printers with a ZebraNet wired Ethernet option

• NETWORK light off

No Ethernet link is available.

• NETWORK light steady green

A 100 Base-T link was found.

• NETWORK light steady yellow

A 10 Base-T link was found.

• NETWORK light steady red

An Ethernet error condition exists. The printer is not connected to your network.

Diagnostics and Troubleshooting

Table 2 Status of Printer As Shown by Indicator Lights (Continued)

Printers with a ZebraNet wireless option

• NETWORK light off

A radio was found during power-up. The printer is attempting to associate with the network. The light flashes red while the printer associates with the network. The light then flashes yellow while the printer is authenticating with the network.

• NETWORK light steady green

The radio is associated with your network and authenticated, and the WLAN signal is strong.

• NETWORK light flashing green

The radio is associated with your network and authenticated, but the WLAN signal is weak.

• NETWORK light steady red

A WLAN error condition exists. The printer is not connected to your network.

Diagnostics and Troubleshooting

Troubleshooting

Printing or Print Quality Issues

Barcode Does Not Scan Possible Cause Recommended Solution

The barcode printed on a label does not scan.

The barcode is not within specifications because the printer is set at an incorrect darkness level.

1. Perform the steps in Running the Print Wizard and

Printing a Test Label on page 27.

2. If necessary, manually adjust the darkness or print speed settings.

• Set the print darkness to the lowest setting that

provides good print quality. If you set the darkness too high, the label image may print unclearly, barcodes may not scan correctly, the ribbon may burn through, or the printhead may wear prematurely.

• Slower print speeds typically yield better print

quality.

Access the darkness and print speed settings from the Home screen by touching Menu > Print > Print Quality.

3. If the issue is not resolved, check the printhead pressure and toggle position. See Toggle

Positioning and Printhead Pressure Adjustment on page 66

There is not enough blank space around the barcode.

Poor Print Quality Possible Cause Recommended Solution

Smudge marks on labels The media or ribbon is not

designed for high-speed operation.

Poor results with thick labels

Fine, angular gray lines on blank labels

Long tracks of missing print on several labels

The print line is not at an optimal position for your media.

Wrinkled ribbon. See wrinkled ribbon causes and solutions in Ribbon

Print element damaged. Replace the printhead.

Wrinkled ribbon. See wrinkled ribbon causes and solutions in Ribbon

Leave at least 3.2 mm (1/8 in.) between the barcode and other printed areas on the label and between the barcode and the edge of the label.

Replace supplies with those recommended for high-speed operation. For more information, see

zebra.com/supplies.

Refer to the Service Guide for instructions on how to adjust the print line for thick media.

Issues on page 100.

Diagnostics and Troubleshooting

Print Consistently Too

Light or Too Dark

Printing is too light or too dark over the entire label

Printing is too light or too dark on one side of the label

Possible Cause Recommended Solution

The media or ribbon is not designed for high-speed operation.

The printer is set at an incorrect darkness level.

You are using an incorrect combination of media and ribbon for your application.

Incorrect printhead pressure. Set the printhead pressure to the minimum needed for

Uneven printhead pressure. Adjust the printhead pressure as needed for good

Replace supplies with those recommended for high-speed operation. For more information, see

zebra.com/supplies.

For optimal print quality, set the darkness to the lowest possible setting for your application.

1. Perform the steps in Running the Print Wizard and

Printing a Test Label on page 27.

2. If necessary, manually adjust the darkness or print speed settings.

• Set the print darkness to the lowest setting that

• Slower print speeds typically yield better print

quality.

Access the darkness and print speed settings from the Home screen by touching Menu > Print > Print Quality.

1. Switch to a different type of media or ribbon to try to find a compatible combination.

2. If necessary, consult your authorized Zebra reseller or distributor for information and advice.

good print quality. See Toggle Positioning and

Printhead Pressure Adjustment on page 66.

print quality. See Toggle Positioning and Printhead

Pressure Adjustment on page 66.

Diagnostics and Troubleshooting

General Print

Quality Issues

General print quality issues

Loss of Registration Possible Cause Recommended Solution

Loss of printing registration on labels.

Excessive vertical drift in top-of-form registration.

Misregistration/skips labels

Misregistration and misprint of one to three labels

The printer is set at an incorrect print speed or darkness level. Keep in mind that printer settings may be affected by the driver or software being used.

You are using an incorrect combination of labels and ribbon for your application.

The printhead is dirty. Clean the printhead and platen roller. See Cleaning

Incorrect or uneven printhead pressure.

The label format is scaling a font that is not scalable.

The platen roller is dirty. Clean the printhead and platen roller. See Cleaning

Media guides are positioned improperly.

The media type is set incorrectly. Set the printer for the correct media type (gap/notch,

The media is loaded incorrectly. Load media correctly. See Ribbon and Media Loading

The printer is not calibrated. Calibrate the printer. See Calibrating the Ribbon and

Improper label format. Check your label format, and correct it as necessary.

The platen roller is dirty. Clean the printhead and platen roller. See Cleaning

Media does not meet specifications.

