LabelZone Zebra Zd500 ZD500™ Series Users Guide (en) User Manual

Zd500 Userguide ZD500_UserGuide

Zebra-Thermal-Transfer-Printer-Zd500-Users-Manual-342274 zebra-thermal-transfer-printer-zd500-users-manual-342274

ZD500 to the manual 29970017-1100-4b98-8178-88d9a07dd443

2017-09-13

User Manual: LabelZone Zebra Zd500

Open the PDF directly: View PDF .
Page Count: 160 [warning: Documents this large are best viewed by clicking the View PDF Link!]

Contents
Introduction
Setup
Printer Configuration
Print Operations
Printer Options
Maintenance
Troubleshooting
Appendix: Interface Wiring
- Serial Port Interface
Appendix: Dimensions
- External ZD500 Series™ Printer Dimensions

User’s Guide

Thermal Transfer Printer

ZD500 Series™

P1062653-002 Rev. A

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

label printer and accessories described therein are owned by ZIH Corp. Unauthorized

reproduction of this manual or the software and/or firmware in the label printer may result in

imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators

may be subject to civil liability.

This product may contain ZPL®, ZPL II®, and ZebraLink™ programs; Element Energy

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

reserved worldwide.

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

Zebra, the Zebra logo, ZPL, ZPL II, Element Energy Equalizer Circuit, and E3 Circuit are

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

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

website.

www.zebra.com/copyright

Proprietary Statement This manual contains proprietary information of Zebra

Technologies Corporation and its subsidiaries (“Zebra Technologies”). It is intended solely for

the information and use of parties operating and maintaining the equipment described herein.

Such proprietary information may not be used, reproduced, or disclosed to any other parties

for any other purpose without the express, written permission of Zebra Technologies.

Product Improvements Continuous improvement of products is a policy of Zebra

Technologies. All specifications and designs are subject to change without notice.

Liability Disclaimer Zebra Technologies takes steps to ensure that its published

Engineering specifications and manuals are correct; however, errors do occur. Zebra

Technologies reserves the right to correct any such errors and disclaims liability resulting

therefrom.

Limitation of Liability In no event shall Zebra Technologies or anyone else involved in the

creation, production, or delivery of the accompanying product (including hardware and

software) be liable for any damages whatsoever (including, without limitation, consequential

damages including loss of business profits, business interruption, or loss of business

information) arising out of the use of, the results of use of, or inability to use such product,

even if Zebra Technologies has been advised of the possibility of such damages. Some

jurisdictions do not allow the exclusion or limitation of incidental or consequential damages,

so the above limitation or exclusion may not apply to you.

iii

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

Compliance and Regulatory Statements

FCC Compliance Statement (USA)

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

1. This device may not cause harmful interference, and

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

undesired operation.

This equipment has been tested and found to comply with the limits for Class B Digital

Devices, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable

protection against harmful interference when the equipment is operated in a residential

environment. This equipment generates, uses, and can radiate radio frequency energy and, if

not installed and used in accordance with the product manuals, may cause harmful interference

to radio communications. However, there is no guarantee that interference will not occur in a

particular installation. If this equipment does cause harmful interference to radio or television

reception, the user is encouraged to do one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

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

is connected.

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

Important •

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

antenna.

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

another radio.

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

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

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

The user is cautioned that any changes or modifications not expressly approved by Zebra

Technologies could void the user’s authority to operate the equipment. To ensure compliance,

this printer must be used with fully shielded communication cables.

Mexico — NOM-121-SCT1-2009

Este equipo ha sido diseñado para operar con las antenas que enseguida se enlistan y para una

ganancia máxima de antena de [x] dB. El uso con este equipo de antenas no incluidas en esta

lista o que tengan una ganancia mayor que [x] dB quedan prohibidas. La impedancia requerida

de la antena es de [y] ohms.

auden - p/n 220370-09

• Gain = 2.77dbi @ 2.4 GHz

• Gain = 2.69 - 3.19dBi @ 5 GHz

• Impedance = 50 ohms

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

Canadian DOC Compliance Statement

Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.

This Class B digital apparatus complies with Canadian ICES-003.

Industry Canada (IC) Warning

Le présent appareil est conforme aux CNR d’Industrie Canada applicables aux appareils radio

exempts de licence. L’exploitation est autorisée aux deux conditions suivantes : (1) l’appareil

ne doit pas produire de brouillage, et (2) l’utilisateur de l’appareil doit accepter tout brouillage

radioélectrique subi, même si le brouillage est susceptible d’en compromettre le

fonctionnement.

This device complies with Industry Canada license-exempt RSS standard(s). Operation is

subject to the following two conditions: 1) This device may not cause interference., 2) This

device must accept any interference, including interference that may cause undesired operation

of the device.

Brasil — Aviso da Anatel

Este equipamento opera em caráter secundário, isto é, não tem direito a proteção contra

interferência prejudicial, mesmo de estações do mesmo tipo, e não pode causar interferência a

sistemas operando em caráter primário.

“Este produto está homologado pela ANATEL, de acordo com os procedimentos

regulamentados pela Resolução 242/2000, e atende aos requisitos técnicos aplicados”

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

This equipment's operation is of a secondary character; that is, it doesn't have the right to

protection against damaging interference, even from stations of the same type, nor can it cause

interference to systems with a primary operating character.

Este produto utiliza internamente o modulo de RF M6E- micro numero de homologação pela

ANATEL 3059-13-8108 e o modulo WYSBMVGXB numero de homologação pela ANATEL

3825-13-9965

Este equipamento opera em caráter secundário, isto é, não tem direito a proteção contra

interferência prejudicial, mesmo de estações do mesmo tipo, e não pode causar interferência a

sistemas operando em caráter primário.

Japan Restricted Frequencies

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

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

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

Taiwan Restricted Frequencies

5.15-5.25 GHz, 該頻段將在臺灣不可用。

For 5.15 - 5.25 GHz, this frequency band will not be available in Taiwan.

Korean Compliance Statement

이 기기는 가정용 (B 급 ) 전자파 적합기기 로서 주로 가정에서 사용하는 것을 목적으로

하며 , 모든 지역에서 사용할 수 있습니다 .

The equipment is for home use (Class B) and has acquired electromagnetic conformity

registration, so it can be used not only in residential area but other areas as well.

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

interference during operation.

European Regulatory Information

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

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

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

NCC

經型式認證合格之低功率射頻電機，非經許可，公司、商號或使用者均不得擅自變

更頻率、加大功率或變更原設計之特性及功能。低功率射頻電機之使用不得影響飛

航安全及干擾合法通信；經發現有干擾現象時，應立即停用，並改善至無干擾時方

得繼續使用。前項合法通信，指依電信法規定作業之無線電通信。低功率射頻電機

須忍受合法通信或工業、科學及醫療用電波輻射性電機設備之干擾。

According to "Administrative Regulations on Low Power Radio Waves Radiated Devices"

Without permission granted by the NCC, any company, enterprise, or user is not allowed to

change frequency, enhance transmitting power or alter original characteristic as well as

performance to an approved low power radio-frequency devices. The low power radio-

frequency devices shall not influence aircraft security and interfere legal communications; If

found, the user shall cease operating immediately until no interference is achieved. The said

legal communications means radio communications is operated in compliance with the

Telecommunications Act.

The low power radio-frequency devices must be susceptible with the interference from legal

communications or ISM radio wave radiated devices.

vii

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

WLAN Radio Specification

802.11 b

•2.4 GHz

• DSSS (DBPSK, DQPSK and CCK)

• RF power 63 mW (ZebraNet n Print Server)

802.11 g

•2.4 GHz

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

• RF power 63 mW (ZebraNet n Print Server)

802.11 n

•2.4 GHz

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

• RF power 63 mW (ZebraNet n Print Server)

802.11 a/n

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

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

• RF power 50 mW (ZebraNet n Print Server)

Bluetooth 2.1 + EDR

•2.4 GHz

•FHSS

• RF power 0.4 mW

RFID Radio Specification

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

• ISO-18000 - 6B; ISO 18000-6C

• RF power <30 dBm ERP

Environmental Management

viii

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

Environmental Management

Document Conventions

Do not dispose of this product in unsorted municipal waste. This product is recyclable, and

should be recycled according to your local standards.

For more information, please see our website at:

Web address: www.zebra.com/environment

Table 1 • Document Conventions

Alternate Color

If you are viewing this guide on-line, you can click the blue text used for cross-references or

hyper-links to jump directly to other sections in the guide or to web sites on the Internet.

Command Line Examples, File Names, and Directories

Command line examples, file names, and directories appear in a Typewriter style

(Courier) mono-spaced font. For example:

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

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

Icons and Advisory Words

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

Caution • Warns you of the potential for electrostatic discharge.

Caution • Warns you of a potential electric shock situation.

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

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

harm to you.

(No icon) Caution • Advises you that failure to take or avoid a specific action could result in physical

harm to the hardware.

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

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

points of the main text.

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

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

Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Contents

xii

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Introduction

This section introduces you to your new Zebra® ZD500 Series™ desktop thermal label

printer. It describes what you get in your shipping box and provides an overview of printer

features. It also includes procedures that describe how to open and close the printer and

report any problems.

Your printer, when connected to a host computer, functions as a complete system for

printing labels, receipts, forms, and tags.

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

basis.

ZD500 Series™ Thermal Printers

The Zebra® ZD500 Series™ models are desktop thermal label printers with the widest

range of features and options including an internal UHF RFID encoder option.

• The 203 dpi (dots per inch print density) version printer provides thermal transfer and

direct thermal printing at speeds up to 6 ips (inches per second).

• The 300 dpi version printer provides thermal transfer and direct thermal printing at

speeds up to 4 ips.

• These printers support ZPL™ Zebra printer programming language and a wide variety

of interface and feature options.

Introduction

ZD500 Series™ Thermal Printers

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

The ZD500 Series™ printer features:

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

controls typically found only in premium printers.

• OpenAccess™ design for simplified media loading.

• Color-coded operator controls and media guides.

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

(and ANSI), Unicode UTF-8 and UTF 16 (Unicode Transformation Formats), XML,

ASCII (7 and 8 bit used by legacy programs and systems), basic single and double

byte font encoding, JIS and Shift-JIS (Japanese International Standards), Hexadecimal

encoding, and custom character mapping (DAT table creation, font linking, and

character remapping).

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

scalable font, and a selection of resident bitmap fonts.

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

eliminating license fees and print server hardware and lowering customization and

programming costs.

• Movable Sensor: A full width movable black mark or notch sensor, and multi center

position transmissive (label gap/web) sensor.

