ZD421 and ZD621 Series Link-OS® Printers User Guide P1123730-01EN
ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corporation, registered in many jurisdictions worldwide. All other trademarks are the property of their respective owners. © 2021 Zebra Technologies Corporation and/or its affiliates. All rights reserved. Information in this document is subject to change without notice. The software described in this document is furnished under a license agreement or nondisclosure agreement.
Contents About ................................................................................................................................................. 11 Printer Resources .......................................................................................................... 11 Zebra OneCare Printer Service and Support ................................................................. 12 Icon Conventions ............................................................................................
Contents Controls and Indicators ................................................................................................................... 37 User Interface................................................................................................................. 37 Standard Interface Controls.................................................................................... 38 Meaning of the Indicator Light Patterns ........................................................................
Contents System > Program Language > Virtual Device .................................................. 78 System > Program Language > ZBI ....................................................................... 79 System > Settings > Display Time Format ............................................................. 80 System > Settings > Password Level ..................................................................... 81 System > Settings > Set Password .....................................................
Contents Print > Print Quality > Print Speed........................................................................ Print > Print Quality > Print Type .......................................................................... Print > Print Quality > Label Type......................................................................... Print > Print Quality > Label Length...................................................................... Print > Print Quality > Label Width (Dots)............................
Contents Attaching Power ........................................................................................................... 156 Getting Ready to Print.................................................................................................. 157 Preparing and Handling Media ............................................................................. 157 Media Storage Tips .............................................................................................. 158 Loading Roll Media ..
Contents Printing with Externally Mounted Roll Media................................................................ 213 Externally Mounted Roll Media Considerations: ................................................... 213 Using the Label Dispenser Option ............................................................................... 214 Using the Linerless Options ......................................................................................... 217 Linerless Printing ...............................
Contents ZD621 and ZD421 Direct Thermal ....................................................................... 260 ZD621 and ZD421 Thermal Transfer Ribbon Roll ................................................ 264 ZD421 Thermal Transfer Ribbon Cartridge .......................................................... 269 Updating Printer Firmware .......................................................................................... 273 Other Printer Maintenance ................................................
Contents Printer Network (and Bluetooth) Configuration Report ......................................... 295 Print Quality Report (FEED self test).................................................................... 296 Reset Printer Factory Defaults (PAUSE + FEED Self Test) ................................. 299 Reset Network Factory Defaults (PAUSE + CANCEL Self Test) ......................... 299 Reset Button....................................................................................................
About This guide is for integrators and operators of Zebra Link-OS ZD421 desktop printers. Use this guide to install, change configuration, operate, and physically support these printers. Information, support, and additional resources are available online to support this printer: • ZD621 Thermal Transfer printer — zebra.com/ZD621t-info • ZD621 Direct Thermal printer — zebra.com/ZD621d-info • ZD421 Thermal Transfer Ribbon Cartridge printer — zebra.
About • Oracle and SAP support • Zebra Savanna ™ Data Intelligence platform - turns raw data from devices (IoT) and sensors into actionable intelligence for your business • A suite of Link-OS Mobile Apps (applications for phones, tablets, etc.) • Link-OS software development kit (SDK) • Additional Operating Systems (OS) and Service platforms Find out more about ZebraLink, Zebra Link-OS, and Zebra Savanna at zebra.com/software.
Introduction This section introduces the Zebra Link-OS 4-inch desktop thermal label printers, the ZD621 and ZD421. It has an overview of the Link-OS printer’s features and options, and what ships with your new printer. This document covers the following ZD-series desktop printer models: • ZD621 Thermal Transfer Printer — zebra.com/ZD621t-info • ZD621 Direct Thermal Printer — zebra.com/ZD621d-info • ZD421 Thermal Transfer Ribbon Cartridge Printer — zebra.
Introduction Common Desktop Link-OS Printer Features • OpenAccess ™ design for simplified media loading. • Color-coded “touch points” for operator controls and media guides. • Enhanced user interface featuring three buttons and five status indicators. • Easy, field-installable media handling options. • Media roll support: • • Outer Diameter (O.D.): Up to 127 mm (5 in.) and • Inner Diameter (I.D.) roll cores:12.7 mm (0.5 in.), 25.4 mm (1 in.
Introduction • Zebra’s Link-OS - an open platform that connects operating systems for smart Zebra devices with powerful software apps (applications), making the devices easy to integrate, manage and maintain from any location. • An On-board Real Time Clock (RTC). • Printhead maintenance reporting enabled and customizable by the user. • Easy tool-less replacement of printhead and platen (driver) roller. • A minimum of 64 MB of internal (E:\) printer memory for storing forms, fonts, and graphics.
Introduction • Media Core Adapter kit include adapters for media rolls with Outer Diameters (O.D.) up to 127 mm (5 in.): • 38.1 mm (1.5 in.) I.D. media cores. • 50.8 mm (2.0 in.) I.D. media cores. • 76.2 (3.0 in.) I.D. media cores. • Attached Power Supply Base with internal power supply. • Attached Battery Base with removable Battery. • • Attached Battery Base and Battery are sold separately.
Introduction Zebra Label Printing Solution The printer is just one of three parts of a printing solution. To print; you need a printer (ZD621 or ZD421), compatible media (thermal transfer ribbon cartridge or rolls, and thermal transfer media; or just direct thermal media), and software (driver, applications or programming) to tell the printer what to do and print. The printer can print without being connected to other devices or systems.
Introduction What’s in the Box? After unpacking, make sure you have all parts shown below. Follow the procedures for inspecting the printer to familiarize yourself with printer parts so you can follow the instructions in this book .
Introduction Open the Printer To access the media compartment, pull the release latches towards you and lift the cover. Check the media compartment for loose or damaged components. CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Printer Features This section will help you identify features of these Zebra® Link-OS 4-inch desktop thermal label printers, the ZD621 and ZD421. ‘How to’ videos on the Zebra Web site include a Printer Features video; as well as; other printer setup and task specific videos. Links to these five (5) Link-OS 4-inch desktop printers are: • ZD621 Thermal Transfer Printer — zebra.com/ZD621t-info • ZD621 Direct Thermal Printer — zebra.com/ZD621d-info • ZD421 Thermal Transfer Ribbon Cartridge Printer — zebra.
Printer Features User Interface Release Latch For more details on printer controls, go to Controls and Indicators on page 37.
Printer Features Inside the ZD421 Dual Capacity Ribbon Roll Printer Printhead Upper Web (Gap) Array Sensor (other side) Roll Holders Media Guides Ribbon Carriage Media Guide Stop Head-Up Sensor (inside) Movable Sensor Platen (Drive) Roller (Black Mark and Lower Web/Gap) 22
Printer Features Inside the ZD621 Dual Capacity Ribbon Roll Printer Printhead Upper Web (Gap) Array Sensor (other side) Roll Holders Media Guides Media Guide Stop Adjustment Ribbon Carriage Head-Up Sensor (inside) Movable Sensor Platen (Drive) Roller (Black Mark and Lower Web/Gap) 23
Printer Features Identifying the ZD621R RFID Antenna Location The ZD621R printers antenna is located between the platen rollover and movable media sensor channel in the center of the printer. This is the only visible RFID item other than the Color Touch Display when on and the product branding and labeling.
Printer Features Dual Capacity Ribbon Chassis - Ribbon Roll Holders Take Up Spindles Supply Spindles (full ribbon rolls) Media Dancer - ZD621 Printer Models Only The printer’s window is removed to show the Media Dancer (plate). The Media Dancer is re-colored to make it easier to locate. It is the same color as the dark gray parts adjacent to it.
Printer Features Inside the ZD421 Direct Thermal Printers Printhead Upper Web (Gap) Array Sensor Roll Holders Media Guides Head-Up Sensor (inside) Media Guide Stop Movable Sensor (Black Mark and Lower Web/Gap) Platen (Drive) Roller 26
Printer Features Inside the ZD621 Direct Thermal Printers Printhead Upper Web (Gap) Array Sensor Roll Holders Media Guides Media Guide Stop Adjustment Head-Up Sensor (inside) Platen (Drive) Roller Movable Sensor (Black Mark and Lower Web/Gap) 27
Printer Features Inside the ZD421 Ribbon Cartridge Printer Ribbon Drive Transport Ribbon Cartridge Shown Installed (sold separately) Upper Web (Gap) Array Sensor Roll Holders Media Guides Media Guide Stop Adjustment Release Arms (2) Head-Up Sensor (inside) Platen (Drive) Roller Movable Sensor (Black Mark and Lower Web/Gap) 28
Printer Features Accessing the Printhead of the Ribbon Cartridge Printer To access the printhead: 1. Pull both release arms out (lighter gray parts). The ribbon drive transport drops down. 2. Lift printhead actuator arm up to access the printhead.
Printer Features Label Dispenser Option (field installable) - All Models Label Liner Exit Area Label Taken Sensor Label Peel Bar Dispenser Door Door Latch Peel Roll Cutter Option (field installable) - All Models Cutter Module Media Exit Slot 30
Printer Features Linerless Media Tear-Off Option (Direct Thermal Models Only) Label Taken Sensor Linerless Cutter Option (Direct Thermal Models Only) Label Taken Sensor Cut Label Landing Area 31
Printer Features Identifying Platen Drive Rollers Types The platen (drive) rollers are colored differently to identify the platen type and print resolution of your printer (and the platen). Do not exchange platen types unless instructed to by an upgrade procedure or Zebra technical support. The printer will not operate correctly and may cause a variety of problems requiring maintenance.
Printer Features Printer Power Supply Options ZD-Series printers offer field-installable attached power options: an attached power supply base or a battery power base. These options easily attach with screws and replace the power supply that was included with your printer.
Printer Features Attached Battery Base and Battery Printer with Battery Base Installed Battery Power Interface Power Input Battery Control Button Battery Power Base Battery Status and Charge Indicators Battery Ready to Install Printer with Battery installed Battery Latch IMPORTANT: The battery can be charged, checked, and configured for storage all without the printer. A printer power supply or other approved Zebra power source is needed to charge your battery.
Printer Features ZD621 Direct Thermal Locking Printer Features This option is only available in Direct Thermal Healthcare printer models. It includes a lock and key access to the printer’s media compartment and a Kensington Lock Slot on the back panel of the printer to secure the printer. For more information on the Locking Printer option, go to ZBI 2.0 ™ — Zebra Basic Interpreter on page 223.
Printer Features Zebra Print Touch The Zebra Print Touch ™ feature allows you to touch an Android ™ -based, Near Field Communication (NFC)-enabled device such as a smart phone or tablet to the printer’s Print Touch logo to pair the device to the printer. Print Touch is available on models with a factory installed networking (Wi-Fi, wired Ethernet, Bluetooth, and Bluetooth Low Power).
Controls and Indicators This section discusses the two user control panel variations and their functionality. User Interface The primary user controls are found on the front of the printer. The ZD-Series Desktop printers support two user interface options. • • Standard User Interface — This interface provides basic control and status needed by an operator. Printer operating status is reported by five (5) icon indicator lights. The icons represent several functional areas of operation.
Controls and Indicators Standard Interface Controls Status Indicators Power Status Pause Pause Data Media Feed8 Network Cancel Status Indicators Pause Button Feed Button Cancel Button Power Button Color Touch Display and Interface 38
Controls and Indicators 1. Power Button — Turns power ON and OFF in the printer. It is also used to initiate low-power sleep and wake states. • Initial Power ON — Press the Power button until the printer’s indicator lights flash on. The indicator lights will flash on and off in various combinations while the printer does self diagnostics, configuration checks, and integrate optional components which will take several seconds to complete.
Controls and Indicators • Green: A data communication operation has not finished, but is not actively being transferred. • Blinking Green: Data communications are in process. • Blinking Amber: Out of memory while storing content (formats, graphics, fonts, etc.). 5. Supplies Indicator — Indicates media (label, receipt, tags, transfer ribbon, ribbon cartridge, etc.) status. • Red: There is a media out condition. • Blinking Red: Ribbon Out.
Controls and Indicators Meaning of the Indicator Light Patterns All of the Link-OS 4 inch printers have status indicators. The indicators may be off or on in a variety of lighting patterns of red, green, or amber (orange/yellow). The status indicators can flash (blink), fade (bright to off), alternate between colors, or just remain on. The status information that these lighting patterns represent is detailed in this section.
Controls and Indicators Ribbon In (Ribbon Cartridge Printers Only) Thermal Transfer printer is in Direct Thermal Mode and has a ribbon cartridge installed. Remove the ribbon cartridge to continue printing in direct thermal mode. Transferring Data Data communications are in process. Data Transfers Paused A data communication operation has not finished, but is not actively being transferred. Out of Memory Out of memory while storing content (formats, graphics, fonts, etc.).
Controls and Indicators Status - Printhead Operation Hot Surface Caution • The printhead may be hot and could cause sever burns. Allow the printhead to cool. Printhead Over Temp The printhead is over temperature and paused to allow the printhead to cool. The print operation will resume after the printhead has cooled. Printhead Under Temp The printhead is under temperature. Typically, the operating environment is below the printer’s minimum operational temperature.
