Zebra Technologies ZD500 User Manual

ZD500 Series™

User’s Guide

Thermal Transfer Printer

P1062653-002 Rev. A

label printer and accessories described therein are owned by ZIH Corp. Unauthorized reproduction of this manual or the software and/or firmware in the label printer may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability.

This product may contain ZPL

Equalizer

Circuit; E3®; and Monotype Imaging fonts. Software © ZIH Corp. All rights

reserved worldwide.

, ZPL II®, and ZebraLink™ programs; Element Energy

ZD500 Series, ZD500R, ZebraLink and all product names and numbers are trademarks, and

Zebra, the Zebra logo, ZPL, ZPL II, Element Energy Equalizer Circuit, and E

Circuit are

All other brand names, product names, or trademarks belong to their respective holders.

For additional copyright and trademark information, please see “Copyright” on the Zebra website.

www.zebra.com/copyright

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.

P1062653-002 Rev. A ZD500 Series™ Thermal Transfer Printer User’s Guide 1/16/2014

Compliance and Regulatory Statements

FCC Compliance Statement (USA)

This device complies with Part 15 rules. Operation is subject to the following two conditions:

1. This device may not cause harmful interference, and

2. This device must accept any interference received, including interference that may cause

undesired operation.

This equipment has been tested and found to comply with the limits for Class B Digital Devices, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the product manuals, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, the user is encouraged to do one or more of the following measures:

• Reorient or relocate the receiving antenna.

iii

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced RF service technician for help.

Important •

1. The radio must be installed with a minimum 20 cm separation between the user and the

antenna.

2. The radio must not be co-located or used in simultaneous transmitting condition with

another radio.

3. The host system shall have a label to indicate that the system contains a certified module.

An example is “Contains FCC ID : I28MD-EXLAN11N , IC ID: 3798B-EXLAN11N”.

4. The radio is for indoor use only in the 5150-5250 GHz frequency range.

The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies could void the user’s authority to operate the equipment. To ensure compliance, this printer must be used with fully shielded communication cables.

Mexico — NOM-121-SCT1-2009

Este equipo ha sido diseñado para operar con las antenas que enseguida se enlistan y para una ganancia máxima de antena de [x] dB. El uso con este equipo de antenas no incluidas en esta lista o que tengan una ganancia mayor que [x] dB quedan prohibidas. La impedancia requerida de la antena es de [y] ohms.

auden - p/n 220370-09

• Gain = 2.77dbi @ 2.4 GHz

• Gain = 2.69 - 3.19dBi @ 5 GHz

• Impedance = 50 ohms

1/16/2014 ZD500 Series™ TThermal Transfer Printer User’s Guide P1062653-002Rev. A

Canadian DOC Compliance Statement

Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada. This Class B digital apparatus complies with Canadian ICES-003.

Industry Canada (IC) Warning

Le présent appareil est conforme aux CNR d’Industrie Canada applicables aux appareils radio exempts de licence. L’exploitation est autorisée aux deux conditions suivantes : (1) l’appareil ne doit pas produire de brouillage, et (2) l’utilisateur de l’appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d’en compromettre le fonctionnement.

This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following two conditions: 1) This device may not cause interference., 2) This device must accept any interference, including interference that may cause undesired operation of the device.

Brasil — Aviso da Anatel

Este equipamento opera em caráter secundário, isto é, não tem direito a proteção contra interferência prejudicial, mesmo de estações do mesmo tipo, e não pode causar interferência a sistemas operando em caráter primário.

“Este produto está homologado pela ANATEL, de acordo com os procedimentos regulamentados pela Resolução 242/2000, e atende aos requisitos técnicos aplicados”

Para maiores informações, consulte o site da ANATEL www.anatel.gov.br

This equipment's operation is of a secondary character; that is, it doesn't have the right to protection against damaging interference, even from stations of the same type, nor can it cause interference to systems with a primary operating character.

Este produto utiliza internamente o modulo de RF M6E- micro numero de homologação pela ANATEL 3059-13-8108 e o modulo WYSBMVGXB numero de homologação pela ANATEL 3825-13-9965

Japan Restricted Frequencies

この周波数帯は 5.725 5.825 GHz の日本で利用できるされません。

For 5.725 - 5.825 GHz, this frequency band will not be available in Japan.