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

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

• Internal ZebraNet10/100 Print Server—supports 10Base-T, 100Base-TX and fast

Ethernet 10/100 auto-switching networks.

• On-board RTC (Real Time Clock).

• Printhead maintenance reporting enabled and customizable by the user.

The ZD500 Series™ printer options:

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

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

• General purpose media cutter.

• Wi-Fi (802.11a/b/g/n)

• Bluetooth 3.0

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

download.

• Asian Language support with printer configuration options for the large Simplified

and Traditional Chinese, Japanese, or Korean character sets. Printers sold in China

have the Simplified Chinese SimSun font pre-installed.

• Zebra® ZBI 2.0™ (Zebra BASIC Interpreter) programming language. ZBI allows you

to create custom printer operations that can automate processes, use peripherals (i.e.

scanners, scales, keyboards, Zebra® ZKDU™, etc.) all without being attached to a PC

or network.

Introduction

ZD500 Series™ Thermal Printers

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

Your printer, when connected to a host computer, functions as a complete system for

printing labels, receipts, forms, and tags. Many printer settings may also be controlled by

your printer’s driver or label design software. Refer to the driver or software

documentation for more information.

To create label formats, refer to your programming guides or label design applications

such as the free label and form design software: ZebraDesigner™.

The printer includes a complete suite of free Link-OS software applications and drivers to

configure printer settings, design and print labels and receipts, get printer status, import

graphics and fonts, send programming commands, update firmware, and download files.

Clone printer settings and send graphics, files, fonts, and firmware (updates) to one or

more Zebra® Ethernet and locally connected printers with ZebraNet™ Bridge.

Introduction

What’s in the Box?

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

What’s in the Box?

Save the carton and all packing materials in case you need to ship or store the printer later.

After unpacking, make sure you have all parts. Follow the procedures for inspecting the

printer to familiarize yourself with printer parts so you can follow the instructions in this

book.

Unpack and Inspect the Printer

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

• Save all packing materials.

• Check all exterior surfaces for damage.

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

If you discover shipping damage upon inspection:

• Immediately notify the shipping company and file a damage report. Zebra

Technologies Corporation is not responsible for any damage to the printer

incurred during shipment, and will not cover the repair of this damage under its

warranty policy.

• Keep all packaging material for shipping company inspection.

• Notify your authorized Zebra® reseller.

Power Cord

varies by locale or region

Documentation

and Software

Power

Supply

USB Cable

Printer

Ribbon Core

3in (76.2 mm) I.D.

Media Roll Adapters

Introduction

Printer Features

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

Printer Features

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

compartment of your printer. Depending on the printer model and the installed options,

your printer may look slightly different.

Figure 1 • Printer Features

Interface

Connectors

Control Panel

Release

Latches

Release

Latches

DC Power

Receptacle

Power

Switch

Fan-Fold Media

Entry Slot

Introduction

Printer Features

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

Figure 2 • Printer Features Continued

Label Taken

Sensor

Peel Bar

Platen

Roller

Printhead

Movable

Black Mark

Sensor

Ribbon Trailer Sensor

(hidden from view)

Roll Holders and

Media Guides

Head-Up Sensor

(inside)

Pinch

Roller

Dispenser Door

(open)

Take Up Spindles

Supply Spindles

Ribbon Roll Holders

Dispenser Option

Web (Gap)

Sensor

Media Guide Stop

Adjustment

RFID Antenna

(inside)

Introduction

Printer Features

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

Figure 3 • Printer Features - Cutter Option

Media Cutter

(Option)

Introduction

Control Panel

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

Control Panel

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

basic printer operation.

Add

6 5811 9 7

Figure 4 • ZD500 Series™ Control Panel

1STATUS light Shows the current status of the printer. For more information, see

Table 1 on page 9.

2The PAUSE button starts or stops printer operation when pressed.

3The FEED button forces the printer to feed one blank label each time the button is pressed.

4The CANCEL button cancels print jobs when the printer is paused.

5The RIGHT ARROW button, which is active only in the menu system, navigates to the right

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

6The DOWN ARROW button changes the parameter values. Common uses are to decrease a value

or to scroll through choices.

7The SELECT () button operates as follows:

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

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

8The UP ARROW button changes the parameter values. Common uses are to increase a value or to

scroll through choices.

9The LEFT ARROW button, which is active only in the menu system, navigates to the left through

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

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

them in the display.

11 LEFT OPTION button

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

Introduction

Control Panel

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

Table 1 • Printer Status Indicator Light

STATUS light steady green

The printer is ready.

STATUS light steady amber

This indicator light on steady indicates one of the following:

•The printer is not ready.

•The printhead is over temperature.

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

the printhead to cool.

STATUS light flashing amber

This indicator light flashing indicates one of the following:

•The printhead is under temperature.

STATUS light steady red

This indicator light on steady indicates one of the following:

•The media supply is out.

•The ribbon supply is out.

•The printhead is open.

•Cutter malfunction.

The printer needs attention and cannot continue without user intervention.

STATUS light flashing red

This indicator light flashing indicates one of the following:

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

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

•The printhead is extremely over temperature.

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

the printhead to cool.

The printer needs attention and cannot continue without user intervention.

STATUS light flashing amber followed by alternating amber/ green

This status light condition indicates the printer is in Forced Download Mode.

Forced Download Mode is used to download new firmware to the printer. This

mode should only be used by trained personnel.

Introduction

Control Panel Display Menu and Status Icons

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

Control Panel Display Menu and Status Icons

Figure 5 • Typical Home Menu

Error

Cover Unlocked

Ribbon In

Media In

Data

Ethernet

Bluetooth

Signal Strength

WiFi

Previous Menu Shortcut

Language Menu

Settings Menu

Sensors Menu

Tools Menu

Ports Menu

Network Menu

Bluetooth Menu

RFID Menu

Introduction

Printer Control Panel Display

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

Printer Control Panel Display

The printer’s control panel includes a display, where you can view the printer’s status or

change its operating parameters. In this section, you will learn how to navigate through the

printer’s menu system and change values for menu items.

After the printer completes the power-up sequence, it moves to the Idle Display (Figure 6).

If a print server is installed, the printer cycles through the information shown and the

printer’s IP address.

Figure 6 • Idle Display

The printer’s operating parameters are organized into several user menus, which you can

access through the printer’s Home menu (Figure 7). For detailed information about

changing the printer settings, see Printer Configuration on page 51.

Figure 7 • Home Menu

1The printer’s current status

2Information that you set through TOOLS Menu on page 56 - IDLE DISPLAY

Home menu shortcut

See SETTINGS Menu on page 52.See LANGUAGE Menu

on page 69.

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

See NETWORK Menu

on page 61.

See PORTS Menu on page 72.

See RFID Menu on page 65 See BLUETOOTH Menu

on page 74

Exit and return to the Idle Display

(Figure 6).

PRINTER READY

V74.19.1Z

SETTINGS

Introduction

Printer Control Panel Display

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

Navigating through Screens in the Menu

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

Table 2 • Navigation

Idle Display

At the Idle Display (Figure 6 on page 11), press LEFT SELECT to go

to the printer’s Home menu (Figure 7 on page 11).

Home Menu

To move from icon to icon in the

Home menu, press the ARROW

buttons.

When an icon is selected, its

image reverses to highlight it.

To select the highlighted menu

icon and enter the menu, press

SELECT () button.

Press LEFT SELECT to exit the

Home menu and return to the Idle

Display.

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

SETTINGS menu icon

SETTINGS menu icon highlighted

and active for selection.

Introduction

Printer Control Panel Display

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

User Menus

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

changes that you make are saved immediately.

Press the UP ARROW or DOWN ARROW to

scroll through accepted values.

To scroll through the items in a User menu, press the

LEFT ARROW or RIGHT ARROW.

A word in the bottom-right corner of the display

indicates an available action.

Press SELECT () button or press RIGHT

SELECT to perform the action shown.

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

Table 2 • Navigation

XXXXXXX

XXX

Introduction

Control Panel Menu Map

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

Control Panel Menu Map

Printer Ready

V74.xx.xxZ

Darkness

Print Speed

Media Type

Print Width

Print Mode

Tear Off

Reprint Mode

Power Up

Action

Head Close

Action

Tools Menu

Left Position

Label Length

Max

Language

ZBI Enabled?

Run ZBI

Program

Stop ZBI

Program

Parity

Baud Rate

Data Bits

Host

Handshake

WLAN IP

Protocol

ESSID

WLAN MAC

Address

WLAN Port

WLAN

Gateway

WLAN Subnet

Mask

WLAN IP

Address

Information

Sensors Menu

ZPL Mode

Command

Character

Control

Character

Delimiter Char

ZPL Override

LCD Backlight

LCD Contrast

Idle Display

Manual

Calibration

Take Label

Sensor Type

Network Menu

Settings

Information

RFID Menu

Ports Menu

Language

RFID Void

Count

Manual

Calibration

RFID Test

RFID Program

Position

RFID Read

Power

RFID Write

Power

RFID Status

RFID Read

Data

RFID Valid

Count

Language

Settings Menu

Min Security

Mode

Discovery

Connected

BT Spec

Version

Mode

Bluetooth

Address

Diagnostic

Mode

Wired IP

Protocol

Wired MAC

Address

Wired Port

Wired

Gateway

Wired Subnet

Mask

Wired IP

Address

Channel

Signal

Parallel Mode

Primary

Network

Print Method

Load Defaults

Label Sensor

Information

Active Print

Server

Reset Network

Load Defaults

Label Top

RFID Calibrate

WML Version

WLAN

Installed

WLAN

Home Menu Items

Menu Item also in other Menus

Yes No

Go to next Menu group

Printer Option. May not be present.

Language

(Menu) htooteulBstroPsrosneSDIFRkrowteNslooTsgnitteS

Bluetooth

IP Port

IP Alternate

Port

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

Setup

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

Basic Printer Setup (Overview)

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

(software/driver) setup.

• Place the printer in a safe location with access to power and where cable or the

wireless option communications can access your printer.

• Attach the printer to a grounded AC power source.

• Select and prepare media for your printer.

• Load the media.

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

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

• Turn the printer OFF.

• Choose method to communicate to your printer - Local connection via USB, Serial, or

Parallel ports; Local network via Ethernet (LAN); or using the printer’s wireless

option that supports Wi-Fi (802.11 a/b/g/n WLAN) and Bluetooth 3.0.

• Attach the printer to the network or host system, and configure the printer as required

for communicating to the print system host/network.

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

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

• Click on ‘Install New Printer’ and run the install wizard. Select ‘Install Printer’ and

select the ZD500R from the list of ZDesigner printers.