Controls and Indicators Status - Bluetooth Low Energy (BTLE) Option Bluetooth LE Paired Bluetooth Low Energy has paired. Bluetooth LE Failed to Pair Bluetooth Low Energy has failed to pair. Status - Ethernet (LAN) Option Ethernet (LAN) No Link No Ethernet link is available. NETWORK status is light off Ethernet (LAN) 100base Link A 100 Base link was found. Ethernet (LAN) 10base Link A 10 Base link was found. Ethernet (LAN) Link Error An error condition exists.
Controls and Indicators Status - Wi-Fi (WLAN) Option Wi-Fi Connecting to WLAN The light flashes red while the printer associates with the network. The light then flashes yellow while the printer is authenticating with the network.f Wi-Fi (WLAN) 100base Link The printer is connected to your network and the Wi-Fi signal is strong. Wi-Fi (WLAN) 10base Link The printer is connected to your network and the Wi-Fi signal is weak. Wi-Fi (WLAN) Link Error An error condition exists.
Controls and Indicators Rear of Battery Health Indicator Charge Level Indicators (3) Battery Control Button Health Indicator Charge Level Indicators (3) Battery Control Button — The button helps you control the battery, both inside and outside of the printer. • Battery On - Press and release • Wakes up (activates power) the battery from Sleep or Shutdown Modes. The battery health and charge status are checked. The battery indicators all flash on and off together 3 times.
Install Hardware Options This section assists you installing common printer connectivity modules and media handling options. IMPORTANT: To simplify and speed up the setup process, install all connectivity modules and media handling options before setting up and using your printer for the first time. IMPORTANT: It is strongly recommended that you update your printer’s firmware after the printer has completed the setup process.
Install Hardware Options • Printer Resolution Upgrade Kits (203 dpi and 300 dpi) — go to Print Resolution Upgrade Kits on page 63. • Media Roll Adapters for 38.1 mm (1.5 in.), 50.8 mm (2.0 in.), or 76.2 mm (3.0 in.) I.D. media cores go to Media Roll Core Size Adapters on page 61. • Fan-Fold Media Access Cover for thermal transfer printers.
Install Hardware Options Printer Connectivity Modules The connectivity modules can be easily installed without tools. CAUTION—ESD: The discharge of electrostatic energy that accumulates on the surface of the human body or other surfaces can damage or destroy the printhead or electronic components used in this device. You must observe static-safe procedures when working with the printhead or the electronic components.
Install Hardware Options Installing the Serial Port Module 1. With the DC power plug and module’s access door removed, slide the serial port module into the printer. 2. Push the circuit card in slowly but firmly until the card is just past the inside lip of the access door. 3. Align the bottom of the serial port’s door cover to the bottom lip of the module access opening. 4. Swing the door up and snap the cover closed.
Install Hardware Options Installing the Internal Ethernet (LAN) Module 1. With the DC power plug and module’s access door removed, slide the Ethernet module into the printer. 2. Push the circuit card in slowly but firmly until the card is just past the inside lip of the access door. 3. Align the bottom of the Ethernet port’s door cover to the bottom lip of the module access opening. 4. Swing the door up and snap the cover closed.
Install Hardware Options Removing Printer Connectivity Modules Connectivity modules can be removed to reconfigure or repair a printer. You should not remove and replace connectivity modules as a general practice. 1. Remove the interface cable (Ethernet or Serial). 2. Remove the module access door. Push down on the top of the door with your finger tip. The latch released. 3. Pull the door away and down to remove. 4. Reattach the interface cable to the connectivity module and secure the cable. 5.
Install Hardware Options Installing the Wireless Connectivity Module Use this procedure to install the Wireless Connectivity Module. CAUTION—ESD: The discharge of electrostatic energy that accumulates on the surface of the human body or other surfaces can damage or destroy the printhead or electronic components used in this device. You must observe static-safe procedures when working with the printhead or the electronic components. Installation Preparation 1. Unload printer media. 2. Turn OFF the printer.
Install Hardware Options 4. Align the antenna arm (1) into the well. 5. Lower and align the module (2) to the printer's Wi-Fi connector (3). 6. Push the module (2) in gently but firmly until fully seated. 7. Align the shortest side of the Wireless Connectivity Door (1) to the shortest side of the opening. 8. Swing the door on the tab (1) in the middle of the door printer and swing the door closed. 9. Push the door to lock the latch.
Install Hardware Options 5. Place the three (3) Wi-Fi identification labels included on the bottom of the printer. These assist with printer configuration (and later reconfiguration) of your printer. Mobile apps, use of scanners, and printer support are aided by these printer configuration labels.
Install Hardware Options Media Handling Options CAUTION—ESD: The discharge of electrostatic energy that accumulates on the surface of the human body or other surfaces can damage or destroy the printhead or electronic components used in this device. You must observe static-safe procedures when working with the printhead or the electronic components. Removing the Standard Bezel The standard bezel must be removed to mount your media handling option. 1.
Install Hardware Options Installing the Label Dispenser The standard bezel must be removed and DC input power disconnected before the Label Dispenser can be installed. Go to Removing the Standard Bezel on page 56. 1. Place the label dispenser module and printer right side up with the top of the module 12.5 mm (0.5 in.) below the bottom of the top cover. 2. Center and push the module into the front of the printer and slide it up until it stops. 3.
Install Hardware Options Installing the Standard Media Cutter The standard bezel must be removed and DC input power disconnected before the Label Dispenser can be installed. Go to Removing the Standard Bezel on page 56. CAUTION: There are no operator serviceable parts in the cutter unit. Never remove the cutter cover (bezel). Never attempt to insert objects or fingers in to the cutter mechanism. IMPORTANT: Using un-approved tools, cotton swabs, solvents, etc.
Install Hardware Options Installing the Linerless Media Cutter The standard bezel must be removed and DC input power disconnected before the Linerless Media Cutter Module can be installed. Go to Removing the Standard Bezel on page 56. 1. Open the printer and remove replace the standard platen roller with the Linerless platen roller. Go to Platen Cleaning and Replacement on page 255 for a replacement procedure.
Install Hardware Options Installing the Linerless Media ‘Tear-Off’ Bezel The standard bezel must be removed and DC input power disconnected before the Linerless Tear-Off Bezel module can be installed. Go to Removing the Standard Bezel on page 56. 1. Open the printer and remove replace the standard platen roller with the Linerless platen roller. Go to Platen Cleaning and Replacement on page 255 for a replacement procedure.
Install Hardware Options Media Roll Core Size Adapters Adapter Kits The media roll adapters kit includes three pairs of media roll adapters. The kits are for the following inner diameter (I.D.) media cores: • 38.1 mm (1.5 in.) • 50.8 mm (2.0 in.) • 76.2 mm (3.0 in.) Adapter Usage • The adapters are intended to be permanently installed in the printer. • They may be changed to support other media roll sizes that require one of these adapter sizes.
Install Hardware Options Example of Label Roll with 76.2 mm (3.0 in.
Install Hardware Options Print Resolution Upgrade Kits There are four (4) print resolution upgrade kits. The same procedure is used to change all the printhead resolution upgrade kits. Both the printhead and platen (drive) rollers must be changed and are resolution dependent. The printer automatically detects the change in printheads and the platen roller materials are identified by color. Standard Printing • Change the printer from 203 dpi to 300 dpi printing.
Install Hardware Options Installing the Attached Power Supply Base Options The power base is ready to attach to the printer. The base is installed using T10 wrench (that you supply) and the mounting screws provided with the upgrade kit. The direct thermal printer models attach to the printer with three screws and thermal transfer printer models use four screws. 1. Remove any media rolls from the printer. Remove the original power supply cable from the back of the printer. 2.
Install Hardware Options 4. Insert the DC input power plug into the printer. DC Input Power Plug DC Input Power Plug 5. Re-connect the AC power cord to the printer power base.
Install Hardware Options Installing the Attached Battery Base Options The battery base is ready to attach to the printer. The base is installed using a T10 wrench and the mounting screws provided with the upgrade kit. The direct thermal printer models attach to the printer with three (3) screws and thermal transfer printer models use four (4) screws. 1. Remove any media rolls from the printer. Remove the original power supply cable from the back of the printer. 2.
Install Hardware Options Installing the Battery into the Attached Power Base IMPORTANT: The printer must have an Attached Battery Base installed and securely connected your printer to keep from damaging the printer or battery. 1. Disconnect the printer’s external power supply from the DC Power Input located in the rear of the printer. 2. Slide the battery into the battery base’s battery slot.
Color Touch Display and Controls The printer's optional Color Touch Display provides easy access to your printer features, run print jobs, use wizards to assist you, and a visually interactive display to help you quickly through tasks and troubleshooting.
Color Touch Display and Controls Color Touch Display Printer Controls The Color Touch Display interface provides easy access to printer setup, configuration, and is customizable for all user types. The interface includes all the Standard User Interface controls and indicators to provide you with common functionality and behaviors for these Link-OS printer models.
Color Touch Display and Controls Home Screen The printer’s Home screen shows you the printer’s current status and allows you to access the printer’s menus. You can rotate the image of the printer 360 degrees to view it from all angles.
Color Touch Display and Controls Printer Info Printers with the optional Color Touch Display interface include the following features: • The printer's Standard Interface controls and status indicators provide quick and easy access to common printed operations.
Color Touch Display and Controls • The Color Touch Display shows the operator Alerts and Error messages • If the background color of the Home Screen is yellow or red, the printer is in an alert or error state. For more information, go to Resolving Alerts and Errors on page 274. • Displays a quick link to online instructions and "How to ... ' videos for access by mobile devices. • Access to Onboard Help.
Color Touch Display and Controls 73
Color Touch Display and Controls User Menus The printer’s user menus can be used to configure the printer. See the following menu sections: • System • Connection • Print • RFID • Storage The user menu descriptions include other ways to change the same settings when other options exist. You can also use the printer’s wizards to change some of the settings. Go to Printer Wizards on page 72.
Color Touch Display and Controls System Menu Use System menu items to set printer function, operational options, languages, and restore defaults.
Color Touch Display and Controls System > Language Use this setting to select from 19 language choices for your printer's displayed and printed information. NOTE: The language selections for this parameter are displayed by language name in the language of the displayed name.
Color Touch Display and Controls System > Program Language > Diagnostic Mode Use Communications Diagnostics Mode to enable the printer to output all communication as printed data for advanced troubleshooting.
Color Touch Display and Controls System > Program Language > Virtual Device If any Virtual Device applications are installed on your printer, you may view or enable/disable them from this user menu. Accepted values: NONE or any Link-OS Virtual Device(s) will be in a list here.
Color Touch Display and Controls System > Program Language > ZBI Zebra Basic Interpreter (ZBI 2.0 ™ ) is a programming option that may be purchased for your printer. Zebra Basic Interpreter (ZBI 2.0 ™ ) is a programming option that may be purchased for your printer. If you would like to purchase 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.
Color Touch Display and Controls System > Settings > Display Time Format Use this setting to select the time format used by the printer. Accepted values: 12-Hour, 24-Hour SGD command used: device.
Color Touch Display and Controls System > Settings > Password Level Use this setting to select the level of password protection for user menu items.
Color Touch Display and Controls System > Settings > Set Password Set a new printer password for menu items protected by the previous parameter. Accepted values: Numerals 0-9 The default printer password is 1234.
Color Touch Display and Controls 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. 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.
Color Touch Display and Controls 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.
Color Touch Display and Controls System > Settings > Screen Calibration Touch each crosshair to calibrate the screen.
Color Touch Display and Controls 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. This menu item is available through two user menus with different default values for each. Accepted values: PRINTER—Restores all printer settings other than the network settings back to the factory defaults.
Color Touch Display and Controls System > Settings > Print: System Settings Prints a printer configuration report. Related ZPL command(s): ~WC Control panel key(s): Hold CANCEL for 2 seconds during printer power-up. Hold FEED + CANCEL for 2 seconds when the printer is in the Ready state.
Color Touch Display and Controls 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.
Color Touch Display and Controls Connection Menu Use this menu to set connection parameters for wired and wireless (Wi-Fi and Bluetooth) printer communication.
Color Touch Display and Controls Connection > Networks > Reset Network This option resets the wired or wireless print server and saves any changes that you made to any network settings. You must reset the print server to allow changes to the network settings to take effect. Related ZPL command(s): ~WR SGD command used: device.
Color Touch Display and Controls 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, WLAN Related ZPL command(s): ^NC SGD command used: ip.
Color Touch Display and Controls Connection > Networks > IP Port This printer setting refers to the internal wired print server's 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.
Color Touch Display and Controls Connection > Networks > IP Alternate Port This command sets the port number of the alternate TCP port. Print servers supporting this command will monitor both the primary port and the alternate port for connections at the same time. SGD command used: internal_wired.ip.port_alternate wlan.ip.
Color Touch Display and Controls Connection > Networks > Print: Network Info Prints the settings for any print server or Bluetooth device that is installed. Related ZPL command(s): ~WL Control panel key(s): Hold CANCEL for 2 seconds during printer power-up. Hold FEED + CANCEL for 2 seconds when the printer is in the Ready state.