P1062653-002 Rev. A ZD500 Series™ Thermal Transfer PrinterUser’s Guide 1/16/2014

Taiwan Restricted Frequencies

5.15-5.25 GHz, 該頻段將在臺灣不可用。 For 5.15 - 5.25 GHz, this frequency band will not be available in Taiwan.

Korean Compliance Statement

이 기기는 가정용 (B 급 ) 전자파 적합기기 로서 주로 가정에서 사용하는 것을 목적으로 하며 , 모든 지역에서 사용할 수 있습니다 .

The equipment is for home use (Class B) and has acquired electromagnetic conformity registration, so it can be used not only in residential area but other areas as well.

This radio device is not allowed to be used for human safety since it has possibility of radio interference during operation.

European Regulatory Information

Note • Member states in the EU with restrictive use for this device are crossed out. This

device is also authorized for use in all EFTA member states (CH, IS, LI, NO).

1/16/2014 ZD500 Series™ TThermal Transfer Printer User’s Guide P1062653-002Rev. A

NCC

經型式認證合格之低功率射頻電機，非經許可，公司、商號或使用者均不得擅自變更頻率、加大功率或變更原設計之特性及功能。低功率射頻電機之使用不得影響飛航安全及干擾合法通信；經發現有干擾現象時，應立即停用，並改善至無干擾時方得繼續使用。前項合法通信，指依電信法規定作業之無線電通信。低功率射頻電機須忍受合法通信或工業、科學及醫療用電波輻射性電機設備之干擾。

According to "Administrative Regulations on Low Power Radio Waves Radiated Devices" Without permission granted by the NCC, any company, enterprise, or user is not allowed to change frequency, enhance transmitting power or alter original characteristic as well as performance to an approved low power radio-frequency devices. The low power radiofrequency devices shall not influence aircraft security and interfere legal communications; If found, the user shall cease operating immediately until no interference is achieved. The said legal communications means radio communications is operated in compliance with the Telecommunications Act.

The low power radio-frequency devices must be susceptible with the interference from legal communications or ISM radio wave radiated devices.

P1062653-002 Rev. A ZD500 Series™ Thermal Transfer PrinterUser’s Guide 1/16/2014

WLAN Radio Specification

802.11 b

•2.4 GHz

• DSSS (DBPSK, DQPSK and CCK)

• RF power 63 mW (ZebraNet n Print Server)

802.11 g

•2.4 GHz

• OFDM (16-QAM and 64-QAM with BPSK and QPSK)

• RF power 63 mW (ZebraNet n Print Server)

802.11 n

•2.4 GHz

• OFDM (16-QAM and 64-QAM with BPSK and QPSK)

• RF power 63 mW (ZebraNet n Print Server)

vii

802.11 a/n

• 5.15-5.25 GHz, 5.25-5.35 GHz, 5.47-5.725 GHz, 5.725-5.825 GHz

• OFDM (16-QAM and 64-QAM with BPSK and QPSK)

• RF power 50 mW (ZebraNet n Print Server)

Bluetooth 2.1 + EDR

•2.4 GHz

•FHSS

• RF power 0.4 mW

RFID Radio Specification

• 902 - 928 MHz (US); 865 - 868 MHz (EU)

• ISO-18000 - 6B; ISO 18000-6C

• RF power <30 dBm ERP

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viii

Environmental Management

Do not dispose of this product in unsorted municipal waste. This product is recyclable, and should be recycled according to your local standards.

For more information, please see our website at:

Web address: www.zebra.com/environment

Document Conventions

Alternate Color

If you are viewing this guide on-line, you can click the blue text used for cross-references or hyper-links to jump directly to other sections in the guide or to web sites on the Internet.

Command Line Examples, File Names, and Directories

Table 1 • Document Conventions

Command line examples, file names, and directories appear in a Typewriter style (Courier) mono-spaced font. For example:

ZTools to get to the Post-Install scripts in the /bin directory.

Type Open the

Icons and Advisory Words

The following icons and advisory words are used to draw your attention to certain areas of text.

Caution • Warns you of the potential for electrostatic discharge.

Caution • Warns you of a potential electric shock situation.

Caution • Warns you of a situation where excessive heat could cause a burn.

Caution • Advises you that failure to take or avoid a specific action could result in physical

harm to you.

(No icon)

Caution • Advises you that failure to take or avoid a specific action could result in physical

harm to the hardware.

Zebra<version number>.tar file in the /root directory.