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

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

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

Setup

Select a Location for the Printer

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

Select a Location for the Printer

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

operations.

Select a location for the printer that meets these conditions:

•Surface: The surface where the printer will be located must be solid, level, and of

sufficient size and strength to hold the printer.

•Space: The area where the printer will be located must include enough space for

ventilation, opening the printer (media access and cleaning), and for accessing the printer

components and connectors. To allow for proper ventilation and cooling, leave open space

on all sides of the printer.

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

easily accessible.

•Data communication interfaces: The printer must be within range of your WLAN or

Bluetooth radio (if applicable) or within an acceptable range for other connectors to reach

your data source (usually a computer).

Data cables should not be routed with or near power cords or conduits, fluorescent

lighting, transformers, microwave ovens, motors or other electrical noise and interference

sources. These interference sources may interfere with communications, host system

operation, and printer functionality.

•Operating conditions: Your printer is designed to function in a wide range of

environmental and electrical conditions, including a warehouse or factory floor. Table 4

shows the temperature and relative humidity requirements for the printer when it is

operating.

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

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

Table 3 • Operating Temperature and Humidity

Mode Temperature Relative Humidity

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

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

Table 4 • Non-Operating and Storage Temperature and Humidity

Mode Temperature Relative Humidity

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

Setup

Attaching Power

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

Attaching Power

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

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

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

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

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

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

make certain the printer cannot carry electrical current, you must separate the power cord

from the power supply receptacle or AC electrical outlet.

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

Serious personal injury could result!

Power

Connector

Power

Switch

Plug Varies

by Country

Active Power Light

Power

Receptacle

Power

Cord

Printer

Power

Supply

IEC 60320

C-13

Note • Ensure the appropriate power cord with a three (3) prong plug and an IEC 60320-C13

connector are used at all times. These power cords must bear the relevant certification mark of

the country in which the product is being used.

Setup

Preparing and Handling Media

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

Preparing and Handling Media

Carefully handling and storing media is important for the print quality in addition to using the

right media (such as Genuine Zebra™ Supplies) and the right printer, your Zebra ZD500

Series™ printer. If the media becomes contaminated or dirty, it can damage or degrade the

printhead or the printer, as well as, cause defects in the printed image (voids, streaks,

discoloration, compromise the adhesive, etc.).

During manufacturing, packaging, handling and storage, the outside length of media may

become dirty or contaminated when handled or dusty when stored. To prevent this type of

contamination, we ask you to remove the outside layer of the media roll or stack. This will

remove any contaminates or adhesive from labels or tape used to secure the media to the roll

that may transfer to the printer or printhead.

Media Storage Tips

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

• Direct thermal media is chemically treated to be heat sensitive. Direct sunlight or heat

sources may ‘expose’ the media.

• Do not store media with chemicals or cleaning products.

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

• Many media types and label adhesives have a ‘shelf life’ or expiration date. Always

use the oldest, viable (non-expired) media first.

Setup

Setting the Printer Menu and Report Display Language

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Setting the Printer Menu and Report Display Language

The printer supports many languages for menu display, time and date format, and

configuration reports.

The primary method used to configure language is the control panels menu. Use the following

procedure to set your printer’s language when the printer is turned on and in the ‘Ready’ state.

1. Press the menus ‘Home’ ( ) button.

2. Navigate to the ‘LANGUAGE’ ( ) menu button and press the ‘Select’ () button.

3. Use the ‘Up’ () and ‘Down’ () navigation arrows to browse the languages.

4. Stop browsing when you have found the language you wish to use for operating the

printer. The language displayed will be your selected language.

Set Media Print Method

Set the printer’s PRINT METHOD using the printer control panel. See SETTINGS Menu

on page 52 - PRINT METHOD for the full procedure.

The ZD500 Series™ printer has been designed to print with DIRECT THERMAL (direct

thermal media which uses heat sensitive media to print) or THERMAL TRANS (thermal

transfer printing which uses ribbon to heat transfer print to the media).

The direct thermal and thermal transfer settings each have optimized Darkness control

characteristics to allow similar visual Darkness and Print Quality at the same DARKNESS and

PRINT SPEED settings.

Setup

Loading Roll Media

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

Loading Roll Media

Use the instructions in this section to load roll media in Tear-Off mode and Gap/Web media

sensing set by default. This mode also works for most full width black mark (black line)

media.

For other common media and setting variations see one of the following:

•Using the Movable Black Mark Sensor on page 89

•Printing on Fan-Fold Media on page 93

•Cutter Option on page 103

•Label Dispenser Option on page 100 after you have loaded media using this

procedure.

Instructions for media loading:

1. Open the printer. Pull the release latch levers toward the front of the printer.

2. Open the media roll holders. Pull the media guides open with your free hand and place the

media roll on the roll holders and release the guides. Orient the media roll so that its

printing surface will face up as it passes over the platen (drive) roller.

Setup

Loading Roll Media

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3. Verify that the movable black mark sensor is aligned in the center default position. This is

the standard operating position for media sensing. When the sensor is moved from the

default label web (gap) sensing area, the printer will only detect black mark and die-cut

notched media.

Movable

Black Mark Sensor

Off Center

Black Mark Sensing Only

Default - Web (Gap) Sensing

Standard Operating Position

Setup

Loading Roll Media

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

4. Pull the media so that it extends out of the front of the printer. Verify the roll turns freely.

The roll must not sit in the bottom of the media compartment. Verify that the media’s

printing surface is facing up.

5. Push the media under both of the media guides.

6. Close the printer. Press down until the cover snaps closed.

Your media may need a ‘Manual Calibration’ to adjust the printer’s sensors and label length

setting to operate properly. See the Manual Calibration - Media on page 75. If you are using

RFID media, run a RFID Calibration procedure, see the RFID Menu on page 65 - RFID

CALIBRATE for details.

Under Media

Guides

Setup

Loading Transfer Ribbon

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Loading Transfer Ribbon

Transfer ribbons come in several varieties and in some cases colors to match your application

needs. Genuine Zebra® transfer ribbons are specifically designed for your printer and Zebra

brand media. Using non-Zebra media or ribbons not approved for use in your Zebra® printer

may damage your printer or printhead.

• The media and ribbon types should be matched to provide you with optimal print results.

• Always use ribbon that is wider than the media to protect the printhead from wear.

• For direct thermal printing, do not load ribbon in the printer.

Before following these steps, prepare the ribbon by removing its wrapping and pulling its

adhesive strip free.

Notch

Adhesive Strip

Right Side

(printer and roll)

Important • DO NOT USE early model desktop printer ribbon cores! The older ribbon cores

can be identified by notches on only one side of the ribbon core. These older cores are too large

and will cause take-up spool to bind.

Note • DO NOT USE ribbon cores with damaged notches - rounded, frayed, smashed, etc. The

core notches should be square to lock the core on the spindle or the core may slip causing

ribbon wrinkle, poor end of ribbon sensing or other intermittent failures.

Setup

Loading Transfer Ribbon

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

1. With the printer open, place a new ribbon roll on printer’s lower ribbon supply spindles.

Rotate the roll until the notches align and lock into the left side of the supply hub.

2. Place an empty ribbon core on printer’s take-up spindles. Rotate the ribbon core until the

notches align and lock into the left side of the take-up hub.

You can find your first ribbon take-up core in the packing box. Subsequently, use the

empty supply core to take up the next roll of ribbon.

Setup

Loading Transfer Ribbon

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3. Pull the transfer ribbon’s leader off the roll and attach it with the adhesive strip on the

leader to the empty ribbon core on the take-up spindle. Center the ribbon on the ribbon

core.

Setup

Loading Transfer Ribbon

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

4. Rotate the thumb wheel on the left side of the supply spindle towards the rear of the

printer until the ribbon is pulled tight across the printhead.

5. Verify that the media is loaded and ready to print and then close the printer cover.

6. Press the Feed button to have the printer feed a minimum of 10 cm (4 inches) of media to

remove slack and ribbon wrinkle, and to align the ribbon on the spindles.

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).

8. To verify the mode change from direct thermal printing to thermal transfer printing, use

the Test Printing with Configuration Report Printouts on page 27 to print a configuration

label. The ‘PRINT METHOD’ should read ‘THERMAL-TRANS’ on the printer

configuration status label.

Your printer is now ready to print.

Your media may need a ‘Manual Calibration’ to adjust the printer’s sensors and label length

setting to operate properly. See the Manual Calibration - Media on page 75. If you are using

RFID media, run a RFID Calibration procedure, see the RFID Menu on page 65 - RFID

CALIBRATE for details.

Setup

Test Printing with Configuration Report Printouts

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Test Printing with Configuration Report Printouts

Before you connect the printer to your computer, make sure that the printer is in proper

working order. You can do this by printing a configuration status report.

1. Make sure the media is properly loaded and the top cover of the printer is closed.

2. Press and hold CANCEL button while setting the printer power switch to on (I).

3. Hold CANCEL button down until the printer status light turns green for the first time and

release.

4. The Printer and Network Configuration Reports (below) will be printed a couple of

seconds after the printer’s display reports ‘PRINTER READY’.

If you cannot get these reports to print and you have checked your printer installation with this

document, then see the Troubleshooting section of the User’s Guide or the Zebra Website for

guidance.

Setup

Connecting your Printer to a Computer

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

Connecting your Printer to a Computer

The printer supports a variety of interface options and configurations. These include:

Universal Serial Bus (USB) interface, RS232 Serial, Parallel (IEEE 1284.4), 10/100 Wired

Ethernet, and an optional internal Wireless Ethernet (WiFi) and Bluetooth radio.

Pre-install Windows® Printer Drivers

Install the Zebra Setup Utilities before applying power to the printer connected to the PC

(running a Zebra driver supported Windows operating system). The Zebra Setup Utility will

prompt you to apply the printer power. Continue to follow the instructions to complete your

printer installation.

The Zebra Setup Utility is designed to assist you with installing these interfaces. The

cabling and unique parameters for each of these physical printer communication interfaces is

discussed in the following pages to assist you with making configuration setup choices prior to

and immediately following applying power. The Zebra Setup Utilities configuration wizards

will instruct you to turn the printer’s power on at the appropriate time to complete the

installation of your printer.

For more details on installing Ethernet (network) and Bluetooth interfaces:

•ZebraNet® Wired and Wireless Print Servers User Guide

Interface Cable Requirements

Data cables must be of fully shielded construction and fitted with metal or metallized

connector shells. Shielded cables and connectors are required to prevent radiation and

reception of electrical noise.