Color Touch Display and Controls Connection > Networks > Visibility Agent When the printer is connected to a wired or wireless network, it will attempt 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.
Color Touch Display and Controls Connection > Wired > Wired IP Protocol 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. You must reset the print server to allow changes to the network settings to take effect.
Color Touch Display and Controls Connection > Wired > Wired IP Address View and, if necessary, change the printer’s wired IP address. To save changes to this setting, set Connection > Wired > Wired IP Protocol to PERMANENT, and then reset the print server (go to Connection > Networks > Reset Network on page 90). Accepted values: 000 to 255 for each field Related ZPL command(s): ^ND SGD command used: internal_wired.ip.
Color Touch Display and Controls Connection > Wired > Wired Gateway View and, if necessary, change the default wired gateway. To save changes to this setting, set Connection > Wired > Wired IP Protocol to PERMANENT, and then reset the print server (go to Connection > Networks > Reset Network on page 90). Accepted values: 000 to 255 for each field Related ZPL command(s): ^ND SGD command used: internal_wired.ip.
Color Touch Display and Controls 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: internal_wired.
Color Touch Display and Controls Connection > WLAN > WLAN IP Protocol 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. You must reset the print server to allow changes to the network settings to take effect. Go to Connection > Networks > Reset Network on page 90.
Color Touch Display and Controls Connection > WLAN > WLAN IP Address View and, if necessary, change the printer’s wireless IP address. To save changes to this setting, set Connection > WLAN > WLAN IP Protocol to PERMANENT, and then reset the print server (go to Connection > Networks > Reset Network on page 90). Accepted values: 000 to 255 for each field Related ZPL command(s): ^ND SGD command used: ip.addr, wlan.ip.
Color Touch Display and Controls Connection > WLAN > WLAN Subnet View and, if necessary, change the wireless subnet mask. To save changes to this setting, set Connection > WLAN > WLAN IP Protocol to PERMANENT, and then reset the print server (go to Connection > Networks > Reset Network on page 90). Accepted values: 000 to 255 for each field Related ZPL command(s): ^ND SGD command used: wlan.ip.
Color Touch Display and Controls Connection > WLAN > WLAN Gateway View and, if necessary, change the default wireless gateway. To save changes to this setting, set Connection > WLAN > WLAN IP Protocol to PERMANENT, and then reset the print server (go to Connection > Networks > Reset Network on page 90). Accepted values: 000 to 255 for each field Related ZPL command(s): ^ND SGD command used: wlan.ip.
Color Touch Display and Controls Connection > WLAN > WLAN Mac Address View the Media Access Control (MAC) address of the wireless print server. This value cannot be modified. SGD command used: wlan.
Color Touch Display and Controls Connection > WLAN > 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.
Color Touch Display and Controls Connection > WLAN > WLAN Security Select the security type being used on your WLAN. Related ZPL command(s): ^WX SGD command used: wlan.
Color Touch Display and Controls Connection > WLAN > WLAN Band Set a preferred band to connect with via Wi-Fi. Accepted values: 2.4, 5, None SGD command used: wlan.
Color Touch Display and Controls Connection > WLAN > WLAN Country Code The country code defines the regulatory country for which the wireless radio is currently configured. Note • 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.
Color Touch Display and Controls Connection > Bluetooth > Bluetooth Select if the printer is “Discoverable” for Bluetooth device pairing. Accepted values: ON—Enables the Bluetooth radio. OFF—Disables the Bluetooth radio. SGD command used: bluetooth.
Color Touch Display and Controls 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.
Color Touch Display and Controls 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 device.reset command (go to Connection > Networks > Reset Network on page 90). If you do not set a friendly name, it will default to the printer serial number. Accepted values: 17-character text string SGD command used: bluetooth.
Color Touch Display and Controls Connection > Bluetooth > Minimum Security Mode This printer setting parameter sets the Bluetooth Minimum Security mode. Minimum Security Mode provides for different levels of security, depending on the printer radio version and printer firmware. Refer to the Zebra Programming Guide at zebra.com/manuals for more information. Accepted values: 1, 2, 3, 4 SGD command used: bluetooth.
Color Touch Display and Controls Connection > Bluetooth > Specification Version This parameter displays the Bluetooth library version number. SGD command used: bluetooth.
Color Touch Display and Controls Connection > Bluetooth > MAC Address This parameter displays the Bluetooth device address. SGD command used: bluetooth.
Color Touch Display and Controls Connection > Bluetooth > Bluetooth Auth. PIN This parameter displays the Bluetooth device address. SGD command used: bluetooth.bluetooth_pin (to set the PIN) bluetooth.
Color Touch Display and Controls Connection > Bluetooth > Bluetooth Bonding Controls whether the Bluetooth stack will “bond” or save link keys for devices that successfully connect to the printer. Accepted values: ON—Enables Bluetooth bonding. OFF—Disables Bluetooth bonding. SGD command used: bluetooth.
Color Touch Display and Controls Print Menu Use this menu to set how the printer prints. Set darkness, speed, size, handling the print job, etc.
Color Touch Display and Controls 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: print.
Color Touch Display and Controls 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: ZD621 203 dpi = 2 to 8 ips ZD621 300 dpi = 2 to 6 ips Related ZPL command(s): ^PR SGD command used: media.
Color Touch Display and Controls Print > Print Quality > Print Type Specify if the printer needs to use ribbon for printing. Accepted values: Thermal Transfer—Uses ribbon and thermal transfer media. Direct Thermal—Uses direct thermal media and no ribbon. Related ZPL command(s): ^MT SGD command used: ezpl.
Color Touch Display and Controls Print > Print Quality > Label Type Select the type of media that you are using. If you select Continuous, you must include a label length (set with Print > Print Quality > Label Length) in your label format layout (^LL if you are using ZPL). If you select Gap/Notch or Mark for various noncontinuous media, the printer feeds media to calculate the label length. Accepted values: Continuous, Gap/Notch, Mark Related ZPL command(s): ^MN SGD command used: ezpl.
Color Touch Display and Controls Print > Print Quality > Label Length View the calibrated label length in dots. This value cannot be modified.
Color Touch Display and Controls Print > Print Quality > Label Width (Dots) Specify the width of the labels being used, in dots. The default value is the maximum width for the printer, based on the printhead’s DPI value. 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.
Color Touch Display and Controls Print > Label Position > Collection Method Select a collection method that is compatible with the options available on your printer. Accepted values: Tear Off, Peel Off, Rewind, Cutter, Delayed Cut, Linerless Peel, Linerless Rewind, Linerless Tear, Applicator, Linerless Cut, Linerless Delayed Cut Related ZPL command(s): ^MM SGD command used: media.
Color Touch Display and Controls Print > Label Position > Tear Line Offset Set the position where the printer stops for tear-off label removal. If necessary, shift the position of the media over the tear-off feature 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).
Color Touch Display and Controls Print > Label Position > Horizontal Label Offset If necessary, shift the position of the image horizontally on the label. If necessary, shift the horizontal position of the print on the media. • 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.
Color Touch Display and Controls Print > Label Position > Vertical Label Offset If necessary, shift the position of the image vertically on the label. If necessary, shift the position horizontal of the print on the media. • 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 SGD command used: zpl.
Color Touch Display and Controls Print > Sensors > Manual Calibration Calibrate the printer to adjust the sensitivity of the media and ribbon sensors. This operation is a Wizard that interactively steps you through a manual calibration of media sensor settings. For complete instructions on how to perform a calibration procedure, go to Manual Media Calibration on page 303. Related ZPL command(s): ~JC SGD command used: ezpl.
Color Touch Display and Controls Print > Sensors > Label Sensor Set the sensitivity of the label sensor. NOTE: 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. Accepted values: 0 to 255 SGD command used: ezpl.
Color Touch Display and Controls Print > Sensors > Sensor Type Select between transmissive and reflective media sensing that is appropriate for the media type that you are using. Transmissive (sees-through media and liner) — Used for gap/web sensing for common labels and continuous media. No tracking marks or notches on these medias. Reflective — Used for the detection of black mark/line and notches/holes on the backside of media. Black markings and holes do not reflect like the liner or paper.
Color Touch Display and Controls Print > Sensors > Print: Sensor Profile Shows the sensor settings compared to actual sensor readings. To interpret the results, go to Sensor Profile on page 302. Transmissive (sees-through media and liner) - Used for gap/web sensing for the basic label and— continuous media Reflective - Used for the detection of black marks/lines and notches/holes on the backside of media. Black markings and holes do not reflect.
Color Touch Display and Controls 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. IMPORTANT: A suitable label format must be stored on the E: drive of the printer to use this option. Refer to the exercises in Using the USB Hosts Port and the NFC Capabilities on page 237 for an exercise using this capability.
Color Touch Display and Controls 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.
Color Touch Display and Controls Print > Applicator > Start Print Mode Determines if the applicator port’s “Start Print” signal is in level mode or pulse mode. Accepted values: Pulse—Start Print signal must be disabled before it can be asserted for the next label. Level—Start Print signal does not need to be disabled to print the next label. As long as the Start Print signal is low and a label is formatted correctly a label prints. Related ZPL command(s): ^JJ SGD command used: device.applicator.
Color Touch Display and Controls 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.
Color Touch Display and Controls 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.
Color Touch Display and Controls RFID Menu Use this menu to configure, monitor, and test the RFID subsystem operation.
Color Touch Display and Controls RFID > RFID Status Display the status of the RFID subsystem of the printer. Related ZPL command(s): ^HL, ~HL SGD command used: rfid.error.
Color Touch Display and Controls RFID > RFID Test During the RFID test, the printer attempts to read and write to a transponder. No printer movement occurs with this test. To test an RFID label: a. Position the RFID label with its transponder over the RFID antenna array. b. Touch Start. The typical results are shown on the display. SGD command used: rfid.tag.test.content , fid.tag.test.
Color Touch Display and Controls RFID > RFID Calibrate 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. Refer to the RFID Programming Guide 3 for more information.
Color Touch Display and Controls 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.
Color Touch Display and Controls 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): ^RW SGD command used: rfid.reader_1.power.
Color Touch Display and Controls RFID > RFID Antenna If the desired antenna selection is not achieved through RFID tag calibration, a value may be specified. Accepted values: A1 default and only valid setting (for center aligned antennas used in this Zebra printer). Related ZPL command(s): ^RW SGD command used: rfid.reader_1.
Color Touch Display and Controls RFID > RFID Valid Count Resets the RFID valid label counter to zero. Related ZPL command(s): ~RO SGD command used: odometer.rfid.
Color Touch Display and Controls RFID > RFID Void Count Resets the RFID void label counter to zero. Related ZPL command(s): ~RO SGD command used: odometer.rfid.
Color Touch Display and Controls 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.
Color Touch Display and Controls 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. To read and display the information stored on an RFID tag: a. Position the RFID label with its transponder over the RFID antenna. b. 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.
Color Touch Display and Controls Storage Menu Use this menu to manage file operations within the printer, accessing external files via the USB Host, and print label formats.
Color Touch Display and Controls Storage > USB > Copy: Files to USB Select files from the printer to store on a USB Flash drive. To copy files from the printer to a USB Flash drive: a. Insert a USB flash drive into the printer’s USB host port. The printer lists available files. a. Touch the box next to the desired files. Select All is also available. b. Touch the checkmark to copy the selected files. SGD command used: usb.host.
Color Touch Display and Controls Storage > USB > Copy: Files to Printer Select files to copy to the printer from a USB Flash drive. To copy files to the printer from a USB Flash drive: a. Insert a USB flash drive into the printer’s USB host port. The printer lists available files. a. Touch the box next to the desired files. Select All is also available. b. Touch the checkmark to copy the selected files. SGD command used: usb.host.
Color Touch Display and Controls 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): ^HH — Returns the printer configuration information returned to the host computer.
Color Touch Display and Controls Storage > USB > Print: From USB Select files to print from a USB Flash drive. To print files from a USB Flash drive: a. Insert a USB flash drive into the printer’s USB host port. The printer lists available files. a. Touch the box next to the desired files. Select All is also available. b. Touch the checkmark to print the selected files. SGD command used: usb.host.
Color Touch Display and Controls 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 printer’s RAM, Flash memory, or optional memory card. Fonts — Prints the available fonts in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM or Flash memory.
Color Touch Display and Controls Storage > USB > Print from E: Select files to print from files in printer E: memory. To print files from printer E: memory: The printer lists available files. a. Touch the box next to the desired files. Select All is also available. b. Touch the checkmark to print the selected files. SGD command used: usb.host.
Setup This section assists you in setting up and operating your printer. The setup process can be broken down into two (2) phases: hardware setup and host system (software/driver) setup. This section covers the physical hardware setup needed to print your first label. Printer Setup Overview Below is an overview of the procedures necessary for setting up your printer. 1. Install any printer hardware options first. Go to Install Hardware Options on page 47. 2.