Important • Advises you of information that is essential to complete a task.

Note • Indicates neutral or positive information that emphasizes or supplements important

points of the main text.

Tools • Tells you what tools you need to complete a given task.

P1062653-002 Rev. A ZD500 Series™ Thermal Transfer PrinterUser’s Guide 1/16/2014

Compliance and Regulatory Statements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Environmental Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

• Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

1 • Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ZD500 Series™ Thermal Printers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

The ZD500 Series™ printer features:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

The ZD500 Series™ printer options: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

What’s in the Box? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Control Panel Display Menu and Status Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Printer Control Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Navigating through Screens in the Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Control Panel Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2 • Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Select a Location for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Attaching Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Preparing and Handling Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Media Storage Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Setting the Printer Menu and Report Display Language. . . . . . . . . . . . . . . . . . . . . . . . . . 19

Loading Roll Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Loading Transfer Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Test Printing with Configuration Report Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1/16/2014 ZD500 Series™ User’s Guide P1062653-002 Rev. A

Contents

Connecting your Printer to a Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Interface Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

USB Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Wired (Ethernet) Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ZebraNet® Internal Wireless Print Server Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Configure Using the Connectivity Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Bluetooth Option Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Connecting to a Windows Vista® SP2 or Windows 7® Master Device . . . . . . . . . . . 45

After Your Printer is Connected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3 • Printer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Changing Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SETTINGS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

TOOLS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

NETWORK Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

RFID Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

LANGUAGE Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

SENSOR Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

PORTS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

BLUETOOTH Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Manual Calibration - Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

RFID Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4 • Print Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Determining Printer Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Thermal Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Modes of Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Setting the Thermal Print Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Determining Thermal Media Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Media Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Attaching the 3 inch Core Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Loading 3 inch I.D. Media rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Removing the 3 inch Core Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Ribbon Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

When to Use Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Coated Side of Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Ribbon Test with Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Ribbon Scratch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Replacing Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Adding a New Transfer Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Replacing a Partially Used Transfer Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

P1062653-002 Rev. A ZD500 Series™ User’s Guide 1/16/2014

Contents

Adjusting the Print Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Adjusting the Print Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Media Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Using the Movable Black Mark Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Adjusting the Movable Sensor for Black Marks or Notches . . . . . . . . . . . . . . . . . . . . 90

Adjusting the Movable Sensor for Web (Gap) Sensing . . . . . . . . . . . . . . . . . . . . . . . 92

Printing on Fan-Fold Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Printing with Externally Mounted Roll Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Sending Files to the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Fonts and Your Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Identifying Fonts in Your Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Localizing the Printer with Code Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Asian fonts and Other Large Font Sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Getting Asian Fonts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

5 • Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Label Dispenser Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Cutter Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Loading Media with the Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

ZebraNet® Internal Wireless Print Server Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Bluetooth Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Printer Network Configuration Status Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

6 • Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

Cleaning the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Media Path Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Sensor Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

Platen Cleaning and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Other Printer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

RTC Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

7 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Printing Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Miscellaneous Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

RFID Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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Contents

xii

Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Power-On Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Configuration Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Print Quality Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Reset Printer Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Reset Network Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Communication Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

A • Appendix: Interface Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Serial Port Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Connecting the Printer to a DTE Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

B • Appendix: Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

External ZD500 Series™ Printer Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Label Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

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Introduction

This section introduces you to your new Zebra® ZD500 Series™ desktop thermal label printer. It describes what you get in your shipping box and provides an overview of printer features. It also includes procedures that describe how to open and close the printer and report any problems.

Your printer, when connected to a host computer, functions as a complete system for printing labels, receipts, forms, and tags.

This users guide provides all the information you need to operate your printer on a daily basis.

ZD500 Series™ Thermal Printers

The Zebra® ZD500 Series™ models are desktop thermal label printers with the widest range of features and options including an internal UHF RFID encoder option.

• The 203 dpi (dots per inch print density) version printer provides thermal transfer and direct thermal printing at speeds up to 6 ips (inches per second).

• The 300 dpi version printer provides thermal transfer and direct thermal printing at speeds up to 4 ips.

• These printers support ZPL™ Zebra printer programming language and a wide variety of interface and feature options.

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Introduction

ZD500 Series™ Thermal Printers

The ZD500 Series™ printer features:

• A user display and control panel for easier installation and direct access feature

• OpenAccess™ design for simplified media loading.

• Color-coded operator controls and media guides.