Possible Cause Recommended Solution

For optimal print quality, set the print speed and the darkness to the lowest possible settings for your application.

1. Perform the steps in Running the Print Wizard and

Printing a Test Label on page 27.

2. If necessary, manually adjust the darkness or print speed settings.

• Set the print darkness to the lowest setting that

• Slower print speeds typically yield better print

quality.

Access the darkness and print speed settings from the Home screen by touching Menu > Print > Print Quality.

1. Switch to a different type of media or ribbon to try to find a compatible combination.

2. If necessary, consult your authorized Zebra reseller or distributor for information and advice.

the Printhead and Rollers on page 73.

Set the printhead pressure to the minimum needed for good print quality. See Toggle Positioning and

Printhead Pressure Adjustment on page 66.

Check the label format for font issues.

the Printhead and Rollers on page 73.

Ensure that the media guides are properly positioned. See Ribbon and Media Loading on page 17.

continuous, or mark).

on page 17.

Media Sensors on page 26.

the Printhead and Rollers on page 73.

Use media that meets specifications. See Media

Specifications on page 128.

Diagnostics and Troubleshooting

Vertical drift in top-of-form position

Horizontal movement in placement of the label image.

Vertical image or label drift

The printer is out of calibration. Calibrate the printer. See Calibrating the Ribbon and

Media Sensors on page 26.

The platen roller is dirty. Clean the printhead and platen roller. See Cleaning

the Printhead and Rollers on page 73.

The previous labels were torn off incorrectly.

The printer is using non-continuous labels but is configured in continuous mode.

The media sensor is calibrated improperly.

The platen roller is dirty. Clean the printhead and platen roller. See Cleaning

Improper printhead pressure settings (toggles).

The media or ribbon is loaded incorrectly.

Incompatible media. You must use media that meets the printer

Pull down and to the left when tearing off labels so that the tear-off bar assists in tearing through the label backing. Pulling up or down and to the right can shift the media sideways.

Set the printer for the correct media type (gap/notch, continuous, or mark) and calibrate the printer, if necessary (see Calibrating the Ribbon and Media

Sensors on page 26).

Calibrate the printer. See Calibrating the Ribbon and

Media Sensors on page 26.

the Printhead and Rollers on page 73.

Adjust the printhead pressure to ensure proper functionality. See Toggle Positioning and Printhead

Pressure Adjustment on page 66.

Ensure that the media and ribbon are loaded correctly. See Ribbon and Media Loading on page 17.

specifications. Ensure that the interlabel gaps or notches are 2 to 4 mm (0.08 to 0.16 in.) and consistently placed (see Media Specifications on

page 128).

Diagnostics and Troubleshooting

Ribbon Issues

For videos of some common procedures, go to zebra.com/ze511-info.

Broken Ribbon Possible Cause Recommended Solution

Broken or melted ribbon Darkness setting too high. 1. Perform the steps in Running the Print Wizard and

Printing a Test Label on page 27.

2. If necessary, manually adjust the darkness or print speed settings.

• Set the print darkness to the lowest setting that

• Slower print speeds typically yield better print

quality.

Access the darkness and print speed settings from the Home screen by touching Menu > Print > Print Quality.

3. Clean the printhead thoroughly. See Cleaning the

Printhead and Rollers on page 73.

The ribbon is coated on the opposite side than what the printer is set for.

The ribbon tension is too high. Set the ribbon tension to a lower setting. See Print >

Replace the ribbon with one coated on the correct side or change the setting. See Print > Print Quality >

Ribbon Ink Side on page 50.

Print Quality > Ribbon Tension on page 51.

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Zebra ZE511, ZE521 User Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Introduction

Print Engine Orientation

Print Engine Components

Control Panel

Home Screen

Print Status Tab

Printer Info Tab

Other Tabs

Preparing to Print

Ordering Supplies and Accessories

Label Design Software

Cables

Media

Ribbon

Specifying the Media Handling Method

Ribbon and Media Loading

Loading Ribbon

Loading Media

Calibrating the Ribbon and Media Sensors

Running the Print Wizard and Printing a Test Label

Printer Configuration and Adjustment

Changing Printer Settings

System Menu

Connection Menu

Print Menu

RFID Menu

Storage Menu

Toggle Positioning and Printhead Pressure Adjustment

Changing the Toggle Position

Adjusting the Printhead Pressure

Routine Maintenance

Cleaning Schedule and Procedures

Cleaning the Exterior, the Media Compartment, and the Sensors

Cleaning the Printhead and Rollers

Removing Used Ribbon

Replacing Print Engine Components

Ordering Replacement Parts

Recycling Print Engine Components

Storing the Print Engine

Lubrication

Troubleshooting

Judging Barcode Quality

Configuration Labels

PAUSE Self-Test

Printing and Interpreting a Sensor Profile

Media Sensor Profile

Ribbon Sensor Profile

Using Communication Diagnostics Mode

Loading Defaults or Last Saved Values

Alert and Error States

Alerts and Error Messages

Indicator Lights

Troubleshooting

Printing or Print Quality Issues

Ribbon Issues