Setup • Space: The area where the printer will be located must include enough space for opening the printer (media access and cleaning), and for printer access to connectivity and power cords. To allow for proper ventilation and cooling, leave open space on all sides of the printer. IMPORTANT: 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.
Setup 1. Plug the power supply into the printer’s DC power receptacle. 2. Insert the AC power cord into the power supply. 3. Plug the other end of the AC power cord into an appropriate AC electrical outlet. Note that AC outlet end of the power cord’s plug type can vary by region. 4. The active power light will turn on green if power is on at the AC outlet. IMPORTANT: Ensure the appropriate power cord with a three (3) prong plug and an IEC 60320-C13 connector are used at all times.
Setup 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 going to be put in the printer. • Many media types and label adhesives have a ‘shelf life’ or expiration date. Always use the oldest, viable (non-expired) media first.
Setup Instructions for media loading: This procedure works for Tear-Off (standard bezel), Label Dispense and Media Cutting printer options. 1. Open the printer. Pull the release latch levers toward the front of the printer. 2. Open the media roll holders. Orient the media roll so that its printing surface will face up as it passes over the platen (drive) roller. Pull the media guides open with your free hand and place the media roll on the roll holders and release the guides.
Setup 3. Pull the media so that it extends out of the front of the printer. 4. Push the media under both of the media guides.
Setup 5. Flip the media up and align the movable media sensor for your media type. • For continuous roll receipt type media or label media without black marks or notches, align the media to the default center position. • For black mark (black line, notches or holes) backed media, adjust the sensor position so the sensor aligns to the center of the black mark. Avoid the center area of the media to only use black mark sensing for operation with black marks.
Setup Using the Movable Sensor The movable sensor is a dual function sensor. It provides transmissive (sees through media) and reflective media sensing. The printer can use either sensing method, but not both at the same time. The movable sensor has a center array of sensors. This provides adjustable transmissive web (gap) sensing to positions that match legacy Zebra® desktop printer sensor locations and positions in between.
Setup • The movable sensor adjustment range covers sensor positions use by legacy Zebra printers. • Web (Gap) sensing with the movable sensor only functions when the movable sensor’s alignment arrow points to any position on the alignment key.
Setup Loading Roll Media (continued) 1. Cutter Models - For printers with the optional cutter module installed, thread the media through cutter’s media slot and pull it out the front of the printer. 2. Close the printer. Press down until the cover snaps closed. You may need a calibrate your printer for the media. The printer’s sensors need to adjust to sense the label, the liner, and the distance between labels to operate properly.
Setup Loading Thermal Transfer Roll Ribbon The ZD621 and ZD421 thermal transfer printers have a flexible ribbon system. It supports 300 meter and 74 meter genuine Zebra® ribbons. The printer includes 300 meter ribbon adapters for non-Zebra ribbon rolls. 74 meter ribbon from non-Zebra printers does not need the Non-Zebra ribbon adapters to operate properly. Transfer ribbons come in several varieties and in some cases colors to match your application needs.
Setup Loading Zebra Transfer Roll Ribbon Before following these steps, prepare the ribbon by removing its wrapping and pulling its adhesive strip free. Notch (Required on left side of ribbon) Right Side (printer and roll) Adhesive Strip Notches are also on right side of the 74m ribbon Verify that the ribbon and empty ribbon core have notches on the left side of the ribbon cores as shown above. If they do not, go to Loading Non-Zebra 300 Meter Transfer Ribbon on page 170. 1.
Setup 2. Place a new ribbon roll on printer’s lower ribbon supply spindle. Push it onto the right spindle and lock the left side the same as the take-up mounting the take-up core.
Setup 3. Attach the ribbon to the take up core. Use the adhesive strip on new rolls; otherwise, use a thin strip of tape. Align the ribbon so that it will be taken straight onto the core. 4. Turn the ribbon take-up hub with the top moving toward rear to remove slack from the ribbon. Rotating the hub helps to finish aligning the take up ribbon position to the supply ribbon roll. The ribbon leader should be completely covered by the ribbon. 5.
Setup 7. Change the print mode setting from direct thermal printing to thermal transfer to set the printer’s temperature profiles for thermal transfer media. This can be done with the printer driver, application software, or printer programming commands. • When controlling printer operations with ZPL programming, refer to the Media Type (^MT) ZPL II command (follow the instructions in the ZPL Programming Guide).
Setup Loading Non-Zebra 300 Meter Transfer Ribbon Loading non-Zebra 300 meter transfer ribbon in your printer requires the use of Zebra ribbon core adapters. Minimum requirements to use non-Zebra 300 meter ribbons with your printer: • Inside core diameter (I.D.) of 25.4mm (1.0 in., range 1.004 to 1.016 in.). Material: Fiberboard; hard materials such as plastic cores may not function correctly. • Ribbon width range of 110 to 33mm (4.3 to 1.3 in.). • The maximum outer diameter of the ribbon is 66mm (2.
Setup 2. Load the non-Zebra ribbon roll onto the ribbon core adapter. Orient the adapter flange on the left side and verify that the ribbon unwraps on the backside of the roll as shown in the illustration. Roughly center the core over the adapters center line. Ribbon Exiting the Roll in the Back Flange - Place on Left NOTE: The maximum roll width of 110 mm (4.3 in.) does not require centering. For media less than maximum width down to the minimum width of 33mm (1.3 in.
Setup 3. Place the adapter with an empty core on the take-up spindles and the adapter with the ribbon roll on the lower supply spindles. The right side of the core adapter fits on the cone tip on each of the spring loaded right side spindles. Continue pushing the adapter onto right side spindle and swing the adapter onto the left side spindle hubs. Rotate the adapters and hubs until the until notches on the adapters flange align and lock ton the left spindles hub spokes.
Setup 4. While the ribbon and empty cores were being installed during the previous steps, they may have been bumped off center. • Verify that the ribbon roll and empty core are aligned to the center of the media (labels, paper, tags, etc.). Remember that you can use the center line scales on the ribbon core adapter to place their positions. • If you have forgotten to check if the ribbon is wide enough the for the media in use, now is the time to check.
Setup 5. Attach the ribbon to the take up core. Use thin strip of tape to secure the ribbon to the take-up core, if your media does not have an adhesive strip on the ribbon leader like genuine Zebra@ ribbon. Align the ribbon so that it will be taken straight onto the core. 6. Turn the ribbon take-up hub with the top moving toward rear to remove slack from the ribbon. Rotating the hub helps to finish aligning the take up ribbon position with the supply ribbon roll.
Setup 7. Verify that the media is loaded and ready to print and then close the printer cover. 8. If printer power is on, press the FEED button to have the printer advance a minimum of 20 cm (8 in.) of media to remove slack and ribbon wrinkle (straightens the ribbon), and to align the ribbon on the spindles. Otherwise, wait to turn on the printer and complete the printer ‘Getting Started’ instructions in this chapter. 9.
Setup Loading the ZD421 Ribbon Cartridge The printer uses a transfer ribbon cartridge for thermal transfer printing. Just slide the cartridge into the ribbon transport and close the printer. The printer reads cartridge information stored on the cartridge. Insert this Cartridge Guide Rails End Hold the Ribbon Cartridge Here In s Cartridge Information Smart Chip ert this En d 1. Insert the ribbon cartridge into the ribbon cartridge slot on the ribbon transport in your open printer.
Setup Run a SmartCal Media Calibration The printer needs to set the media parameters for prior to printing optimal operation. The printer will automatically determine media type (web/gap, black mark/notch, or continuous) and measure media characteristics. IMPORTANT: After the initial calibration to a specific media is completed, it is not required to perform additional calibrations each time the media is replaced.
Setup Test Printing with the Configuration Report Before you connect the printer to a computer, make sure that the printer is in proper working order. You can do this by printing a configuration report. The information on the Configuration reports printout that may be helpful with printer installation and with troubleshooting your printer. 1. Make sure the media and ribbon cartridge (if you are thermal transfer printing) are loaded properly in the printer and the top cover of the printer is closed. 2.
Setup Detecting a Media Out Condition When you run out of media, your printer will report a ‘Media Out’ condition with the Status and Media indicators both light solid red. This is part of the normal media usage cycle. Recovering from a Media Out condition 1. Open the printer. 2. Observe that the media is at the end or nearly at the end of the roll with a label missing from the liner. 3. Remove the remaining media and roll core. 4. Insert a new roll of media. Go to Loading Roll Media on page 158.
Setup Detecting a Ribbon Out Condition When you run out of printable ribbon, your printer will report a ‘Ribbon Out’ condition with the Status and Media indicators. This is part of the normal media usage cycle. When the printer detects that the ribbon is out, the Status indicator will turn solid red and the Media indicator will be flashing red. Recovering from a Ribbon Out condition 1. Open the printer. 2.
Setup Connecting your Printer to a Computer The printer supports a variety of interface options and configurations. These include: • Universal Serial Bus (USB 2.0) interface - Standard. • RS232 Serial - ZD621 standard. Field Upgrade Option for ZD421 printers. • Ethernet (LAN) - ZD621 standard. Field Upgrade Option for ZD421 printers. • Internal Wi-Fi (802.11ac) and Bluetooth Classic 4.1 - Factory Installed Option.
Setup USB Interface Universal Serial Bus (version 2.0 compliant) provides a fast interface that is compatible with your existing PC hardware. USB’s “plug and play” design makes installation easy. Multiple printers can share a single USB port/hub. When using a USB cable, verify that the cable or cable packaging bears the “Certified USB ™ ” mark to guarantee USB 2.0 compliance. .
Setup Serial Interface The printer uses a Null Modem (cross-over) cable for DTE communications. The required cable must have a nine-pin “D” type (DB-9P) male connector on one end which plugs into the mating (DB-9S) serial port located on the back of the printer. The other end of this signal interface cable connects to a serial port on the host computer. For pin-out information, refer to Appendix A.
Setup Ethernet (LAN, RJ-45) The printer requires UTP RJ45 Ethernet cable rated CAT-5 or better. The printer has a built-in network print server. For more information on configuring your printer to run on a compatible Ethernet based network, refer to the Wired and Wireless Print Server User Guide. The printer must be configured to run on your network. The print server on board your printer can be accessed through the printer’s print server Web pages.
Setup Assigning an IP Address for Network Access All devices on an Ethernet network (LAN and WLAN) require a network IP (Internet Protocol) address. The printer’s IP address is needed to access the printer for printing and printer configuration.
® Setup for Windows OS The section helps you setup communications between your printer and the Windows operating system environment. Windows to Printer Communication Setup (Overview) For supported Windows Operating systems (most common) with a Local (wired) connection: 1. Download the Zebra Setup Utilities from the Zebra web site. • ZD621 Thermal Transfer Printer — zebra.com/ZD621t-info • ZD621 Direct Thermal Printer — zebra.com/ZD621d-info • ZD421 Thermal Transfer Ribbon Cartridge Printer — zebra.
Setup for Windows® OS For more details on installing Ethernet (network) and Bluetooth interfaces: • Wired and Wireless Print Servers User Guide • Bluetooth Wireless Guide Setting Up the Wi-Fi Print Server Option This section covers basic configuration of your internal Wi-Fi Print Server option. For more detailed information, refer to the Wired and Wireless Print Servers User Guide.
Setup for Windows® OS 2. Launch the ZebraNet Bridge Enterprise program. If you are prompted for a serial number, you may click Cancel. You will still be able to use the Connectivity Wizard. 3. From the Menu bar, select Tools > Connectivity Wizard. The Connectivity Wizard opens. 4. From the Choose Port list, select the port to which your printer is connected. • If you will save the file without sending it to the printer, you may select any available port.
Setup for Windows® OS 5. Click Next. The wizard prompts for the print server device to configure. 6. Select Wireless and then click Next. The wizard prompts you for the type of printer you are using.
Setup for Windows® OS 7. Select the type of printer you are using and then click Next. The wizard prompts for the wireless IP information. 8. Enable the DHCP (dynamic) or Static IP option. • DHCP i. Select DHCP and click Next. ii. Continue with step 9. • Static (IP) iii. Select Static. iv. The IP settings fields are activated. v. Enter the IP Address, Default Gateway, and Subnet Mask for the wireless print server. Contact your network administrator for the correct values. vi. Continue with step 9.
Setup for Windows® OS 9. Click Next. The Wireless Settings window opens.
Setup for Windows® OS 10. Enter the ESSID. NOTE: The ESSID and pass phrase, if used, must be set at your access point before completing these steps. 11. From the drop-down, select your Security Mode. • None (no security protocol selected) • WEP 40-Bit or WEP 128-Bit In the WEP Options section of the window, enter the following values: • Authentication Type • WEP Index • Encryption Key Storage • WEP Keys Click Next and continue with step 12.
Setup for Windows® OS 12. Click Advanced Options in the Wireless Settings window. step 12 The Advanced Wireless Settings window opens. 13. Review the settings in the Advanced Wireless Settings window. Change the settings as necessary, and then click OK. The Wireless Settings window returns.