• Zebra™ Global Printing Solution – supports Microsoft Windows keyboard encoding

• On–The –Fly OpenType and TrueType font scaling and import, Unicode, resident

• XML-Enabled printing—allows XML communications for bar code label printing,

controls typically found only in premium printers.

(and ANSI), Unicode UTF-8 and UTF 16 (Unicode Transformation Formats), XML, ASCII (7 and 8 bit used by legacy programs and systems), basic single and double byte font encoding, JIS and Shift-JIS (Japanese International Standards), Hexadecimal encoding, and custom character mapping (DAT table creation, font linking, and character remapping).

scalable font, and a selection of resident bitmap fonts.

eliminating license fees and print server hardware and lowering customization and programming costs.

• Movable Sensor: A full width movable black mark or notch sensor, and multi center position transmissive (label gap/web) sensor.

• 56 MB of user accessible flash memory for storing forms, fonts, and graphics.

• USB 2.0, Serial RS-232 and bi-directional parallel ports.

• Internal ZebraNet10/100 Print Server—supports 10Base-T, 100Base-TX and fast Ethernet 10/100 auto-switching networks.

• On-board RTC (Real Time Clock).

• Printhead maintenance reporting enabled and customizable by the user.

The ZD500 Series™ printer options:

• Internal UHF RFID Encoder (See the RFID Programmimg Guide 3 for details)

• Label Dispense (Peel-Off Liner and Present Label for Operator).

• General purpose media cutter.

• Wi-Fi (802.11a/b/g/n)

• Bluetooth 3.0

• Pre-loaded Swiss 721 Latin 1 font (for EU zone printers). Font is available for download.

• Asian Language support with printer configuration options for the large Simplified and Traditional Chinese, Japanese, or Korean character sets. Printers sold in China have the Simplified Chinese SimSun font pre-installed.

• Zebra® ZBI 2.0™ (Zebra BASIC Interpreter) programming language. ZBI allows you to create custom printer operations that can automate processes, use peripherals (i.e. scanners, scales, keyboards, Zebra® ZKDU™, etc.) all without being attached to a PC or network.

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Introduction

ZD500 Series™ Thermal Printers

Your printer, when connected to a host computer, functions as a complete system for printing labels, receipts, forms, and tags. Many printer settings may also be controlled by your printer’s driver or label design software. Refer to the driver or software documentation for more information.

To create label formats, refer to your programming guides or label design applications such as the free label and form design software: ZebraDesigner™.

The printer includes a complete suite of free Link-OS software applications and drivers to configure printer settings, design and print labels and receipts, get printer status, import graphics and fonts, send programming commands, update firmware, and download files.

Clone printer settings and send graphics, files, fonts, and firmware (updates) to one or more Zebra® Ethernet and locally connected printers with ZebraNet™ Bridge.

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Introduction

Power Cord

varies by locale or region

Documentation

and Software

Power

Supply

USB Cable

Printer

Ribbon Core

3in (76.2 mm) I.D.

Media Roll Adapters

What’s in the Box?

Save the carton and all packing materials in case you need to ship or store the printer later. After unpacking, make sure you have all parts. Follow the procedures for inspecting the printer to familiarize yourself with printer parts so you can follow the instructions in this book.

P1062653-002 Rev. A ZD500 Series™ Thermal Transfer Printer User’s Guide 1/16/2014

Unpack and Inspect the Printer

When you receive the printer, immediately unpack it and inspect for shipping damage.

• Save all packing materials.

• Check all exterior surfaces for damage.

• Open the printer and inspect the media compartment for damage to components.

If you discover shipping damage upon inspection:

• Immediately notify the shipping company and file a damage report. Zebra Technologies Corporation is not responsible for any damage to the printer incurred during shipment, and will not cover the repair of this damage under its warranty policy.

• Keep all packaging material for shipping company inspection.

• Notify your authorized Zebra

reseller.

Printer Features

Interface

Connectors

Control Panel

Release Latches

DC Power

Receptacle

Power

Switch

Fan-Fold Media

Entry Slot

Figure 1 shows features on the outside and Figure 2 shows features inside the media

compartment of your printer. Depending on the printer model and the installed options, your printer may look slightly different.