To minimize electrical noise pickup in the cable:

• Keep data cables as short as possible (6 foot [1.83 m] recommended).

• Do not tightly bundle the data cables with power cords.

• Do not tie the data cables to power wire conduits.

Caution • Keep the power switch in the OFF position when attaching the interface cable.

The power cord must be inserted into the power supply and the power receptacle on the

back of the printer before connecting or disconnecting the communications cables.

Important • This printer complies with FCC “Rules and Regulations,” Part 15, for Class B

Equipment, using fully shielded data cables. Use of un-shielded cables may increase radiated

emissions above the Class B limits.

Setup

Connecting your Printer to a Computer

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

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 (not supplied with your printer), verify that the cable or cable

packaging bears the “Certified USB™” mark (see below) to guarantee USB 2.0 compliance.

Parallel Interface

The required cable must have a 25 pin “D” type (DB-25P) male connector on one and a

Centronics on the other end (IEEE 1284 A-B parallel interface specification).

USB Cable

Parallel Cable

Setup

Connecting your Printer to a Computer

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

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 pinout information, refer to

Appendix A.

The serial port communication settings between the printer and host (typically a PC) must

match for reliable communication. The Bits per second (or Baud rate) and Flow control are the

most common settings that get changed.

Serial communications between the printer and the host computer can be set by:

• Using the printers Control Panel ‘PORTS’ menu.

• ZPL programming ^SC command

• Resetting the printer to its default printer configuration.

Factory defaults for serial communication settings are: 9600 baud, 8 bit word length, NO

parity, 1 stop bit, and XON/XOFF (‘Software’ data flow control in the Windows based host

system).

Tighten

Serial Cable

Setup

Connecting your Printer to a Computer

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

Wired (Ethernet) Interface

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, see the ZebraNet® Wired and Wireless

Print Server users guide. The printer must be configured to run on your LAN (local area

network) or WAN (wide area network). The print server on board your printer can be accessed

through the printer’s print server Web pages.

Assigning a IP Address for Network Access All devices on a Ethernet network

require a network IP (Internet Protocol) address. The printer’s IP address is needed to access

the printer for printing and printer configuration. The four different ways to assign an IP

address are:

• DHCP (Dynamic Host Connection Protocol) - Default setting

• ZebraNet Bridge

• Using the printer’s Control Panel ‘NETWORK’ menu

•Telnet

• Zebra Setup Utilities (includes the ZebraDesigner Windows printer driver)

DHCP for Personal Networks The printer by default is set to operate on LAN or WAN

with DHCP by default to aid end-user installations. This is intended primarily for personal

networks. The network automatically provides a new network IP address each time the printer

is turned on. The Windows printer driver uses a Static IP address to connect to the printer. The

IP address set in the printer driver will need to be changed to access the printer if its assigned

IP address has changed after the printer’s initial installation.

Managed Networks Using the printer in a structured network (LAN or WAN) requires a

network administrator to assign the printer a Static IP address and other settings needed to

operate on the network properly.

Viewing the Printer’s IP Address Use the printer’s control panel to access the Ethernet

settings in your printer.

1. Press the menus ‘Home’ ( ) button.

2. Navigate to the ‘NETWORK’ ( ) menu button and press the ‘Select’ () button.

3. Use the ‘Up’ () and ‘Down’ () navigation arrows to browse to the

‘WIRED IP ADDRESS’ setting. You can read the assigned IP address or set the IP

address. The printer’s default address (all 0’s - zeros) is not a valid address. With

assistance of your network administrator, you can set all of the ‘WIRED’ network setting

in this ‘NETWORK’ menu branch.

Setup

Connecting your Printer to a Computer

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

Ethernet Status/Activity Indicators

Print Server - Default User ID and Password

There are some features that require the default User ID and/or default password to access

printer’s print server or if you have the Wi-Fi option in the printer. The Factory Default Values

are shown below:

•User ID: admin

•Password: 1234

Ethernet Cable

(RJ45 Connector)

LED Status Description

Both OFF No Ethernet link detected

Green 100 Mbps link detected

Green with the Amber

flickering on and off

100 Mbps link and Ethernet activity detected

Amber 10 Mbps link detected

Amber with the Green

flickering on and off

10 Mbps link and Ethernet activity detected

Green LED Amber LED

Setup

ZebraNet® Internal Wireless Print Server Option

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ZebraNet® Internal Wireless Print Server Option

This section covers basic configuration of your ZebraNet Internal Wireless Print Server option

for operation. For more detailed information, refer to the ZebraNet Wired and Wireless Print

Servers User Guide.

You may configure your printer for wireless operation in the following ways. This basic guide

covers only the first option, the Connectivity Wizard.

•Through the Connectivity Wizard, which writes a ZPL script for you. On the last screen

of the utility, you may choose to send the command directly to your printer, or you may

choose to save the ZPL script to a file. The saved ZPL file has several purposes:

• The file can be sent to the printer through any available connection (serial, parallel,

USB, or wired print server).

• The file can be resent to the printer after the network settings have been restored to

factory defaults.

• The file can be sent to multiple printers that will use the same network settings.

•Through ZPL script that you write yourself. Use the ^WX command to set the basic

parameters for security type. You can send the command through any available connection

(serial, parallel, USB, or wired print server). Refer to the ZPL Programming Guide for

more information on this option.

•Through Set/Get/Do (SGD) commands that you send to the printer. Begin with

wlan.security to set the wireless security type. Depending on which security type

that you select, other SGD commands will be necessary to specify other parameters. You

can send the commands through any available connection (serial, parallel, USB, or wired

print server). Refer to the ZPL Programming Guide for more information on this option.

Important • A wireless option board must be installed on your printer before you can

configure the printer to communicate using the wireless radio option.

Setup

Configure Using the Connectivity Wizard

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

Configure Using the Connectivity Wizard

The ZebraNet Bridge Enterprise utility resides on the User CD for your printer and is available

through http://www.zebra.com/software. ZebraNet Bridge Enterprise version 1.2.5 or later is

required to configure the printer correctly for use.

The Connectivity Wizard, which is part of this software, allows you to configure your printer

easily for wireless operation by writing the appropriate ZPL script for you. Use this utility

when you are first installing the wireless print server or after you set the network options back

to factory defaults.

To use the Connectivity Wizard, complete these steps:

1. If it is not already installed, install ZebraNet Bridge Enterprise on your computer.

You can get the program from the user CD that came with your printer, or you can

download it at http://www.zebra.com/software.

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.

Note • You can only set up one print server at a time with the Connectivity Wizard. To

configure multiple print servers (wired and wireless), run the program once for each print

server.

Setup

Configure Using the Connectivity Wizard

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

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.

• If you select File:, you will be asked to browse to the location of the file you want to

save.

• If you select a serial port, the serial configuration information appears below the

Choose Port list. If necessary, change the serial communication settings to match your

printer’s settings.

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.

Note • If a port is in use by another device, it will not be included in the drop-down

list.

Setup

Configure Using the Connectivity Wizard

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

7. Select the type of printer you are using and then click Next.

The wizard prompts for the wireless IP information.

Setup

Configure Using the Connectivity Wizard

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

8. Enable the DHCP (dynamic) or static IP option.

9. Click Next.

The Wireless Settings window opens.

10. Enter the ESSID.

If you will be using... Complete the following steps...

DHCP a. Select DHCP and click Next.

b. Continue with step 9.

Static a. Select Static.

The IP settings fields are activated.

a. Enter the IP Address, Default Gateway, and Subnet

Mask for the wireless print server. Contact your network

administrator for the correct values.

b. Continue with step 9.

Important • The ESSID and pass phrase, if used, must be set at your access point before

completing these steps.

Setup

Configure Using the Connectivity Wizard

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

11. From the drop-down, select your Security Mode.

If you select… Then…

None Continue with step 12.

WEP 40-Bit

WEP 128-Bit

a. In the WEP Options section of the window, enter the

following values:

•Authentication type

•WEP Index

•Encryption Key Storage

•WEP Keys

b. Click Next and continue with step 12.

EAP-TLS

EAP-TTLS

EAP-FAST

WPA-EAP-TLS

In the EAP section of the window, if necessary:

a. Enter the Optional Private Key.

b. Click Next and continue with step 12.

PEAP

LEAP

WPA-EAP-TTLS

WPA-PEAP

WPA-LEAP

In the General Security section of the window:

a. Enter the Security Username and Password.

b. Click Next and continue with step 12.

WPA-PSK In the WPA section of the window:

a. Select the PSK Type.

b. Enter the PSK Name.

c. Click Next and continue with step 12.

WPA-EAP-FAST a. In the General Security section of the window, enter the

Security Username and Password.

b. In the EAP section of the window, if necessary, enter the

Optional Private Key.

c. Click Next and continue with step 12.

KERBEROS a. In the Kerberos Settings section of the window, enter the

following values:

•Kerberos User

•Kerberos Password

•Kerberos Realm

•Kerberos KDC

b. Click Next and continue with step 12.

c.KERBEROS is not supported on Internal

Wireless Plus print servers or radio cards.

Setup

Configure Using the Connectivity Wizard

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

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

Configure Using the Connectivity Wizard

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

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… Then a dialog box similar to this displays.

Tabletop/Desktop

Mobile

Setup

Configure Using the Connectivity Wizard

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

15. Determine if you will send the script immediately, or save it for use at a later time.

16. Observe the wireless status on the printer’s control panel, and confirm that you have set up

your printer for wireless connectivity. Printers that have an LCD display text or symbols

(see Table 5 and Table 6).

To... Then...

Complete setup by sending

the ZPL script to the printer

through the port selected at

the beginning of this

procedure

a. Verify that the printer is connected to the computer

through the port you selected.

Note • For serial connections, use a serial null

modem cable.

b. If you have not already done so, turn on (I) the printer.

c. On the Review and Send ZPL for Wireless window,

click Finish.

The printer sends the ZPL script to the printer through

the selected port. The Wireless Setup Wizard screen

closes.

d. Turn the printer off (O) and then back on (I).

Save the ZPL script to a file

for later use or for use on

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.

a. On the Review and Send ZPL for Wireless window,

highlight the script, right-click, and select Copy.

b. Open a text editor, such as Notepad, and paste the

script into the application.

c. Save the script.

d. In the Connectivity Wizard, click Cancel to exit

without sending the script at this time.

e. If you have not already done so, turn on (I) the printer.

f. Send the ZPL file to the printer through the connection

of your choice.

Setup

Configure Using the Connectivity Wizard

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

LCD Link Status and Wireless Signal Indicators

This section applies to printers and print engines other than the HC100 printer.