Setup for Windows® OS 14. Click Next. Based on your selections in the Wireless Setup Wizard, the program writes the appropriate ZPL commands and displays them for your review. If you selected Tabletop/Desktop then the a dialog box similar to this displays. 15. Determine if you will send the script immediately, or save it for use at a later time. Using a Configuration Script Complete setup by sending the ZPL script to the printer through the port selected at the beginning of this procedure. 1.
Setup for Windows® OS Saving a Configuration Script Save the ZPL script to a file for use later or for use with other printers. NOTE: You can send the ZPL script file to multiple printers that use the same configuration, or you can send the file to a printer that had the network settings restored to the factory defaults. This saves you from having to go through the Wireless Setup Wizard more than once. 1. On the Review and Send ZPL for Wireless window, highlight the script, right-click, and select Copy. 2.
Setup for Windows® OS 6. In the Friendly Name text field, set the Bluetooth name of the device. This name appears during device discovery and the central device will label the printer with this name. 7. Set Discoverable to On or Off to set whether the device will appear when central devices are looking for new devices to pair with. 8. Set Authentication to On. NOTE: This setting does not exist in Link-OS, but you need to turn on if you want to enter a PIN in ZSU.
Setup for Windows® OS 9. The values set in the Authentication PIN field will vary depending on the Bluetooth (BT) version of the central device. If the central device uses BT v2.0 or older, enter a numeric value in this field. You will be prompted to enter this same value on the central device to verify pairing. Security Mode 2 or 3 in Advanced Settings should also be selected for PIN paring. 10. If the central device uses BT v2.1 or newer, this setting has no effect. BT v2.
Setup for Windows® OS Connecting to a Windows XP® SP2 Central Device This process covers the printer installation for Windows XP SP2 (or above) 1. From the Windows Start menu, open the Printers and Faxes window. Click on Add Printer and a wizard will start. Click Next when the “Welcome” window displays to continue. 2. Leave the Local radio button with the Automatic detect ... checkbox (checked) selected and click Next. 3. No printer should be found.
Setup for Windows® OS Connecting to a Windows Vista® SP2 or Windows 7® Central Device The Windows Vista (SP2 or higher) and Windows 7 Bluetooth install differs from the XP install. • Windows Vista: Open the Add Printer wizard by clicking the Start button, clicking Control Panel, clicking Hardware and Sound, clicking Printers, and then clicking Add a printer.
Setup for Windows® OS 3. Hover over the Bluetooth icon with the mouse pointer and the icon will highlight. Right-Click on the high-lighted Bluetooth icon. Select Bluetooth Settings from the pop-up menu. Verify that both of the Connections check boxes are checked. Verify that the Turn off the Bluetooth adapter is not checked. Click the Apply button. Click the OK button to close the window. 4. Click on the Add a device in the top bar of the “Devices and Printers window.
Setup for Windows® OS 6. The printer will print a pairing code. Verify that the pairing numbers match with those on your display screen. If the numbers match, then press the Next button in the Add a device window. 7. When the pairing process successfully completes, the following message will be displayed. Note • The COM port number displayed in the task bar pop-up. It will only remain for a few seconds.
Setup for Windows® OS Connecting the Printer to a Windows 8 Before adding (also called pairing) a Bluetooth enabled device, make sure it is turned on and discoverable. As stated in the previous section under Connecting to a Windows Vista® SP2 or Windows 7® Central Device on page 199, your Windows device may need a Bluetooth adapter to connect to Bluetooth device. Check with your device manufacturers User Manual for further information. 1.
Setup for Windows® OS Connecting the Printer to a Windows 10 PC Before adding (also called pairing) a Bluetooth enabled device, make sure it is turned on and discoverable. As stated in the previous section under “Installing the Printer on a Windows 7 PC,” your Windows device may need a Bluetooth adapter to connect to Bluetooth device. Check with your device manufacturers User Manual for further information. 1. Open the Windows Start Menu by clicking on the Windows Start ( . 2.
Setup for Windows® OS 3. Click on Bluetooth. If your PC doesn’t have Bluetooth installed, the Bluetooth category will not be displayed in the list of device categories. The printer is identified by the serial number. Printer Serial Number 4. Click on the printer and then click on the pairing button for the printer.
Setup for Windows® OS 5. The printer will print a passcode. Compare that with the passcode showing on screen. Click Yes if they match. 6. The printer status changes to connected when pairing has completed. After Your Printer is Connected Now that you have basic communication to your printer, you may want to test printer communications and then install other printer related applications, drivers or utilities.
Setup for Windows® OS Test Printing with Zebra Setup Utility: 1. Open the Zebra Setup Utility. 2. Click on the newly installed printer’s icon to select the printer and activate the printer configuration buttons below it in the window. 3. Click the Open Printer Tools button. 4. In the Print tab window, click on the Print configuration label line and click on the Send button. The printer should print a configuration report. Test Printing with Windows Printer and Faxes menu: 1.
Setup for Windows® OS Test Print with a Copied ZPL Command File for Non-Windows Operating Systems: 1. Create a text file with the following ASCII three characters: ~WC 2. Save the file as: TEST.ZPL (an arbitrary file name and extension name). 3. Copy the file to the printer. For DOS, a file sent to a printer connected to the system’s serial port would be as simple as: COPY TEST.ZPL COM1 Other interface connection types and operating systems will have different command strings.
Print Operations This section provides general information on media and print handling, font and language support, and the setup of less common printer configurations. Thermal Printing The ZD-Series printers use heat to expose direct thermal media or heat and pressure to melt and transfer ‘ink’ to the media. Extra care should be taken to avoid touching the printhead which gets hot and is sensitive to electrostatic discharges. CAUTION—HOT SURFACE: The printhead becomes hot while printing.
Print Operations Print Modes • TEAR OFF -— This mode (default) can be used with any printer options and most media types. The printer prints label formats as it receives them. The printer operator can tear off the printed labels any time after they print. • PEEL — Label Dispenser Option only. The printer peels the label from the liner during printing and then pauses until the label is removed. • CUTTER — Cutter Option only. The printer cuts between labels after each one is printed.
Print Operations NOTE: Go to About on page 11 section for information and support links for your specific printer model. Replacing Supplies while Using the Printer If media (ribbon, labels, receipts, tags, tickets, etc.) run out while printing, leave the printer power on while reloading (data loss results if you turn off the printer). After you load a new roll of media, press the FEED button to restart.
Print Operations 4. For all ZD621 printers and the ZD421 Cartridge printer — Adjust the media guide stop position with the gold thumb wheel. Use a piece of the fan-fold media to set the stop position. Rotate the wheel away from you to make the guides wider. Rotate the wheel toward you to make the media guides narrower.
Print Operations 5. For all ZD421 printers except for the ZD421 Cartridge printer — Adjust the media guide stop position with the slide lock on the left side media guide. Use a piece of the fan-fold media to set the stop position. Push the gray down towards the base of the media roll holder to lock the roll position. Rotate the wheel toward you to make the media guides narrower.
Print Operations 6. Insert the media through the slot at the rear of the printer and place the media between the media guide and roll holders. 7. Close the top cover. IMPORTANT: After printing or using the FEED button to advance several labels: If the media does not track down the center (moves from side to side) or the sides of the media (liner, tag, paper, etc.) are frayed or damaged when exiting the printer, then the media guide stop position may need further adjustment.
Print Operations • The printer should not touch the media roll. • The printer should not slip or lift up off the operating surface. Using the Label Dispenser Option The label dispenser option allows you to print a label and have the backing material (liner/web) automatically removed. When printing multiple labels, removing the dispensed (peeled) label triggers the printer to print and dispense the next label.
Print Operations 2. Lift the liner over the top of the printer. Pull the gold latch in the center of dispenser door away from the printer and the door will open.
Print Operations 3. Insert the label liner between the dispenser door and the printer body. 4. Close the dispenser door while pulling the end of the label liner tight.
Print Operations 5. Press and release the FEED (Advance) button one or more times until a label gets presented for removal. 6. During the print job, the printer will peel off the backing and present a single label. Take the label from the printer to allow the printer to print the next label. NOTE: If you did not activate the label taken sensor to detect the removal of the dispensed (peeled) label with software commands, the printed labels will stack and may bind the mechanism.
Print Operations Linerless Printing • Linerless media loads the same as models with the standard ‘tear-off’’ bezel or the general cutter factory options. Go to Loading Roll Media on page 158. • Media Reloading - Clean the printhead and inspect the media path and platen roller for build up of adhesive and debris. Remove particles with the adhesive side of your linerless media.
Print Operations Printing with the Attached Battery Base and Battery Option Printer operating procedures change slightly when using the battery. Power connections and power loss scenarios requjire differences in operation. The battery is designed to maximize battery life, maintain print quality, and have simple operation. • Connecting the printer’s external power supply to the battery will wake up the battery. The battery determines if charging is needed.
Print Operations Printer Fonts The ZD-Series printer supports your language and font requirements. The ZPL ™ programming language provides advanced font mapping and scaling technology to support outline fonts (TrueType ™ or OpenType ™ ) and Unicode character mapping as well as basic bitmapped fonts and character code pages. The printer’s font capabilities are programming language dependent.
Print Operations Asian fonts and Other Large Font Sets Asian language ideographic and pictographic fonts have large character sets with thousands of characters that support single language code page. In order to support the large Asian character sets, the industry adopted a double-byte (67840 maximum) character system instead of the single-byte characters (256 maximum) used by Latin based language characters to address large font sets.
Print Operations EPL Line Mode - Direct Thermal Printers only Your direct thermal printer supports Line Mode printing. EPL Line Mode printing is designed to be command compatible with EPL1 programming language used in early model LP2022 and LP2042 printers. The Zebra 2800 series direct thermal printers also included Line Mode printer language support. The Link-OS 4 inch Desktop continues Zebra’s support of Line Mode.
Print Operations Zebra® ZKDU — Printer Accessory The Zebra® ZKDU (keyboard display unit) is a small terminal unit that interfaces with the printer for accessing EPL or ZPL label forms stored in the printer. The ZKDU is strictly a terminal and does not have the capability to store data or set up parameters.
Print Operations Setting the Power Failure Recovery Mode Jumper The printer can be configured to re-start itself after a power failure, unattended, with Power Failure Recovery Mode. NOTE: The Power Failure Recovery Mode is only available on printers with a Printer Connectivity Module installed in your printer. The Printer Connectivity Modules have a Power Failure Recovery jumper set to OFF.
USB Host Port and Link-OS Usage Examples This section has information on using the printer’s USB Host port along with Link-OS features and Apps (applications). USB Host The USB host port allows you to connect USB devices — such as a keyboard, scanner, or USB Flash (memory) drive — to the printer. USB Host Port Uses • Firmware updates • File transfers and management • A port for low power USB data entry devices (keyboards, scales, scanners, and other wedge devices).
USB Host Port and Link-OS Usage Examples Using USB Host for Firmware Updates The USB host port allows you to connect an USB Flash drive to the printer to perform firmware updates. This is an example of using the powerful printer management, Zebra Mirror functions. Refer to the ZPL Programming Guide — Mirror and Set-Get-Do (SGD) usb.mirror commands operation. NOTE: Go to About on page 11 for information and support links for your specific printer model.
USB Host Port and Link-OS Usage Examples USB Host and Printer Usage Examples The exercises in this section will teach you how to perform USB mirror (using an alternate firmware update procedure), how to transfer files to and from the printer, and how to provide information for which you are prompted and then print a label using that information. Items Required for the USB Host Exercises To perform the exercises in this document, you will need the following: • USB Flash drive up to 1 Terabyte (TB).
USB Host Port and Link-OS Usage Examples File 4: USBSTOREDFILE.ZPL CT~~CD,~CC^~CT~ ^XA~TA012~JSN^LT0^LH0,0^JMA^PR4,4~SD15^LRN^CI0^XZ ~DG000.GRF,07680,024,,[image data] ^XA ^LS0 ^SL0 ^BY3,3,91^FT35,250^BCN,,Y,N^FC%,{,#^FD%d/%m/%Y^FS ^FT608,325^XG000.GRF,1,1^FS ^FT26,75^A0N,28,28^FH\^FDThis label was printed from a format stored^FS ^FT26,125^A0N,28,28^FH\^FDon a USB Flash Memory drive. ^FS ^BY3,3,90^FT33,425^BCN,,Y,N ^FD>:Zebra Technologies^FS ^PQ1,0,1,Y^XZ ^XA^ID000.
USB Host Port and Link-OS Usage Examples File 7: KEYBOARDINPUT.ZPL ^XA ^CI28 ^BY2,3,91^FT38,184^BCN,,Y,N^FC%,{,#^FD%d/%m/%Y^FS ^FO385,75^XGE:zebra.bmp^FS ^FT40,70^A0N,28,28^FH\^FDThis label was printed using a keyboard input. ^FS ^FT35,260^A0N,28,28^FH\^FDThis label was printed by:^FS ^FT33,319^A0N,28,28^FN1"Enter Name"^FS ^XZ This label format, used for the USB keyboard input exercise, does the following: • Creates a barcode with the current date, based on your Real-Time Clock (RTC) setting.