Figure 1 • Printer Features

Introduction

Printer Features

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Introduction

Label Taken

Sensor

Peel Bar

Platen

Roller

Printhead

Movable

Black Mark

Sensor

Ribbon Trailer Sensor

(hidden from view)

Roll Holders and

Media Guides

Head-Up Sensor

(inside)

Pinch

Roller

Dispenser Door

(open)

Take Up Spindles

Supply Spindles

Ribbon Roll Holders

Dispenser Option

Web (Gap)

Sensor

Media Guide Stop

Adjustment

RFID Antenna

(inside)

Printer Features

Figure 2 • Printer Features Continued

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Figure 3 • Printer Features - Cutter Option

Media Cutter

(Option)

Introduction

Printer Features

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Introduction

6 5811 9 7

Figure 4 • ZD500 Series™ Control Panel

Control Panel

The control panel indicates the printer’s operating status and allows the user to control basic printer operation.

STATUS light Shows the current status of the printer. For more information, see

The PAUSE button starts or stops printer operation when pressed.

The FEED button forces the printer to feed one blank label each time the button is pressed.

The CANCEL button cancels print jobs when the printer is paused.

The RIGHT ARROW button, which is active only in the menu system, navigates to the right

through the main menu and to previous items in sub-menus.

The DOWN ARROW button changes the parameter values. Common uses are to decrease a value

or to scroll through choices. The SELECT () button operates as follows:

• When on the Home screen, pressing enters the menu system.

• When in the menu system, pressing  accepts the values shown.

The UP ARROW button changes the parameter values. Common uses are to increase a value or to

scroll through choices.

The LEFT ARROW button, which is active only in the menu system, navigates to the left through

the main menu and to the next item in sub-menus.

RIGHT OPTION button These buttons execute the actions or commands shown directly above

LEFT OPTION button

The display shows the printer’s operating status and allows the user to navigate the menu system.

Table 1 on page 9.

them in the display.

Add

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Table 1 • Printer Status Indicator Light

STATUS light steady green

The printer is ready.

STATUS light steady amber

This indicator light on steady indicates one of the following:

• The printer is not ready.

• The printhead is over temperature.

Caution • The printhead may be hot and could cause severe burns. Allow

the printhead to cool.

STATUS light flashing amber

This indicator light flashing indicates one of the following:

• The printhead is under temperature.

STATUS light steady red

This indicator light on steady indicates one of the following:

• The media supply is out.

• The ribbon supply is out.

• The printhead is open.

• Cutter malfunction.

The printer needs attention and cannot continue without user intervention.

Introduction

Control Panel

STATUS light flashing red

This indicator light flashing indicates one of the following:

• The printer is unable to correctly identify the printhead type.

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

• The printhead is extremely over temperature.

Caution • The printhead may be hot and could cause severe burns. Allow

the printhead to cool.

The printer needs attention and cannot continue without user intervention.

STATUS light flashing amber followed by alternating amber/ green

This status light condition indicates the printer is in Forced Download Mode. Forced Download Mode is used to download new firmware to the printer. This

mode should only be used by trained personnel.

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Introduction

Error

Cover Unlocked

Ribbon In

Media In

Data

Ethernet

Bluetooth

Signal Strength

WiFi

Previous Menu Shortcut

Language Menu

Settings Menu Sensors Menu

Tools Menu Ports Menu

Network Menu

Bluetooth Menu

RFID Menu

Control Panel Display Menu and Status Icons

Figure 5 • Typical Home Menu

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Printer Control Panel Display

PRINTER READY

V74.19.1Z

SETTINGS

The printer’s control panel includes a display, where you can view the printer’s status or change its operating parameters. In this section, you will learn how to navigate through the printer’s menu system and change values for menu items.

After the printer completes the power-up sequence, it moves to the Idle Display (Figure 6). If a print server is installed, the printer cycles through the information shown and the printer’s IP address.

Figure 6 • Idle Display

Introduction

Printer Control Panel Display

The printer’s current status

Information that you set through TOOLS Menu on page 56 - IDLE DISPLAY

Home menu shortcut

The printer’s operating parameters are organized into several user menus, which you can access through the printer’s Home menu (Figure 7). For detailed information about changing the printer settings, see Printer Configuration on page 51.

Figure 7 • Home Menu

See SETTINGS Menu on page 52.See LANGUAGE Menu

on page 69.

See TOOLS Menu on page 56.See SENSOR Menu on page 71.

See NETWORK Menu

on page 61.

See RFID Menu on page 65 See BLUETOOTH Menu

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Exit and return to the Idle Display (Figure 6).