• Link Status Indicator (Table 5)

The wireless link status indicator appears at the upper right of the LCD, providing a

real-time display of the printer’s network status.

• Wireless Signal Indicators (Table 6)

The wireless signal indicators appears at the upper right of the LCD, providing a real-

time display of the signal strength and quality.

Table 5 • Link Status Indicators

Status Indicator Meaning

The wireless radio is associated with the WLAN.

The wireless radio is not associated with the WLAN. Verify that your

printer’s wireless settings match those of the WLAN.

The wireless radio is associated and authenticated to the WLAN.

blank •The printer is checking for a wired print server.

•The printer is running a wired print server.

•The wireless print server board is not installed or not installed correctly.

Table 6 • Wireless Signal Indicators

Wireless Signal Indicator Description

These bars indicate relative strength of the wireless signal. The more bars

shown, the better the connection is between the printer and the network.

If your printer indicates a signal strength but you cannot communicate with

the printer from your computer, move the printer to a different location to

try to get a better signal strength or signal quality. This situation could also

indicate that the printer is associated with, but not authenticated with, your

access point.

Setup

Bluetooth Option Configuration

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Bluetooth Option Configuration

The Zebra Setup Utilities provides a quick and easy way to configure a Bluetooth wireless

connection with your printer.

1. Double-click the Zebra Setup Utilities icon on your desktop.

2. Connect a USB cable from your printer to your computer.

3. On the first ZSU screen, highlight the printer displayed in the window and click on the

Configure Printer Connectivity where shown.

4. Select “Bluetooth” on the Connectivity Type screen and click on the Next button.

5. On the Bluetooth Settings screen, check “Enabled” to enable Bluetooth functionality.

6. In the Friendly Name text field, set the Bluetooth name of the device. This name appears

during device discovery and the master device will label the printer with this name.

7. Set Discoverable to “On” or “Off” to set whether the device will appear when master

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. Actual authentication setting on the printer is

set in the Security Mode on the Advanced Settings menu.)

Setup

Bluetooth Option Configuration

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

9. The values set in the Authentication PIN field will vary depending on the Bluetooth

version of the master device. If the master uses BT v2.0 or older, enter a numeric value in

this field. You will be prompted to enter this same value on the master device to verify

pairing. Security Mode 2 or 3 in Advanced Settings should also be selected for PIN

paring.

10. If the master device uses BT v2.1 or newer, this setting has no effect. BT v2.1 and newer

uses Secure Simple Paring (SSP) which does not require the use of a PIN.

11. Clicking on the Advanced Settings button will display the Advanced Bluetooth Settings

window. For more information on Advanced Settings, refer to the Wired and Wireless

Print Server Guide.

12. Click Next to continue configuring your printer.

13. The SGD commands to properly configure your printer will be displayed. Click Next to

continue to the Send Data screen.

14. On the Send Data screen, you may click on the Printer that you want to immediately send

the commands to or you may click on the File button to save the commands to a file on

your computer that can be sent to one or more printers at a later time.

15. To send the commands to the printer, click on the Finish button and the printer will be

updated and then reboot. You may disconnect the USB interface from your printer now.

16. To complete the Bluetooth paring process, enable Bluetooth device discovery on your

master device and follow the directions provided with the master device.

Setup

Bluetooth Option Configuration

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Connecting to a Windows XP® SP2 Master 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. If there is one or more new printers detected, then do not

select any of those printers and click ‘Next’.

4. Select the ‘Create a new port’ radio button and select ‘Bluetooth Printer Port’ from the

associated pull down menu.

5. From the new ‘Bluetooth Printer Port’ window, select your printer from the Bluetooth

devices in the list. This may take several minutes. Click on the ‘Connect’ button.

6. The ‘Install Printer Software’ window will open. Select ‘ZDesigner’ as ‘Manufacture’

to select supported Zebra printer models, and then select your printer model in the

‘Printers’ selection. Click ‘Next’ to continue.

7. Select ‘Keep the existing drivers’ and click ‘Next’.

8. Name your printer and choose your default printer setting as desired. Click ‘Next’.

9. Answer ‘Yes’, you want to print a test page. Click ‘Next’ to continue.

10. Click ‘Finish’ on the ‘Completing the Add Printer Wizard’ window and the Bluetooth

printer will complete installation and print a Windows test print page (a Windows logo at

minimum).

Connecting to a Windows Vista® SP2 or Windows 7® Master 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’.

•Windows 7: Open Devices and Printers by clicking the ‘Start’ button, and then,

on the ‘Start’ menu, clicking ‘Devices and Printers’

• Some non-Microsoft Bluetooth dongles and built-in Bluetooth devices in the host

PC’s have marginal driver support for Secure Simple Paring (SSP) printing and

may not complete the ‘Add printer’ wizard normally. You may need to go to the

‘Bluetooth Devices’ in the ‘Control Panel’ or from the system tray on the

Windows ‘Start’ bar and activate SPP for the ‘device’, your Bluetooth printer you

are installing. Install the printer to a local printer (USB or Serial Port for your

ZD500 Series™ printer) and then change the ‘Port’ after the install has completed

to the SPP (virtual serial port) COM port.

Setup

Bluetooth Option Configuration

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

1. Access the ‘Devices and Printers’ from the Windows Start menu ( ).

2. Check for Bluetooth devices in the ‘Devices and Printers’ window. Note the generic

Windows Bluetooth icon below.

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.

Setup

Bluetooth Option Configuration

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4. Click on the ‘Add a device’ in the top bar of the “Devices and Printers’ window. After

a few moments the “Add a device’ windows will populate with Bluetooth devices near

you.

5. Turn the Bluetooth 3.0 enabled Zebra printer on. After a few moments the

“Add a device’ windows will add your new printer. Click on the printer icon. Right-Click

and select ‘Add device’.

6. The ‘Add a device’ window changes to a code pairing screen, see an example below. The

pairing code displayed is randomly generated by the Window operating system. Complete

the next two steps quickly

Setup

Bluetooth Option Configuration

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7. Check the printer’s display for the following screen. Verify that the pairing numbers

match.

If the numbers match, then press the ‘Next button’ in the ‘Add a device’ window and

then press the OK/Check Mark button on the printer’s control panel.

If the numbers do not match, use the printer’s control panel arrow keys to change the

highlighted ACCEPT to REJECT and then press the OK/Check Mark button on the

printer’s control panel.

8. When the paring process successfully completes, the following message will be displayed.

Note • Note the COM port number displayed in the task bar pop-up. It will only remain for a

few seconds.

Setup

After Your Printer is Connected

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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.

Testing Communications by Printing

Verifying the print system’s operation is a relatively simple process. For Windows operating

systems, the Zebra Setup Utility or the Windows ‘Printers and Faxes’ Control Panel to access

and print a test label. For non-Windows operation systems, coping a basic ASCII text file with

a single command (~WC) to print a configuration status label.

Test Printing with Zebra Setup Utility:

1. Open the Zebra Setup Utility.

2. Click on the newly install printer’s icon to select the printer and active 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 status label.

Test Printing with Windows ‘Printer and Faxes’ menu:

1. Click on the Windows ‘Start’ menu button, to access the ‘Printers and Faxes’ menu or

‘Control Panel’ to access the ‘Printers and Faxes’ menu. Open the menu.

2. Select the newly install printer’s icon to select the printer and right-click the mouse to

access the printer ‘Properties’ menu.

3. From the printer’s ‘General’ tab window, click on the ‘Print Test Page’ button. The

printer should print a Windows test print page.

Test Print on a Ethernet printer connected to a network (LAN or WAN) with a

(MS-DOS) ‘Command Prompt’ (or ‘Run’ from the Windows XP Start menu):

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. Read the IP address off the printer’s Configuration Status Label’s Network Status printout.

On a system that is connected to the same LAN or WAN as the printer, type the following

in the Web browser window’s address bar and enter:

ftp (IP address)

(for IP address 123.45.67.01 it would be: ftp 123.45.67.01)

4. Type the word ‘put’ followed by the file name and enter. For this ‘test print’ file, it would

be: put TEST.ZPL

The printer should print a new Print Configuration Status label.

Setup

After Your Printer is Connected

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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

parallel port would be as simple as:

COPY TEST.ZPL LPT1

Other interface connection types and operating systems will have different command

strings. See your operating system documentation for detailed instructions to copy to the

appropriate printer interface for this test.

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Printer Configuration

Changing Printer Settings

This section presents the printer settings that you can change and identifies the tools for

changing them. These tools include the following:

• The control panel menu

• ZPL and Set/Get/Do (SGD) commands (See the Zebra® Programming Guide for

more information.)

• The printer’s web pages when the printer has an active wired or wireless print server

connection (See the ZebraNet Wired and Wireless Print Servers User Guide for more

information.)

Copies of the referenced manuals are available at http://www.zebra.com/manuals or on the

user CD that came with your printer.

This section contains the following subsections:

•SETTINGS Menu on page 52

•TOOLS Menu on page 56

•NETWORK Menu on page 61

•RFID Menu on page 65

•LANGUAGE Menu on page 69

•SENSOR Menu on page 71

•PORTS Menu on page 72

•BLUETOOTH Menu on page 74

•Manual Calibration - Media on page 75

•RFID Calibration on page 76

Printer Configuration

Changing Printer Settings

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

SETTINGS Menu

Table 7 • SETTINGS Menu

Darkness

Set the darkness to the lowest setting that provides good print quality. If you set the darkness

too high, the label image may print unclearly, bar codes may not scan correctly, the ribbon

may burn through, or the printhead may wear prematurely.

If desired, use the Print Quality Report on page 135 to determine the best darkness setting.

Accepted values: 0.0 – 30.0

Related ZPL command(s): ^MD, ~SD

SGD command used: print.tone

Printer web page: View and Modify Printer Settings > General Setup >

Darkness

Print Speed Select the speed for printing a label (given in inches per second). Slower print speeds

typically yield better print quality.

Accepted values: 2, 3, 4, 5, 6

Related ZPL command(s): ^PR

SGD command used: media.speed

Printer web page: N/A

Media Type Select the type of media that you are using.

•If you select CONTINUOUS, you must include a label length in your label format (^LL

if you are using ZPL).

•If you select GAP/NOTCH or MARK for various non-continuous media, the printer

feeds media to calculate the label length.

See Types of Media on page 79 for more information.

Accepted values: •CONTINUOUS

•GAP/NOTCH

•MARK

Related ZPL command(s): ^MN

SGD command used: ezpl.media_type

Printer web page: View and Modify Printer Settings > Media Setup >

Media Type

Print Method Specify if the printer is to use Direct Thermal mode (no ribbon) or Thermal Transfer mode

(using thermal transfer media and ribbon).