USB Host Port and Link-OS Usage Examples Exercise 1: Copy Files to a USB Flash Drive and Perform USB Mirror 1. On your USB Flash Drive, create the following: • a folder called Zebra • in that folder, three sub folders: • appl • commands • files 2. In the /appl folder, place a copy of the latest firmware for your printer. NOTE: Some functions may not work properly if there are underscores in a file name. Use periods instead. 2. In the /files folder, place the following file: • File 1: ZEBRA.
USB Host Port and Link-OS Usage Examples Exercise 1: Advanced User Information Refer to the ZPL Programming Guide for more information about these commands. Enable/disable mirroring: ! U1 setvar "usb.mirror.enable" "value" — Values: "on" or "off" Enable/disable automatic mirroring that occurs when a USB Flash drive is inserted into the USB host port: ! U1 setvar "usb.mirror.
USB Host Port and Link-OS Usage Examples Exercise 2: Print a Label Format from a USB Flash Drive The Print USB File option allows you to print files from a USB mass storage device, such as a USB Flash drive. Only printable files (.ZPL and .XML) may be printed from the USB mass storage device, and the files must be located at the root level, not in a directory. 1. Copy the following files to your USB Flash drive: • File 4: USBSTOREDFILE.ZPL • File 5: VLS_BONKGRF.ZPL • File 6: VLS_EIFFEL.ZPL 2.
USB Host Port and Link-OS Usage Examples 6. Touch and select Menu > Storage > USB > Print: From USB. The printer lists available files. 7. Touch the box next to the desired files. Select All is also available. 8. Touch the checkmark to print the selected files. 9. Remove the USB Flash drive from the printer.
USB Host Port and Link-OS Usage Examples Exercise 3: Copy Files to/from a USB Flash Drive The Copy USB File option allows you to copy files from a USB mass storage device to the printer’s Flash memory E: drive. 1. Copy the following files to the root directory of your USB Flash drive. Do not put these files into a sub-folder. • File 7: KEYBOARDINPUT.ZPL • File 8: SMARTDEVINPUT.ZPL 2. Insert the USB Flash drive into a USB host port on the front of your printer. 3.
USB Host Port and Link-OS Usage Examples 8. You can now copy files from the printer to a USB Flash drive using the Menu > Storage > USB > Copy: Files to USB. The option SELECT ALL is available to store all of the available files from the printer to the USB Flash drive. Any .ZPL file that is copied will be post-processed such that the contents of the file will be suitable to be sent to a printer for normal execution.
USB Host Port and Link-OS Usage Examples Exercise 4: Enter Data for a Stored File with a USB Keyboard and Print a Label The Print Station feature allows you to use a USB Human Interface Device (HID), such as a keyboard or a barcode scanner, to enter ^FN field data into a *.ZPL template file. 1. After performing the previous exercise, plug a USB keyboard into a USB host port. 2. Touch Menu > Print. 3. Touch Menu > Print > Print Station. The printer loads any executable files and processes them.
USB Host Port and Link-OS Usage Examples Using the USB Hosts Port and the NFC Capabilities The Zebra Print Touch ™ feature allows you to touch an Android ™ -based, Near Field Communication (NFC)-enabled device such as a smart phone or tablet to the printer’s Print Touch logo to pair the device to the printer. This capability allows you to use your device to provide information for which you are prompted and then print a label using that information.
USB Host Port and Link-OS Usage Examples Exercise 5: Enter Data for a Stored File with a Smart Device and Print a Label NOTE: The steps in this exercise may vary somewhat based on your smart device, on your service provider, or on whether you already have the free Zebra Utilities app installed on your smart device. Refer to the Zebra Bluetooth User Guide for specific instructions for configuring your printer to use a Bluetooth interface. A copy of this manual is available at: zebra.com/manuals. 1.
USB Host Port and Link-OS Usage Examples 6. Enter your name at the prompt. 7. Change the quantity of labels to print, if desired. 8. Tap PRINT to print the label.
Maintenance This section provides routine cleaning and maintenance procedures. Cleaning Your Zebra printer may require periodic maintenance to keep your printer functional and printing high quality labels, receipts, tags, etc. Cleaning Supplies The following printer cleaning supplies are recommended for use with your printer: • • Printhead Cleaning Pens for simple operator printhead cleaning. 99.7% pure Isopropyl Alcohol (Use a labeled dispenser.
Maintenance Recommended Cleaning Schedule Printhead Interval: Clean the printhead after every 5 rolls printed. Procedure: Cleaning the Printhead on page 243 Standard Platen (Drive) Roller Interval: As needed to improve print quality. Platen rollers can slip causing print image distortion and in worst case scenarios not move the media (labels, receipts, tags, etc.). Procedure: Go to Platen Cleaning and Replacement on page 255.
Maintenance Interior Interval: Clean the printer as needed. Method: Use a soft cloth, brush or compressed air to wipe or blow dust and particles out of the printer. Use 90% isopropyl alcohol and a fiber-free cleaning cloth to dissolve contaminants like oils and grime. Exterior Interval: Clean as needed. Method: Use a soft cloth, brush or compressed air to wipe or blow dust and particles out of the printer. The exterior of the printer can be cleaned using plain soap and water solutions to moisten the cloth.
Maintenance Cleaning the Printhead Always use a new cleaning pen on the printhead (an old pen carries contaminants from its previous use that may damage the printhead). When you load new media, you should clean the printhead for optimal print operations. CAUTION—HOT SURFACE: The printhead becomes hot while printing. To protect from damaging the printhead and risk of personal injury, avoid touching the printhead. Only use the cleaning pen to perform printhead maintenance.
Maintenance ZD621 / ZD421 Thermal Transfer Printers When you load new media or ribbon, you can also clean the printhead. 1. If transfer ribbon is installed, remove it before proceeding. 2. Rub the cleaning pen across the dark area of the printhead. Clean from the middle to the outside. This will move adhesive transferred from the edges of media to the outside of media path. 3. Wait one minute before closing the printer or loading ribbon to allow all components to dry.
Maintenance ZD421 Ribbon Cartridge Printers 1. Pull the two (2) Release Arms out to release the Ribbon Drive Transport. Go to Accessing the Printhead of the Ribbon Cartridge Printer on page 29 for more details. 2. Lift the Printhead Actuator Arm up to gain access to the printhead. Rub the cleaning pen across the dark area of the printhead. Clean from the middle to the outside. This will move adhesive transferred from the outer edges of media to the area outside of media path. 3.
Maintenance Media Path Cleaning Use a cleaning swab and/or a lint free cloth to remove debris, dust or crust that has built-up on the holders, guides and media path surfaces. Lightly moisten the swab or cloth with 99% solution isopropyl alcohol. For hard to clean areas, use extra alcohol on a cleaning swab to soak the debris to break up any adhesive that may have accumulated on surfaces in the media compartment. Do not clean the printhead, sensors, or platen as part of this process.
Maintenance Upper Half of ZD621/ZD421 Direct Thermal Printers 1. Wipe the areas (outlined in orange) to remove adhesive and other contaminants. Do not clean the sensor array. Don’t Clean Sensor Upper Half of ZD621/420 Thermal Transfer Printers 1. Wipe the area (outlined in orange) near the printhead on the front of the ribbon carriage.
Maintenance Upper Half of ZD421 Thermal Transfer Ribbon Cartridge Printers 1. Pull the two (2) Release Arms out to release the Ribbon Drive Transport. Go to Accessing the Printhead of the Ribbon Cartridge Printer on page 29 for more details. 2. Wipe the areas (outlined in orange) below the Printhead Actuator Arm and the Ribbon Drive Transport. Don’t Clean Sensor 3. Release the Printhead Actuator Arm and then push the Ribbon Drive Transport into the Printhead Actuator Arm.
Maintenance Cleaning the Cutter and Label Dispenser Options This is a continuation of cleaning the media path for either option, if installed. Cutter Option Cleaning IMPORTANT: The plastic media path surfaces can be cleaned but not the internal cutter blades or mechanism. The cutter blade mechanism does not require maintenance cleaning. DO NOT clean the blade. This blade has a special coating to resist adhesives and wear. CAUTION: There are no operator serviceable parts in the cutter unit.
Maintenance Label Dispenser Option Cleaning 1. Open the door and clean the peel bar, inner surfaces and ridges on the door. 2. Wipe the roller while rotating it. Discard the swab or cloth. Clean again to remove diluted residue. 3. Clean the sensor window. The window should be clear of streaks and residue.
Maintenance Sensor Cleaning Dust can accumulate on the media sensors. Do not use an air compressor to remove dust. Compressors add moisture, fine grit, and lubricant which can contaminate your printer. Lower Half of ZD60/ZD421 Printers 1. Clean the Movable Sensor’s window. Gently brush away dust or use a can of compressed air; if necessary, use a dry swab to brush away dust. If adhesives or other contaminants remain, use an alcohol moistened swab to break it up. 2.
Maintenance Upper Half of ZD621/ZD421 Direct Thermal Printers 1. Spray the Upper Web (Gap) Array Sensor below the printhead with a can of compressed air. If necessary, use an alcohol moistened swab to break up adhesive or other non-dust contaminants. Use a dry swab to remove any residue that may be left from the first cleaning. Upper Half of ZD621/ZD421 Thermal Transfer Printers 1. Spray the Upper Web (Gap) Array Sensor below the printhead with a can of compressed air.
Maintenance Upper Half of ZD421 Ribbon Cartridge Printers 1. Pull the two (2) Release Arms out to release the Ribbon Drive Transport. Go to Accessing the Printhead of the Ribbon Cartridge Printer on page 29 for more details. 2. Swing the Printhead Actuator Arm up until it touches the printer’s top cover. Hold the Printhead Actuator Arm in this position for access to the area below the printhead. 3.
Maintenance Cleaning Ribbon Cartridge Sensor 1. Ribbon Cartridge Sensor Pins - Only clean when the cartridges are failing detection. Clean the Ribbon Cartridge interface pins with a gentle wiping from right to left. Up and down motions may damage the pins. .
Maintenance Platen Cleaning and Replacement The platen (drive roller) normally does not require cleaning. Normally, paper and liner dust can accumulate without affecting print operations. Clean the platen (and media path) whenever the printer has significantly poorer performance, print quality or media handling. The platen is the print surface and drive roller for your media. If sticking or jamming continues even after cleaning, you must replace the platen.
Maintenance Removing the Platen Roller The platen can be cleaned with a fiber-free swab (such as a Texpad swab) or a lint free, clean, damp cloth very lightly moistened with medical grade alcohol (90% pure or better). 1. Open the cover (and dispenser door, if the dispenser is installed). Remove media from platen area. 2. Pull the platen bearing latch release tabs on the right and left sides towards the front of the printer and rotate them up.
Maintenance 3. Lift the platen out of the printer’s bottom frame. Platen Bearings 4. Slide the gear and the two (2) bearings off the shaft of the platen roller.
Maintenance 5. Cleaning Only — Clean the platen with the alcohol moistened swab. Clean from the center out. Repeat this process until all of the roller surface has been cleaned. If there has been heavy adhesive build-up or label jam, repeat with a new swab to remove residual contaminants. Adhesives and oils, for example, may be thinned by the initial cleaning but not completely removed. Discard the cleaning swabs after use - do not reuse.
Maintenance Replacing the Printhead If you need to replace the printhead, read the procedure and review the removal and installation steps before actually replacing the printhead. CAUTION—ESD: Prepare your work area by protecting against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself.
Maintenance ZD621 and ZD421 Direct Thermal Removing the Printhead 1. Turn the printer OFF. Open the printer. Printhead 2. Push the printhead release latch away from the printhead. The right side of printhead releases. 3. Swing the loose right side of the printhead out of the printer. Pull it out and to the right a little to get the left side of the printhead clear. Pull the printhead out and free of the top cover to gain access to its attached cables on the backside of the printhead.
Maintenance 4. Gently but firmly pull the two printhead cable bundle connectors off of the printhead. Pull the ground wire off the printhead.
Maintenance Replacing the Printhead 1. Push the right side printhead cable connector into the printhead. The connector is keyed to only insert one way. 2. Attach the ground wire to the printhead’s ground tab. 3. Push the left side printhead cable connector onto the printhead. Printhead Ground Wire Connector with Key Printhead Ground Tab Spring Wire Notch 4. Insert the left side of the printhead assembly into the recessed slot (highlighted in red) on the left side of the printer.
Maintenance 5. Align the Spring Wire Notch on the backside of the printhead to the Spring Wire. Push the right side of the printhead into the printer until the latch locks the right side of the printhead into the printer. Spring Wire in Notch 6. Verify that the printhead moves up and down freely when pressure is applied and remains locked when released. 7. Clean the printhead. Use a new pen to wipe body oils (finger prints) and debris of the printhead.
Maintenance ZD621 and ZD421 Thermal Transfer Ribbon Roll Removing the Printhead 1. Turn the printer OFF. Open the printer. Printhead 2. Push the printhead release latch toward the printhead (shown as green for visibility). The right side printhead releases down and away from the Printhead Actuator Arm.