See PORTS Menu on page 72.

on page 74

Introduction

SETTINGS menu icon

SETTINGS menu icon highlighted and active for selection.

Printer Control Panel Display

Navigating through Screens in the Menu

Idle Display

Home Menu

Table 2 shows navigating through the screens in the control panel display.

Table 2 • Navigation

At the Idle Display (Figure 6 on page 11), press LEFT SELECT to go to the printer’s Home menu (Figure 7 on page 11).

To move from icon to icon in the Home menu, press the ARROW buttons.

To select the highlighted menu icon and enter the menu, press

SELECT (

) button.

Press LEFT SELECT to exit the Home menu and return to the Idle Display.

When an icon is selected, its image reverses to highlight it.

Note • The printer automatically returns to the Idle Display after 15 seconds of inactivity in the Home menu.

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Introduction

XXXXXXX

XXX

Printer Control Panel Display

Table 2 • Navigation

User Menus

Press LEFT SELECT to return to the Home menu. ▼and ▲ indicate that a value can be changed. Any

changes that you make are saved immediately.

Press the UP ARROW or DOWN ARROW to scroll through accepted values.

To scroll through the items in a User menu, press the LEFT ARROW or RIGHT ARROW.

A word in the bottom-right corner of the display indicates an available action.

Press SELECT (

) button or press RIGHT

SELECT to perform the action shown.

Note • The printer automatically returns to the Home menu after 15 seconds of inactivity in a User menu.

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Introduction

Control Panel Menu Map

Home Menu Items

Menu Item also in other Menus

Printer Option. May not be present.

Go to next Menu group

Printer Ready

V74.xx.xxZ

Darkness

Print Speed

Media Type

Print Method

Tear Off

Print Width

Print Mode

Label Top

Left Position

Reprint Mode

Label Length

Max

Language

Tools Menu

Information

LCD Contrast

LCD Backlight

Idle Display

Power Up

Action

Head Close

Action

Load Defaults

Manual

Calibration

Diagnostic

Mode

ZBI Enabled?

Yes No

Run ZBI

Program

Stop ZBI Program

Network Menu

Wired IP

Address

Wired Subnet

Mask

Wired

Gateway

Wired IP Protocol

Wired MAC

Address

Wired Port

WLAN

Installed

WLAN

Reset Network

Active Print

Server

Primary Network

Information

WLAN IP

Address

WLAN Subnet

Mask

WLAN

Gateway

WLAN IP

Protocol

WLAN MAC

Address

WLAN Port

ESSID

Channel

Signal

IP Port

IP Alternate

Port

RFID Status

RFID Calibrate

RFID Read

Data

RFID Test

RFID Program

Position

RFID Read

Power

RFID Write

Power

RFID Valid

Count

RFID Void

Count

Language

(Menu)

Language

ZPL Override

Command Character

Control

Character

Delimiter Char

ZPL Mode

Sensors Menu

Sensor Type

Manual

Calibration

Information

Label Sensor

Take Label

Ports Menu

Baud Rate

Data Bits

Parity

Host

Handshake

Parallel Mode

WML Version

Settings

Bluetooth

Address

Mode

Discovery

Connected

BT Spec

Version

Min Security

Mode

Settings Menu

htooteulBstroPsrosneSDIFRkrowteNslooTsgnitteS

Load Defaults

RFID Menu

P1062653-002 Rev. A ZD500 Series™ Thermal Transfer Printer User’s Guide 1/16/2014

This section assists you in setting up and operating your printer for the first time.

Basic Printer Setup (Overview)

The setup process to can be broken down to two (2) phases: hardware setup and host system (software/driver) setup.

Setup

• Place the printer in a safe location with access to power and where cable or the wireless option communications can access your printer.

• Attach the printer to a grounded AC power source.

• Select and prepare media for your printer.

• Load the media.

• Load the transfer ribbon if you are using thermal transfer media.

• Turn the printer ON. Print a ‘Configuration Report’ to verify basic printer operation.

• Turn the printer OFF.

• Choose method to communicate to your printer - Local connection via USB, Serial, or Parallel ports; Local network via Ethernet (LAN); or using the printer’s wireless option that supports Wi-Fi (802.11 a/b/g/n WLAN) and Bluetooth 3.0.

• Attach the printer to the network or host system, and configure the printer as required for communicating to the print system host/network.