Accepted values: •THERMAL TRANS

•DIRECT THERMAL

Related ZPL command(s): ^MT

SGD command used: ezpl.print_method

Printer web page: View and Modify Printer Settings > Media Setup >

Print Method

Printer Configuration

Changing Printer Settings

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Tear-Off

Position

If necessary, adjust the position of the media extending out of the printer after printing.

•Higher numbers move the media out (the tear line moves closer to the leading edge of

the next label).

•Lower numbers move the media in (the tear line moves closer to the edge of the label

just printed).

•Note - Tear-Off does not affect RFID program position.

Accepted values: –120 to 120

Related ZPL command(s): ~TA

SGD command used: ezpl.tear_off

Printer web page: View and Modify Printer Settings > General Setup >

Te a r Of f

Print Width Specify the width of the labels being used. 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. This setting can

affect the horizontal position of the label format if the image was inverted using the

^POI ZPL II command.

Accepted values: 0000 to 0832 dots (200 dpi printers)

0000 to 1280 dots (300 dpi printers)

Related ZPL command(s): ^PW

SGD command used: ezpl.print_width

Printer web page: View and Modify Printer Settings > Media Setup >

Print Width

Table 7 • SETTINGS Menu (Continued)

1Media direction

2Factory-set tear line location at position 000

Printer Configuration

Changing Printer Settings

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

Print Mode Select a print mode that is compatible with your printer options.

Accepted values: •TEAR OFF

•PEEL OFF (use this value for Label Dispensing:

Separates the liner from the label and presents a

peeled label to the operator)

•REWIND

•CUTTER

•DELAYED CUT

•LINERLESS PEEL

•LINERLESS REWIND

•LINERLESS TEAR

Related ZPL command(s): ^MM

SGD command used: media.printmode

Printer web page: View and Modify Printer Settings > General Setup >

Print Mode

Label Top If necessary, shift the print position vertically on the label. A negative value moves the

format towards the top of the label; a positive value moves the format away from the top of

the label.

Accepted values: –120 to 120

Related ZPL command(s): ^LT

SGD command used: zpl.label_top

Printer web page: View and Modify Printer Settings > Advanced Setup

> Top Position

Label Left

Position

If necessary, shift the print position horizontally on the label. Positive numbers move the left

edge of the image toward the center of the label by the number of dots selected, while

negative numbers move the left edge of the image toward the left edge of the label.

Accepted values: –9999 to 9999

Related ZPL command(s): ^LS

SGD command used: zpl.left_position

Printer web page: View and Modify Printer Settings > Advanced Setup

> Left Position

Reprint

Mode

When reprint mode is enabled, you can reprint the last label printed by pressing and holding

PAUSE + CANCEL on the printer’s control panel.

Accepted values: •ON

•OFF

Related ZPL command(s): ^JZ

SGD command used: ezpl.reprint_mode

Printer web page: N/A

Table 7 • SETTINGS Menu (Continued)

Printer Configuration

Changing Printer Settings

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Maximum

Label Length

Set the maximum label length to a value that is at least 1.0 in. (25.4 mm) greater than the

actual label length plus the interlabel gap. If you set the value to one that is smaller than the

label length, the printer assumes that continuous media is loaded, and the printer cannot

calibrate.

For example, if the label length is 6.0 inches (152 mm) including the inter-label gap, set the

parameter for at least 7.0 inches (178 mm).

Accepted values: 0 to the maximum label length supported by the printer

Related ZPL command(s): ^ML

SGD command used: ezpl.label_length_max

Printer web page: View and Modify Printer Settings > Media Setup >

Maximum Length

Table 7 • SETTINGS Menu (Continued)

1Label length (including interlabel gap)

2Interlabel gap

3Set the maximum label length to approximately

this value

Printer Configuration

Changing Printer Settings

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TOOLS Menu

Table 8 • TOOLS MENU

Information

Prints the specified information on the media, if non-continuous media the information

will be displayed on one or more labels (tags, tickets, etc.).

Accepted values: •SETTINGS—prints the printer configuration

report.

•NETWORK—prints the settings for any print

server that is installed.

•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.

•BARCODES—prints the available bar codes in

the printer. Bar codes may be stored in RAM or

Flash memory.

•ALL—prints the previous six labels.

•SENSOR PROFILE—shows the sensor settings

compared to actual sensor readings. To interpret

the results of the sensor profile, see Sensor Profile

on page 140.

Related ZPL command(s): Settings: ~WC

Network: ~WL

Sensor profile: ~JG

Others: ^WD

SGD command used: none

Control panel key(s): Settings and Network: Do one of the following:

•Hold CANCEL during printer power-up.

•Hold FEED + CANCEL for 2 seconds when

the printer is in the Ready state.

Sensor profile: Hold FEED + CANCEL during

printer power-up.

Printer web page: View and Modify Printer Settings >

Print Listings on Label

Printer Configuration

Changing Printer Settings

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LCD Contrast Change the contrast on the printer’s display.

Accepted values: 3 to 15

Related ZPL command(s): none

SGD command used: display.contrast

Printer web page: N/A

Idle Display Select the information shown on the printer’s display when the printer is idle.

Accepted values: •FW VERSION

•IP ADDRESS

•MM/DD/YY 24 HR

•M/DD/YY 12 HR

•DD/MM/YY 24 HR

•DD/MM/YY 12 HR

Related ZPL command(s): none

SGD command used: device.idle_display_format

Printer web page: N/A

Power-Up Action Set the Power-Up Action

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

•CALIBRATE adjusts sensor levels and thresholds, determines the label length, and

feeds the media to the next web.

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

•LENGTH determines the label length using current sensor values, and feeds the

media to the next web.

•NO MOTION tells the printer not to move the media. You must manually ensure

that the web is positioned correctly, or press feed to position the next web.

•SHORT CAL sets the media and web thresholds without adjusting sensor gain,

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

Accepted values: •CALIBRATE

•FEED

•LENGTH

•NO MOTION

•SHORT CAL

Related ZPL command(s): ^MF

SGD command used: ezpl.power_up_action

Printer web page: View and Modify Printer Settings > Calibration

Table 8 • TOOLS MENU (Continued)

Printer Configuration

Changing Printer Settings

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Head-Close

Action

Set the Head-Close Action

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

•CALIBRATE adjusts sensor levels and thresholds, determines the label length, and

feeds the media to the next web.

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

•LENGTH determines the label length using current sensor values, and feeds the

media to the next web.

•NO MOTION tells the printer not to move the media. You must manually ensure

that the web is positioned correctly, or press feed to position the next web.

•SHORT CAL sets the media and web thresholds without adjusting sensor gain,

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

Accepted values: •CALIBRATE

•FEED

•LENGTH

•NO MOTION

•SHORT CAL

Related ZPL command(s): ^MF

SGD command used: ezpl.head_close_action

Printer web page: View and Modify Printer Settings > Calibration

Table 8 • TOOLS MENU (Continued)

Printer Configuration

Changing Printer Settings

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Load Defaults Load Printer or Print Server Defaults

•FACTORY—Restores all printer settings other than the network settings back to the

factory defaults. Use care when loading defaults because you will need to reload all

settings that you changed manually.

•NETWORK—Reinitializes the printer’s wired or wireless print server. With a

wireless print server, the printer will also reassociate with your wireless network.

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

Accepted values: •FACTORY

•NETWORK

•LAST SAVED

Related ZPL command(s): Factory: ^JUF

Network: ^JUN

Last saved: ^JUR

SGD command used: none

Control panel key(s): Factory: Hold FEED + PAUSE during printer

power-up to reset the printer parameters to factory

values.

Network: Hold CANCEL + PAUSE during printer

power-up to reset the network parameters to factory

values.

Last saved: N/A

Printer web page: Factory: View and Modify Printer Settings >

Restore Default Configuration

Network: Print Server Settings > Reset Print

Server

Last saved: View and Modify Printer Settings >

Restore Saved Configuration

Manual

Calibration

Calibrate the printer to adjust the sensitivity of the media and ribbon sensors.

For complete instructions on how to perform a calibration procedure, see Manual

Calibration - Media on page 75.

Accepted values: N/A

Related ZPL command(s): ~JC

SGD command used: ezpl.manual_calibration

Control panel key(s): Hold PAUSE + FEED + CANCEL for 2 seconds to

initiate calibration.

Printer web page: The calibration procedure cannot be initiated through

the web pages. See the following web page for

settings that are set during sensor calibration:

View and Modify Printer Settings > Calibration

Important • Do not change these settings

unless you are told to do so by Zebra

Technical Support or by an authorized service

technician.

Table 8 • TOOLS MENU (Continued)

Printer Configuration

Changing Printer Settings

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Communication

Diagnostics Mode

Use this diagnostics tool to cause the printer to output the hexadecimal values for all

data received by the printer.

For more information, see Communication Diagnostics Test on page 139.

Accepted values: •DISABLED

•ENABLED

Related ZPL command(s): ~JD to enable, ~JE to disable

SGD command used: device.diagnostic_print

Control panel key(s): Hold PAUSE + FEED for 2 seconds when the

printer is in the Ready state.

Printer web page: N/A

Enable ZBI 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.

Accepted values: N/A

Related ZPL command(s): none

SGD command used: zbi.key (identifies if the ZBI 2.0 option is enabled

or disabled on the printer)

Printer web page: N/A

Run a ZBI

Program

If you have ZBI installed, you may choose to run a ZBI program that you have

downloaded to your printer.

Accepted values: N/A

Related ZPL command(s): ^JI, ~JI

SGD command used: zbi.control.run

Printer web page: Directory Listing

Stop a ZBI

Program

If your printer is running a ZBI program, you may stop that program.

Accepted values: N/A

Related ZPL command(s): ~JQ

SGD command used: zbi.control.terminate

Printer web page: Directory Listing

Table 8 • TOOLS MENU (Continued)

Printer Configuration

Changing Printer Settings

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NETWORK Menu

Table 9 • NETWORK Menu

WIRED or

WLAN

IP Address

View or Set the Printer’s IP Address

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

Changes to this setting are saved only if IP PROTOCOL is set to PERMANENT. To

allow any saved changes to take effect, reset the print server (see RESET NETWORK

in this section).

Accepted values: 000 to 255 for each field

Related ZPL command(s): ^ND

SGD command used: Wired: internal_wired.ip.addr

Wireless: ip.addr, wlan.ip.addr

Printer web page: View and Modify Printer Settings >

Network Communications Setup >

TCP/IP Settings

WIRED or

WLAN

Subnet Mask

View or Set the Subnet Mask

View and, if necessary, change the subnet mask.