Maintenance 3. Swing the loose right side of the printhead out of the printer. Pull it to the right a little to get the left side of the printhead clear. Pull the printhead down and free of the ribbon carriage to gain access to its attached cables. 4. Gently but firmly pull the two printhead cable bundle connectors off of the printhead.
Maintenance Replacing the Printhead 1. Push the right side printhead cable connector into the printhead. The connector is keyed to only insert one way. 2. Push the left side printhead cable connector onto the printhead. 3. Insert the center tab on the printhead assembly into the center slot on the Printhead Actuator Arm.
Maintenance 4. Insert the left side tab of the printhead assembly into the recessed slot on the left side of the Printhead Actuator Arm. Slot Tab 5. Push the right side of the printhead into the printer until the latch locks the right side of the printhead into the printer.
Maintenance 6. Verify that the printhead moves up and down freely when pressure is applied and remains locked when released. 7. Clean the printhead. Use a new pen to wipe body oils (finger prints) and debris of the printhead. Clean from the center of the printhead to the outside. Go to Cleaning the Printhead on page 243. 8. Reload media. Plug in the power cord, turn on the printer and print a status report to ensure proper function. Go to Test Printing with the Configuration Report on page 178.
Maintenance ZD421 Thermal Transfer Ribbon Cartridge Printhead Removal 1. Turn the printer OFF. Open the printer. 2. Pull the two (2) Release Arms out to release the Ribbon Drive Transport. Go to Accessing the Printhead of the Ribbon Cartridge Printer on page 29 for more details. 3. Swing the Printhead Actuator Arm up until it touches the printer’s top cover. Hold the Printhead Actuator Arm in this position for access to the printhead.
Maintenance 5. Gently but firmly pull the two printhead cable bundle connectors off of the printhead.
Maintenance Replacing the Printhead 1. Push the right side printhead cable connector into the printhead. The connector is keyed to only insert one way. 2. Push the left side printhead cable connector onto the printhead. 3. Insert the center tab on the printhead assembly into the center slot on the Printhead Actuator Arm. Tab Slot 4. Insert the left side tab of the printhead assembly into the recessed slot on the left side of the Printhead Actuator Arm.
Maintenance 5. Push the right side of the printhead into the printer until the latch locks the right side of the printhead into the printer. Slot Guide 6. Verify that the printhead moves freely into the printer when pressure is applied (see arrow) and remains locked when pressure is released. 7. Clean the printhead by using a new cleaning pen to wipe body oils (fingerprints) and debris off the printhead. Go to Cleaning the Printhead on page 243. 8. Reload media.
Maintenance Updating Printer Firmware The printer’s firmware may need to be updated periodically to get new features, improvements, and printer upgrades for media handling and communications. Use Zebra Setup Utilities (ZSU) to load new firmware. 1. Open Zebra Setup Utilities. 2. Select your installed ZD621/ZD421 printer. 3. Click on the ‘Open Printer Tools’ button and a ‘Tools’ window will open. 4. Click on the ‘Action’ tab. 5. Load the printer with media. Go to Loading Roll Media on page 158. 6.
Troubleshooting This section provides troubleshooting procedures and information. Resolving Alerts and Errors Alert: Printhead Open A print command or a FEED button has been pressed and the printer has detected that the printhead (cover) is not closed. Possible Cause - 1 The cover is open or has not been closed properly. Resolution Close the cover/printhead. Push down on the front top corners of the printer’s cover.
Troubleshooting Alert: Media Out A print command, a FEED button has been pressed, or you are printing; and the printer can not detect media in the print path. Possible Cause - 1 There is no media (roll) in the printer. Resolution Load your chosen media in the printer and close the printer. You may need to press the FEED button once or the PAUSE button the get the printer to resume your print operation. Go to Loading Roll Media on page 158.
Troubleshooting Resolution Check the position of the media sensor is in the center default location. Go to Using the Movable Sensor on page 162. The printer may need to be calibrated for the media after the adjusting the sensor location. Go to Run a SmartCal Media Calibration on page 177. Possible Cause - 5 The media sensor is dirty. Resolution Clean the Upper Web (Gap) Sensor Array and the lower Movable Media sensors. Go to Sensor Cleaning on page 251.
Troubleshooting Alert: Ribbon In (ZD421 Cartridge Printer only) A print command has been sent to the printer and it is in Direct Thermal Mode with Ribbon installed. NOTE: The printer has two different heat settings - one for Direct Thermal and one for Thermal Transfer. They are designed to have equivalent print density/darkness at the same setting level. Possible Cause - 1 There is a Ribbon Cartridge in the printer while the printer is set to Direct Thermal Mode (and printing on direct thermal media).
Troubleshooting Alert: Ribbon Out • The printer is printing and stops while printing. • A print job has been sent to the printer and the printer immediately reports this Alert. Possible Cause - 1 The printer has detected the end of the ribbon. The end of the ribbon has a reflective trailer on the end of Genuine Zebra Transfer Ribbon that the printer ‘sees’ as End of Ribbon. Resolution Remove the ribbon and replace the ribbon rolls or ribbon cartridge in the printer without turning the printer OFF.
Troubleshooting Possible Cause - 4 (Standard Roll - Thermal Transfer Printers) The media sensing is not working. Resolution 1. Reload the printer’s firmware. Go to Updating Printer Firmware on page 273. 2. If this does not fix this issue, call a service technician. Alert: Ribbon Low (ZD421 Cartridge Printer only) The printer reports this Alert. Possible Cause - 1 The printer has calculated that the ribbon cartridge has only 10% of the ribbon left in the cartridge.
Troubleshooting Alert: CUT ERROR The cutter blade is bound and is not moving properly. Possible Cause - 1 Media, adhesive, or external object has stopped the cutter blade from operating. Resolution 1. Turn the printer off by holding the power button down for 5 seconds. Wait for the printer to shutdown completely. Turn the printer on. 2. If the printer does not recover from this error, call a service technician. This is not a operator serviceable item.
Troubleshooting Alert: PRINTHEAD OVER TEMP The printhead is over temperature and paused to allow the printhead to cool. Possible Cause - 1 The printer is printing a large batch job, typically with large amounts of print. Resolution The print operation will resume after the printhead has cooled. Possible Cause - 2 The ambient temperature at the printers location exceeds the specified operating range. Sometimes, ambient temperatures in the printer can be higher if it is in direct sunlight.
Troubleshooting Alert: PRINTHEAD SHUTDOWN The printhead is below operating temperature for proper printing. Possible Cause - 1 Printhead has had a critical current or power failure Resolution 1. Turn the printer off by holding the power using the POWER button down for 5 seconds. Wait for thee printer to shutdown completely. Turn the printer on. 2. If the printer does not recover from this error, call a service technician. This is not a operator serviceable item.
Troubleshooting Alert: PRINTHEAD UNDER TEMP The printhead is below operating temperature for proper printing. Possible Cause - 1 The ambient temperature at the printers location is below the specified operating range. Resolution Turn the printer off. Move the printer location and wait for it to warm naturally. Moisture may condense in and on the printer if the temperature changes too quickly. Possible Cause - 2 The printhead thermistor has failed. Resolution 1.
Troubleshooting Alert: OUT OF MEMORY Data can not be stored in the specified memory location. There are four types of storage memory: Graphic, Format, Bitmap and Font. There is not enough memory to perform the function specified on the second line of the error message. Possible Cause - 1 There is not enough memory to perform the function specified on the second line of the error message. Resolution 1.
Troubleshooting Resolving Print Issues This section helps you identify issues with printing or print quality, the possible causes, and the recommended solutions. Issue: General Print Quality Issues The printed image does not look right. Possible Cause - 1 The printer is set at an incorrect darkness level and/or print speed. Resolution Perform the Print Quality Report (FEED self test) to determine the ideal darkness and speed settings for your application.
Troubleshooting Possible Cause - 6 You may be using the wrong power supply. Resolution Verify you are using the power supply that came with this printer. Issue: No Print on the Label The printed image does not look right. Possible Cause - 1 The media may not be direct thermal media (and is thermal media made for thermal transfer printers). Resolution Go to the test procedure Determining Thermal Media Types on page 334. Possible Cause - 2 Media has been loaded incorrectly.
Troubleshooting Issue: Labels Are Distorted in Size or Print Area Start Position Varies Includes printed image that skips between labels (mis-registration). Possible Cause - 1 Media has been loaded incorrectly or the movable media sensor is not set properly. Resolution Verify that the sensor is set and positioned correctly for your media type and sensing location. Go to Loading Roll Media on page 158 ,Setting Media Sensing by Media type on page 158, and Using the Movable Sensor on page 162.
Troubleshooting Communication Issues This section identifies problems with communications, the possible causes, and the recommended solutions. Issue: Label Job Sent, No Data Transfer A label format was sent to the printer but was not recognized. The DATA light does not flash. Possible Cause The communication parameters are incorrect. Resolution - 1 Check the printer driver or software communications settings (if applicable).
Troubleshooting Issue: Label Job Sent, Data Transfers, But No Print A label format was sent to the printer but was not recognized. The DATA light flashes but no printing occurs. Possible Cause - 1 The prefix and delimiter characters set in the printer do not match the ones in the label format. Resolution Verify the ZPL command prefix (COMMAND CHAR) and delimiter (DELIM./CHAR) characters. Configuration Setting to Command Cross-reference on page 341.
Troubleshooting Miscellaneous Issues This section identifies miscellaneous issues with the printer, the possible causes, and the recommended solutions. Issue: Settings are Lost or Ignored Some parameters are set incorrectly. Possible Cause - 1 Printer settings were changed without saving them. Resolution The ZPL ^JU command was not used to save your configuration before turning the printer off. Cycle the printer OFF and then back ON to verify settings have been saved.
Troubleshooting Issue: Non-continuous labels act as Continuous labels. A non-continuous label format with matching media loaded in the printer, was sent to the printer but prints like it is continuous media. Possible Cause - 1 The printer was not calibrated for the media being used. Possible Cause - 2 The printer is configured for continuous media.
Troubleshooting 3. Reload printer firmware. Go to Updating Printer Firmware on page 273. 4. If the printer does not recover from this error, call a service technician. This is not a user serviceable item. Issue: Battery has a Red Indicator Battery has a fault. Possible Cause - 1 The battery has reached its usable life or has a general component failure. Possible Cause - 2 Battery is too hot or too cold Resolution 1. Remove the battery from the printer and check charge status by charging the battery. 2.
Tools This section provides a variety of tools and utilities built into your printer. They are designed to assist you with setup, configuration, and debugging (printer and command programming) Printer Diagnostics Diagnostic reports, calibration procedures, restoring factory defaults, and other diagnostics provide specific information about the condition of the printer. IMPORTANT: Use full-width media when performing self tests.
Tools 3. The printer will FEED and measure several labels. When done, the printer will return to READY status. If the printer should fail to recognize and correctly calibrate to the media, please refer to the Manual Media Calibration procedure later in this section. Configuration Report (CANCEL Self Test) The Configuration Report diagnostic prints a set of printer and network configuration reports. To print the configuration report, complete these steps: 1.
Tools Printer Network (and Bluetooth) Configuration Report ZD-Series printers with Wired or Wireless connectivity options installed will print an additional printer configuration report. This information needed to establish and trouble shoot Ethernet (LAN and WLAN), Bluetooth 4.1 and Bluetooth LE network printing. The following printout is printed with the ZPL ~WL command. iOS Support Setting iOS Bluetooth Support • iOS devices have Bluetooth Classic 4.
Tools Print Quality Report (FEED self test) Different types of media may require different darkness settings. This section contains a simple but effective method for determining the ideal darkness for printing barcodes that are within specifications. During the Print Quality Report (FEED self test), a series of labels are printed at different darkness settings at two different print speeds. The relative darkness and the print speed are printed on each label.
Tools 4. See Figure 2 and Table 1. Inspect the test labels and determine which one has the best print quality for your application. If you have a barcode verifier, use it to measure bars/spaces and calculate the print contrast. If you do not have a barcode verifier, use your eyes or the system scanner to choose the optimal darkness setting based on the labels printed in this self test.
Tools Table 1 Visual Darkness Descriptions Print Quality Too dark Slightly dark “In-spec” Slightly light Too light Description • 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 appear filled in. • Rotated barcode have bars and spaces run together. • Slightly dark labels are not as obvious. • The normal barcode will be “in-spec.
Tools Reset Printer Factory Defaults (PAUSE + FEED Self Test) This resets the printer configuration to the factory default values for the non-network printer settings. Perform a sensor calibration after this procedure. (Go to Manual Media Calibration on page 303.) To perform a Reset Printer Factory Defaults procedure, complete these steps: 1. Turn OFF the printer. 2. Press and hold PAUSE + FEED while turning ON the printer. 3. Hold PAUSE + FEED until the STATUS indicator ( ) is the only indicator lit.
Tools Reset Button In addition to the power on configurations described previously, the ZD-Series printer has a dedicated reset button located on the bottom of the printer which can be pressed with a paperclip or similar small object.