For supported Windows Operating systems (most common) with a Local (cabled) connection:

• ‘Run’ the Zebra Setup Utilities for systems from the User’s CD.

• Click on ‘Install New Printer’ and run the install wizard. Select ‘Install Printer’ and select the ZD500R from the list of ZDesigner printers.

• Select the port (USB, Serial or Parallel) that you connected to the PC.

• Turn the printer ON and configure printer communications for your interface type.

• Print a Windows driver ‘Test Print’ to verify operation with Windows.

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Setup

Select a Location for the Printer

The printer and media need a clean safe area with moderate temperatures to have optimal print operations.

Select a location for the printer that meets these conditions:

• Surface: The surface where the printer will be located must be solid, level, and of sufficient size and strength to hold the printer.

• Space: The area where the printer will be located must include enough space for ventilation, opening the printer (media access and cleaning), and for accessing the printer components and connectors. To allow for proper ventilation and cooling, leave open space on all sides of the printer.

Caution • Do not place any padding or cushioning material under or around the base

of the printer because this restricts air flow and could cause the printer to overheat.

• Power: The printer should be within a short distance of an appropriate power outlet that is easily accessible.

• Data communication interfaces: The printer must be within range of your WLAN or Bluetooth radio (if applicable) or within an acceptable range for other connectors to reach your data source (usually a computer).

Data cables should not be routed with or near power cords or conduits, fluorescent lighting, transformers, microwave ovens, motors or other electrical noise and interference sources. These interference sources may interfere with communications, host system operation, and printer functionality.

• Operating conditions: Your printer is designed to function in a wide range of environmental and electrical conditions, including a warehouse or factory floor. Table 4 shows the temperature and relative humidity requirements for the printer when it is operating.

Table 3 • Operating Temperature and Humidity

Mode Temperature Relative Humidity

Thermal Transfer 41° to 104°F (5° to 40°C) 20 to 85% non-condensing

Direct Thermal 32° to 104°F (0° to 40°C)

Table 4 • Non-Operating and Storage Temperature and Humidity

Mode Temperature Relative Humidity

Both -40° to 140°F (-40° to 60°C) 5 to 85% non-condensing

P1062653-002 Rev. A ZD500 Series™ Thermal Transfer Printer User’s Guide 1/16/2014

Attaching Power

Power Connector

Power

Switch

Plug Varies by Country

Active Power Light

Power

Receptacle

AC Power Cord

Printer

Power Supply

IEC 60320 C-13

Important • Set up your printer so that you can handle the power cord easily if needed. To

make certain the printer cannot carry electrical current, you must separate the power cord from the power supply receptacle or AC electrical outlet.

Caution • Never operate the printer and power supply in an area where they can get wet.

Serious personal injury could result!

1. Make sure the printer’s power switch is in the off position (down).

2. Insert the AC power cord into the power supply.

3. Plug the other end of the cord into an appropriate AC electrical outlet. Note: The active

power light will go on if power is on at the AC outlet.

4. Insert the power supply’s power connector into the printer’s power receptacle.

Setup

Attaching Power

Note • Ensure the appropriate power cord with a three (3) prong plug and an IEC 60320-C13 connector are used at all times. These power cords must bear the relevant certification mark of the country in which the product is being used.

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Setup

Preparing and Handling Media

Carefully handling and storing media is important for the print quality in addition to using the right media (such as Genuine Zebra™ Supplies) and the right printer, your Zebra ZD500 Series™ printer. If the media becomes contaminated or dirty, it can damage or degrade the printhead or the printer, as well as, cause defects in the printed image (voids, streaks, discoloration, compromise the adhesive, etc.).

During manufacturing, packaging, handling and storage, the outside length of media may become dirty or contaminated when handled or dusty when stored. To prevent this type of contamination, we ask you to remove the outside layer of the media roll or stack. This will remove any contaminates or adhesive from labels or tape used to secure the media to the roll that may transfer to the printer or printhead.

Media Storage Tips

• Store media in a clean, dry, cool, dark area.

• Direct thermal media is chemically treated to be heat sensitive. Direct sunlight or heat sources may ‘expose’ the media.

• Do not store media with chemicals or cleaning products.

• Leave media in its protective packaging until it is to be placed in the printer for use.

• Many media types and label adhesives have a ‘shelf life’ or expiration date. Always use the oldest, viable (non-expired) media first.

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+ 130 hidden pages