This menu item appears only if a wired or wireless print server is installed on your

printer. To save changes to this setting, set IP PROTOCOL to PERMANENT, and then

reset the print server (see RESET NETWORK in this section).

Accepted values: 000 to 255 for each field

Related ZPL command(s): ^ND

SGD command used: Wired: internal_wired.ip.netmask

Wireless: wlan.ip.netmask

Printer web page: View and Modify Printer Settings >

Network Communications Setup >

TCP/IP Settings

WIRED or

WLAN

Gateway

View or Set the Default Gateway

View and, if necessary, change the default gateway.

This menu item appears only if a wired or wireless print server is installed on your

printer. To save changes to this setting, set IP PROTOCOL to PERMANENT, and then

reset the print server (see RESET NETWORK in this section).

Accepted values: 000 to 255 for each field

Related ZPL command(s): ^ND

SGD command used: Wired: internal_wired.ip.gateway

Wireless: wlan.ip.gateway

Printer web page: View and Modify Printer Settings >

Network Communications Setup >

TCP/IP Settings

Printer Configuration

Changing Printer Settings

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

WIRED or

WLAN

IP Protocol

Set the IP Resolution Method

This parameter tells if the user (permanent) or the server (dynamic) selects the

IP address. If a dynamic option is chosen, this parameter tells the method(s) by which

the wired or wireless print server receives the IP address from the server.

Accepted values: •ALL

•GLEANING ONLY

•RARP

•BOOTP

•DHCP

•DHCP & BOOTP

•PERMANENT

Related ZPL command(s): ^ND

SGD command used: Wired: internal_wired.ip.protocol

Wireless: wlan.ip.protocol

Printer web page: View and Modify Printer Settings >

Network Communications Setup >

TCP/IP Settings

WIRED or

WLAN

MAC Address

View the MAC Address

View the Media Access Control (MAC) address of the print server that is installed in the

printer (wired or wireless).

Accepted values: N/A

Related ZPL command(s): none

SGD command used: Wired: internal_wired.mac_addr

Wireless: wlan.mac_addr

Printer web page: View and Modify Printer Settings >

Network Communications Setup >

Wireless Setup

ESSID View the ESSID Value

The Extended Service Set Identification (ESSID) is an identifier for your wireless

network. This setting, which cannot be modified from the control panel, gives the

ESSID for the current wireless configuration.

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

Related ZPL command(s): none

SGD command used: wlan.essid

Printer web page: View and Modify Printer Settings >

Network Communications Setup >

Wireless Setup

Table 9 • NETWORK Menu (Continued)

Printer Configuration

Changing Printer Settings

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Channel View the Channel Value

This parameter retrieves the current WI-FI channel the printer is using.

Accepted values: N/A

Related ZPL command(s): none

SGD command used: wlan.essid

Printer web page: View and Modify Printer Settings >

Network Communications Setup >

Wireless Setup

Signal View the Signal Value

This parameter returns the signal strength of the connection to the access point

as a percentage value between zero (not connected) and 100 (strongest signal). Values

below 40% represent a very poor signal and radio communication is not reliable.

Accepted values: N/A

Related ZPL command(s): none

SGD command used: wlan.signal_strength

Printer web page: View and Modify Printer Settings >

Network Communications Setup >

Wireless Setup

IP Port View the IP Port Value

This printer setting refers to the wireless 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.

Accepted values: N/A

Related ZPL command(s): none

SGD command used: wlan.ip.port

Printer web page: View and Modify Printer Settings >

Network Communications Setup >

Wireless Setup

IP Alternate Port View the IP Alternate Port Value

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

Note - Print servers supporting this command will monitor both the primary port and

the alternate port for connections at the same time.

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

Related ZPL command(s): none

SGD command used: wlan.ip.port_alternate

Printer web page: View and Modify Printer Settings >

Network Communications Setup >

Wireless Setup

Table 9 • NETWORK Menu (Continued)

Printer Configuration

Changing Printer Settings

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

Reset Network This option resets the wired or wireless print server. You must reset the print server to

allow any changes to the network settings to take effect.

Accepted values: N/A

Related ZPL command(s): ~WR

SGD command used: device.reset

Printer web page: Print Server Settings >

Factory Print Server Settings

Table 9 • NETWORK Menu (Continued)

Printer Configuration

Changing Printer Settings

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RFID Menu

See the latest version of the RFID Programming Guide 3 for more information on using this

printer’s RFID module. Go to the Zebra Web site: www.zebra.com

Table 10 • RFID Menu

RFID Status Display the status of the RFID subsystem of the printer.

Accepted values: N/A

Related ZPL command(s): ^HL or ~HL

SGD command used: rfid.error.response

Printer web page: N/A

RFID Calibrate Use this command to initiate tag calibration for RFID media. (Not the same as manual

calibration for media.) During the process, the printer moves the media, calibrates the

RFID tag position, and determines the optimal settings for the RFID media being used.

Important • Before you use this command, load the printer with RFID media, ensure

that the printer is calibrated for the media, and close the printhead. Feed one label.

See Manual Calibration - Media on page 75 to calibrate the media (and RFID

Calibration on page 76 for a menu accessible alternative method to this command).

Depending on the printer, these settings include the programming position, the antenna

element to use, the read/write power level to use, and it read's the tag's TID to determine

the chip type.

To restore the printer’s default programming position at any time, use the "restore"

option in the rfid.tag.calibrate SGD command.

Leave all transponders before and after the tag that is being calibrated. This allows the

printer to determine RFID settings which do not encode the adjacent tag. Allow a

portion of media to extend out the front of the printer to allow for backfeed during the

tag calibration procedure.

Accepted values: N/A

Related ZPL command(s): ^HR

SGD command used: rfid.tag.calibrate

Printer web page: N/A

Printer Configuration

Changing Printer Settings

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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.

Accepted values: EPC = reads the first 128 bits of EPC data

memory bank sizes = reads the EPC, TID, and

USER memory banks sizes. Determines the

sizes of the EPC, TID, and USER memory

banks.

protocol bits = reads the protocol bits from the EPC

memory banks and converts that value to the

EPC size

TID information = reads the first 32 bits of the TID

(Tag ID)

password status = reads the tag’s access and kill

passwords

Related ZPL command(s): ^RF

SGD command used: rfid.tag.read.content

and

rfid.tag.read.execute

Printer web page: N/A

RFID Test During the RFID test, the printer attempts to read and write to a transponder. No printer

movement occurs with this test.

Note - Ensure that the RFID tag is positioned over the printer's RFID antenna.

Accepted values: quick = performs a read EPC test and a write EPC

test (using random data)

read = performs a read EPC test

write = performs a write EPC test (using random

data)

Related ZPL command(s): N/A

SGD command used: rfid.tag.test.content

and

rfid.tag.test.execute

Printer web page: N/A

Table 10 • RFID Menu (Continued)

Printer Configuration

Changing Printer Settings

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Programming

Position

If the desired programming position (read/write position) is not achieved through RFID

tag calibration, a value may be specified. See the Zebra RFID Programming Guide 3 for

more details.

Accepted values: F0 to Fxxx (where xxx is the label length in

millimeters or 999, whichever is less)

The printer feeds the label forward for the

specified distance and then begins

programming.

B0 to B30

The printer backfeeds the label for the

specified distance and then begins

programming. To account for the backfeed,

allow empty media liner to extend out of the

front of the printer when using a backward

programming position.

Related ZPL command(s): ^RS

SGD command used: rfid.position.program

Printer web page: View and Modify Printer Settings > RFID Setup

> PROGRAM POSITION

RFID Read

Power

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

specified.

Accepted values: 0 to 30

Related ZPL command(s): ^RW

SGD command used: rfid.reader_1.power.read

Printer web page: View and Modify Printer Settings > RFID Setup

> RFID READ PWR

RFID Write

Power

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

specified.

Accepted values: 0 to 30

Related ZPL command(s): ^RW

SGD command used: rfid.reader_1.power.write

Printer web page: View and Modify Printer Settings > RFID Setup

> RFID WRITE PWR

RFID Valid

Counter

Resets the RFID valid label counter to zero.

Accepted values: N/A

Related ZPL command(s): ~RO

SGD command used: odometer.rfid.valid_resettable

Printer web page: N/A

Table 10 • RFID Menu (Continued)

Printer Configuration

Changing Printer Settings

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RFID Void

Counter

Resets the RFID void label counter to zero.

Accepted values: N/A

Related ZPL command(s): ~RO

SGD command used: odometer.rfid.void_resettable

Printer web page: N/A

RFID Tag

Calibration

Initiate tag calibration for RFID media. (Not the same as manual calibration for media.)

Accepted values: N/A

Related ZPL command(s): ^HR

SGD command used: rfid.tag.calibrate

Printer web page: N/A

Table 10 • RFID Menu (Continued)

Printer Configuration

Changing Printer Settings

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LANGUAGE Menu

Table 11 • LANGUAGE Menu

Language If necessary, change the language that the printer displays.

This change affects the words shown on the following:

•the Home menu

•the user menus

•error messages

•the printer configuration label, the network configuration label, and other labels that you

can select to print through the user menus.

Note • The selections for this parameter are displayed in the actual languages to

make it easier for you to find one that you are able to read.

Accepted values: See the ZPL programmer’s guide - ZPL and SGD enter

the values differently.

Related ZPL command(s): ^KL

SGD command used: display.language

Printer web page: View and Modify Printer Settings > General Setup >

Language

ZPL

Override

Enable ZPL Override

Enable this menu item to prevent the following ZPL commands from changing the printer’s

current settings:

•^MM (print mode)

•^MT (Direct Thermal or Thermal Transfer print method)

•^MN (media type non-continuous or continuous)

When this menu item is disabled, these commands override the printer’s settings.

Accepted values: •DISABLED

•ENABLED

Related ZPL command(s): none

SGD command used: zpl.zpl_override

Printer web page: N/A

Printer Configuration

Changing Printer Settings

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Command

Character

Set the Format Command Prefix Value

The format command prefix is a two-digit hex value used as a parameter place marker in

ZPL/ZPL II format instructions. The printer looks for this hex character to indicate the start

of a ZPL/ZPL II format instruction.

Set the format command character to match what is used in your label formats.

Important • You cannot use the same hex value for the format command prefix,

control character, and delimiter characters. The printer must see different characters

to work properly. If you are setting the value through the control panel, the printer

will skip any value that is already in use.