Tools Communication Diagnostics Test The communication diagnostics test is a troubleshooting tool for checking the connection between the printer 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 printer prints all characters received, including control codes such as CR (carriage return). Figure 3 shows a typical test label from this test.
Tools Sensor Profile Use the sensor profile image (which will extend across several labels or tags) 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. With the printer in the Ready state, print a sensor profile in one of these ways: Using the buttons on the user interface 1. Turn OFF the printer. 2.
Tools Figure 5 Sensor Profile (Black Mark Tag Media) 5 5 1 2 4 4 3 Advanced Mode Advanced Mode is used to access several manual adjustment modes in the printer. Each manual adjustment mode is described in detail in the following sections. To activate Advanced Mode, complete these steps: 1. Ensure media is loaded and printer power is ON. 2. Press PAUSE for two seconds, all indicators will flash yellow. 3.
Tools Manual Print Width Adjustment While in Advanced Mode, pressing the PAUSE button while the Pause indicator is illuminated yellow will start Manual Print Width Adjustment while in Advanced mode, go to Advanced Mode on page 303. The printer will print a 16mm (0.63 in.) box and pause momentarily. The printer will then print a slightly larger box and again pause. When you see the printer print a box that matches the width of your media, press FEED to set the print width and return to READY state.
Tools Manual Print Darkness Adjustment Pressing PAUSE while the DATA indicator( ) is illuminated yellow will start Manual Print Darkness Adjustment. The printer will print a test pattern showing the current darkness number and several barcode patterns and then pause momentarily. The printer will then repeat the pattern with the next darkness level. When you see the printer print a pattern with solid even black lines, press FEED to set the darkness value and return to the READY state.
Tools Factory Test Modes The printer includes print modes that are intended for factory test only. Test mode 1 Initiated by holding PAUSE button while turning ON printer power. When activated, the printer will begin printing various test patterns used to evaluate printer performance. Test mode 2 Initiated by holding PAUSE + FEED + CANCEL button for two seconds while printer power is ON. When activated, the printer will begin printing various test patterns used to evaluate printer performance.
Interface Wiring Universal Serial Bus (USB) Interface The figure below displays the cable wiring required to use the printer’s USB two interfaces. IMPORTANT: When using third party cables, the printer requires USB cables or the cable packaging that bears the “Certified USB ™ ” mark to guarantee USB 2.0 compliance. A B usb.org Wiring - USB Connector “A” Style for “connecting to” the printer or device Pin 1 — Vbus (+5VDC).
Interface Wiring Serial Port Interface Zebra Auto-Detecting DTE and DCE for 9-Pin RS-232 Interface Pin DTE DCE Description (DTE) 1 — 5V 2 RXD TXD RXD (receive data) input to the printer 3 TXD RXD TXD (transmit data) output from the printer 4 DTR DSR DTR (data terminal ready) output from the printer -- controls when the host may send data 5 GND GND Circuit ground 6 DSR DTR DSR (data set ready) input to the printer 7 RTS CTS RTS (request to send) output from the printer -- alway
Interface Wiring Connecting the Printer to a DCE Device DB-25S Connector to DCE Device DB-9P Connector to Printer DB-9S Connector to DCE Device DB-9P Connector to Printer Interconnecting to DCE Devices — When the printer is connected via its RS-232 interface to data communication equipment (DCE) such as a modem, a STANDARD RS-232 (straight-through) interface cable must be used.
Dimensions This section provides external printer dimensions for the following printers: • ZD621 / ZD421 Thermal Transfer Models on page 311. • ZD421 Ribbon Cartridge Thermal Transfer Models on page 319. • ZD621 / ZD421 Direct Thermal Models on page 327.
Dimensions ZD621 / ZD421 Thermal Transfer Models All dimension are in millimeters 266.7 202.3 192.4 Standard Printer 371.0 348.0 Standard Printer 372.
Dimensions ZD621 / ZD421 Thermal Transfer Models All dimension are in millimeters 289.2 202.3 192.4 Printer with Label Dispenser (open) 371.0 348.0 Printer with Label Dispenser (open) 413.
Dimensions ZD621 / ZD421 Thermal Transfer Models All dimension are in millimeters 285.6 202.3 194.2 Printer with Cutter 371.0 348.0 Printer with Cutter 410.
Dimensions ZD621 / ZD421 Thermal Transfer Models 0 All dimension are in millimeters 202.3 236.4 Printer with Attached Power Supply Base 307.8 (DISPENSER OPEN) 304.1 (CUTTER) 285.
Dimensions ZD621 / ZD421 Thermal Transfer Models All dimension are in millimeters 415.0 392.0 372.7 (STANDARD) 389.1 (DISPENSER) 410.1 (CUTTER) 413.
Dimensions ZD621 / ZD421 Thermal Transfer Models All dimension are in millimeters 247.0 Printer with Attached Battery Base and Battery 275.0 291.
Dimensions ZD621 / ZD421 Thermal Transfer Models All dimension are in millimeters 415.0 392.0 Printer with Attached Power Supply Base 374.9 ( 1 — BATTERY BASE) 389.1 ( 2 — DISPENSER) 410.1 ( 3 —CUTTER) 413.
Dimensions ZD621 / ZD421 Thermal Transfer Models Dimensions are in millimeters (mm) Use M3 thread forming screws with maximum hole depth of 6 mm into the printer body. Note - Do not remove the rubber feet or the printer can overheat. 148.8 Mounting Holes Hardware Reset Access (Provide 20-25 mm hole in mounting plate or surface) 139.0 Mounting Holes 9.0 130.
Dimensions ZD421 Ribbon Cartridge Thermal Transfer Models All dimension are in millimeters 202.3 176.4 Standard Printer 254.
Dimensions ZD421 Ribbon Cartridge Thermal Transfer Models All dimension are in millimeters 354.5 346.9 Standard Printer 311.
Dimensions ZD421 Ribbon Cartridge Thermal Transfer Models All dimension are in millimeters Printer with Label Dispenser 289.5 264.
Dimensions ZD421 Ribbon Cartridge Thermal Transfer Models All dimension are in millimeters Printer with Label Dispenser (open) 352.
Dimensions ZD421 Ribbon Cartridge Thermal Transfer Models All dimension are in millimeters 285.8 Printer with Cutter Printer with Cutter 348.
Dimensions ZD421 Ribbon Cartridge Thermal Transfer Model All dimension are in millimeters Printer with Attached Power Supply Base 220.9 Printer with Attached Power Supply Base 264.6 272.
Dimensions ZD421 Ribbon Cartridge Thermal Transfer Model All dimension are in millimeters 231.5 Printer with Attached Battery Base with Battery Printer with Attached Battery Base with Battery 274.5 278.
Dimensions ZD421 Ribbon Cartridge Thermal Transfer Models Dimensions are in millimeters (mm) 1 Hardware Reset Access — Provide 20-25 mm hole in mounting plate or surface. 2 Mounting Holes 148.8 1 139.0 2 9.0 130.8 Use M3 thread forming screws with maximum hole depth of 6 mm into the printer body. Note - Do not remove the rubber feet or the printer can overheat.
Dimensions ZD621 / ZD421 Direct Thermal Models All dimension are in millimeters 177.5 220.8 150.7 291.0 286.0 282.
Dimensions ZD621 / ZD421 Direct Thermal Models All dimension are in millimeters 234.6 Printer with Label Dispenser Printer with Label Dispenser 286.3 328 235.3 271.
Dimensions ZD621 / ZD421 Direct Thermal Models All dimension are in millimeters 244.5 Printer with Cutter Printer with Cutter 317.
Dimensions ZD621 / ZD421 Direct Thermal Models All dimension are in millimeters Printer with Attached Power Supply Base 328.0 343.
Dimensions ZD621 / ZD421 Direct Thermal Models All dimension are in millimeters 194.5 Printer with Attached Battery Base and Battery 328 343.0 Printer with Attached Battery Base and Battery 220.0 331 286.
Dimensions ZD621 / ZD421 Direct Thermal Models All dimension are in millimeters 207.7 182.3 Optional: Locking Media Cabinet Lock and Key 220.8 34.9 Optional: Locking Media Cabinet Lock and Key 42.
Dimensions ZD621ZD621 / ZD421 Direct Thermal Models Dimensions are in millimeters (mm) 1 Mounting Holes 2 Hardware Reset Access — Provide 20-25 mm hole in mounting plate or surface. 55.0 10.0 1 2 3.0 1 116.0 130.0 Use M3 thread forming screws with maximum hole depth of 6 mm into the printer body. IMPORTANT: Do not remove the rubber feet or the printer can overheat.
Media This section provides a simple media overview for your printer. Types of Thermal Media IMPORTANT: Zebra strongly recommends the use of Zebra-brand supplies in order to ensure consistent high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the printing capabilities of the printer and to prevent premature printhead wear. To purchase supplies, go to zebra.com/howtobuy.
Media General Media and Print Specifications • Direct Thermal — Max. Media width: 108mm (4.25 in.) • Thermal Transfer ZD621, ZD621R, ZD421 Cartridge — Max. Media width: 112mm (4.09 in.) • Thermal Transfer ZD421, ZD421CN — Max. Media width: 118mm (4.65 in.) • All Printers — Min. Media width: 15mm (0.585 in.) • Media length: • • 990mm (39 in.) max. • 6.35mm (0.25 in.) min. – Tear Off or Label • 12.7mm(0.50 in.) min. – Peel • 12.7mm (0.50 in.) min. - Cutter Media thickness: • 0.06mm (0.
Media • • • Ribbon Length - 74 m (243 feet) • Ribbon Width Max. - 110 mm (4.33 in.) • Ribbon Width Min. - 33 mm (1.3 in.) ‡ • Colors available in Black - Wax, Wax Resin, and Resin transfer materials Dot pitch: • 203 dpi: 0.125mm (0.0049 in.) • 300 dpi: 0.085mm (0.0033 in.) Barcode modulus x-dim: • 203 dpi: 0.005-0.050 in. • 300 dpi: 0.00327 - 0.03267 in.
Media Standard (Media) Cutter The printer supports a field installed media cutter option for full width cutting of label liner, tag or receipt media. • A medium duty cutter for cutting label liner and light tag media (LINER/TAG). Do not cut through labels, adhesive or embedded circuitry. • Paper Thickness: • • Min. 0.06 mm (0.0024 in.) • Max. 0.1905 mm (0.0075 in.) Cut Width: • Min.15 mm (0.585 in.) • Thermal Transfer ZD621, ZD621R, and ZD421 Cartridge Max. 118 mm (4.65 in.
Media Table 2 Types of Media Roll and Fanfold Media Media Type Non-Continuous Roll Media How It Looks Description Labels have adhesive backing that sticks them to a liner. Tags (or tickets) are separated by perforations. Individual labels or tags are tracked and position controlled by one or more of the following methods: 1. Web media separates labels by gaps, holes, or notches. 2. Black mark media uses pre-printed black marks on the back side of the media to indicate label separations. 3.
ZPL Configuration This section provides an overview of managing printer configuration, the Configuring Status Report, and Printer and Memory Printouts. Managing the ZPL Printer Configuration The ZPL printer is designed to allow you to change printer settings dynamically for fast first label out printing. Printer parameters that are persistent will be retained for future formats to use.
ZPL Configuration ZPL Printer Configuration Format Managing more than one printer can be done by creating a printer configuration programming file to send to one or more printers or ZebraNet™ Bridge can be used to clone a printer’s setup. Figure 1 below shows the basic structure of a ZPL programming configuration file. Refer to the ZPL programmer’s guide and the Configuration Setting to Command Cross-reference to create a programming file.
ZPL Configuration Configuration Setting to Command Cross-reference The Printer Configuration Report, shown below, provides a listing of a majority of the configurations settings that can be set by ZPL command.
ZPL Configuration Table 3 ZPL Commands and Configuration Report Callout Cross-Reference Command Listing Name Description ~SD DARKNESS Default: 10.0 — DARKNESS SWITCH LOW (Default), MEDIUM, or HIGH ^PR PRINT SPEED Default: 152.4 mm/s / 6 IPS (max.) - 203 dpi 101.6 mm/s / 4 IPS (max.
ZPL Configuration The configuration settings listed here resume after the TAKE LABEL sensor value. These listings contain printer features seldom changed from default or provide status information.
ZPL Configuration Printer Memory Management and Related Status Reports To help you manage printer resources, the printer supports a variety of format commands to manage memory, transfer objects (between memory areas, import and export), object naming, and provide various printer operating status reports. They are very similar to the old DOS commands like DIR (directory listing) and DEL (delete file). The most common reports are also part of the Zebra Setup Utility and ZebraDesigner ™ Windows driver.
ZPL Configuration Table 5 Object Management and Status Report Commands Command Name Description ^WD Print Directory Label Prints a list of objects and resident barcodes and fonts in all addressable memory locations ~WC Print Configuration Label Prints a configuration Status Receipt (Label) Same as FEED Button mode one flash routine ^ID Object Delete Deletes objects from printer memory ^TO Transfer Object Used to copy an object or group of objects from one memory area to another.
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