Accepted values: 00 to FF

Related ZPL command(s): ^CC or ~CC

SGD command used: zpl.caret

Printer web page: View and Modify Printer Settings > ZPL Control

Control

Character

Set the Control Prefix Character Value

The printer looks for this two-digit hex character to indicate the start of a ZPL/ZPL II

control instruction.

Set the control prefix character to match what is used in your label formats.

Accepted values: 00 to FF

Related ZPL command(s): ^CT or ~CT

SGD command used: zpl.control_character

Printer web page: View and Modify Printer Settings > ZPL Control

Delimiter

Character

Set the Delimiter Character Value

The delimiter character is a two-digit hex value used as a parameter place marker in

ZPL/ZPL II format instructions.

Set the delimiter character to match what is used in your label formats.

Accepted values: 00 to FF

Related ZPL command(s): ^CD or ~CD

SGD command used: zpl.delimiter

Printer web page: View and Modify Printer Settings > ZPL Control

ZPL Mode Set the ZPL Mode

Select the mode that matches what is used in your label formats.

This printer accepts label formats written in either ZPL or ZPL II, eliminating the need to

rewrite any ZPL formats that already exist. The printer remains in the selected mode until it

is changed in one of the ways listed here.

Accepted values: •ZPL II

•ZPL

Related ZPL command(s): ^SZ

SGD command used: zpl.zpl_mode

Printer web page: View and Modify Printer Settings > ZPL Control

Table 11 • LANGUAGE Menu (Continued)

Printer Configuration

Changing Printer Settings

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SENSOR Menu

Table 12 • SENSOR Menu

Sensor Type Select the Media Sensor

Select the media sensor that is appropriate for the media that you are using. The

reflective sensor can be used with all media types. The transmissive sensor should be

used only for simple gap media.

Accepted values: •TRANSMISSIVE

•REFLECTIVE

Related ZPL command(s): ^JS

SGD command used: device.sensor_select

Printer web page: View and Modify Printer Settings > Media Setup

Label Sensor Set the Sensitivity of the Label Sensor

Important • This value is set during sensor calibration. Do not change this

setting unless you are told to do so by Zebra Technical Support or by an

authorized service technician.

Accepted values: 0 – 255

Related ZPL command(s): none

SGD command used: ezpl.label_sensor

Printer web page: View and Modify Printer Settings > Calibration

Take Label Set the Intensity of the Take Label LED

Important • This value is set during sensor calibration. Do not change this

setting unless you are told to do so by Zebra Technical Support or by an

authorized service technician.

Accepted values: 0 – 255

Related ZPL command(s): none

SGD command used: ezpl.take_label

Printer web page: View and Modify Printer Settings > Calibration

Printer Configuration

Changing Printer Settings

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PORTS Menu

Table 13 • PORTS Menu

Baud Rate Set the Baud Rate

Select the baud value that matches the one being used by the host computer.

Accepted values: •115200

•57600

•38400

•28800

•19200

•14400

•9600

•4800

Related ZPL command(s): ^SC

SGD command used: comm.baud

Printer web page: View and Modify Printer Settings >

Serial Communications Setup

Data Bits Set the Data Bits Value

Select the data bits value that matches the one being used by the host computer.

Accepted values: •7

•8

Related ZPL command(s): ^SC

SGD command used: comm.data_bits

Printer web page: View and Modify Printer Settings >

Serial Communications Setup

Parity Set the Parity Value

Select the parity value that matches the one being used by the host computer.

Accepted values: •NONE

•EVEN

•ODD

Related ZPL command(s): ^SC

SGD command used: comm.parity

Printer web page: View and Modify Printer Settings >

Serial Communications Setup

Printer Configuration

Changing Printer Settings

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Host Handshake Set the Host Handshake Protocol Value

Select the handshake protocol that matches the one being used by the host computer.

Accepted values: •XON/XOFF

•RTS/CTS

•DSR/DTR

Related ZPL command(s): ^SC

SGD command used: comm.handshake

Printer web page: View and Modify Printer Settings >

Serial Communications Setup

Parallel Mode Set the parallel port to allow two-way or one-way host to printer communication.

Select the method that matches the one being used by the host computer for various

error and status messages from the printer.

Accepted values: •"bidirectional"

•"unidirectional"

Related ZPL command(s): ^SC

SGD command used: parallel_port.mode

Printer web page: View and Modify Printer Settings >

Serial Communications Setup

Table 13 • PORTS Menu (Continued)

Printer Configuration

Changing Printer Settings

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BLUETOOTH Menu

Table 14 • BLUETOOTH Menu

Bluetooth

Address

Displays the printer’s Bluetooth Device Address

Accepted values: N/A

SGD command used: bluetooth.address

Mode Displays the Bluetooth connection pair printer’s device type - Slave (typical) or Master.

Accepted values: N/A

SGD command used: N/A

Discovery Sets and displays if the printer is ‘Discoverable’ for Bluetooth device pairing.

Accepted values: "on" = enables Bluetooth discoverable mode

"off" = disables Bluetooth discoverable mode

SGD command used: bluetooth.discoverable

Connected Displays the Bluetooth connection status to it’s paired device - Yes or No

Accepted values: N/A

SGD command used: N/A

BT Spec Version Displays the Bluetooth operational specification level. This printer’s Bluetooth radio is

operating to Bluetooth Spec. 3.0

Accepted values: N/A

SGD command used: bluetooth.radio_version

Min. Security

Mode

Displays the printer’s Bluetooth minimum level of applied security - Security Mode 1

Accepted values: N/A

SGD command used: N/A

Printer Configuration

Manual Calibration - Media

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Manual Calibration - Media

The printer may need to have the sensors and the label length adjusted for a new media. Small

variations in media from manufacture to manufacture and even from batch to batch of media

may necessitate recalibrating the printer for the media being used.

Use the Manual Calibration procedure when you change media unless to it media from the

same batch you have been using.

The primary method used to set the printer for media in use is the control panels SENSORS

menu to access the MANUAL CALIBRATION procedure. Use the following procedure to set

your printer’s language when the printer is turned on and in the ‘Ready’ state.

Procedure for calibration of label media with liner and inter-label ‘GAP’ between labels.

1. Load the printer with your chosen label media. Verify the media sensor is in the center

position for label gap (transmissive) sensing, see below.

2. Remove the first 3 inches or 80 mm of labels from the liner. Place the label-less liner over

the platen (driver roller) and the leading edge of the first label under the media guides.

3. Close the printer. Turn the printer power ON. Press the menus ‘Home’ ( ) button.

4. Navigate to the ‘SENSORS’ ( ) menu button and press the ‘Select’ () button.

5. Use the ‘Left’ () and ‘Right’ () navigation arrows to browse to the ‘MANUAL

CALIBRATION’ procedure.

6. Press the select button (—) below the START on the lower right hand of the display.

7. The display will have a message:

LOAD BACKING

PRINTER PAUSED

8. Press the Pause button once to start the calibration procedure.

9. When it has finished the first part of the calibration, the display will read:

RELOAD ALL

CONTINUE.

10. Press the Pause button once again to continue the calibration procedure. The printer will

begin feeding several labels and then it will stop with the display message reading:

READY

Remove excess media. Media calibration has finished and you are ready to print.

Center

Position

Media

Guide

Printer Configuration

RFID Calibration

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RFID Calibration

RFID calibration sets communication parameters for your tag type. This procedure should be

done after the printer has been calibrated for the media (length and gap settings), typically a

Manual Media Calibration. During the RFID calibration 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 read/write power level to use, and reads

the tag's TID to determine the chip type (or choose F0 from the front panel RFID menu).

To restore the printer’s default programming position at any time, use the "restore" option in

the rfid.tag.calibrate SGD command.

Do not remove any labels or tag from the liner (label backing or ‘web’). This allows the printer

to determine RFID settings which do not encode adjacent tags. Allow a portion of media to

extend out the front of the printer to allow for backfeed during the tag calibration procedure.

Always do a Manual Media Calibration and RFID Calibration when you change media type. It

should not be necessary when simply replacing an empty roll of the same media.

Before beginning, load RFID media into the printer and perform the manual media

calibration.

1. Press the Feed button once to feed (advance) one label.

2. Press the menus ‘Home’ ( ) button. Navigate to the ‘RFID’ ( ) menu button and press

the ‘Select’ () button.

3. Use the ‘Left’ () and ‘Right’ () navigation arrows to browse to the ‘RFID

CALIBRATE’ procedure. Press the select button (—) below the START on the lower

right hand of the display.

4. The printer will slowly feed a label while adjusting the location and RFID read/write

communication settings for your chosen RFID tag/label.

The printer will feed an additional label in some cases when calibration has completed

successfully with the display message reading: READY

5. Remove excess media. Media calibration has finished and you are ready to print.

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Print Operations

This section provides media and print handling, font and language support, and the setup of

less common printer configurations.

Print Operations

Determining Printer Configuration

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Determining Printer Configuration

The ZD500 Series™ printer uses the configuration report to provide the printer’s status for

both ZPL. Operational status (darkness, speed, media type, etc.), installed printer options

(network, interface settings, cutter, etc.) and printer description information (serial number,

model name, firmware version, etc.) are all includes on the status label. See Test Printing with

Configuration Report Printouts on page 27 to print this label.

Thermal Printing

Modes of Printing

You can operate this printer in many different modes and media configurations:

• Direct thermal printing (which uses heat sensitive media to print).

• Thermal transfer printing (which uses ribbon to heat transfer print to the media).

• Standard Tear-Off mode allows you to tear off each label (or batch print a strip of labels)

after it is printed.

• Label Dispense Mode: If an optional dispenser is installed, the backing material can be

peeled away from the label as it is printed. After this label is removed, the next one is

printed.

• Media Cutting: If an optional media cutter is installed, the printer can cut the label liner

between labels, receipt paper or tag stock depending upon the cutter option purchased.

• Stand-alone: The printer can print without being connected to a computer using the

printer’s auto running label form feature (programming based) or by using a data input

device connected to the printer’s serial port. This mode accommodates data input devices,

such as scanners, weigh scales, a Zebra Keyboard Display Unit (ZKDU), etc.

• Shared network printing: Printers configured with the Ethernet interface option include an

internal print server with ZebraLink™ printer configuration web page and ZebraNet™

Bridge software for managing and monitoring status of Zebra® printers on a network.

Caution • 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.

Caution • 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 under the top cover.

Print Operations

Types of Media

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Setting the Thermal Print Method

The ZD500 Series™ printer has been designed to print in direct thermal and thermal transfer

modes. Press the menus ‘Home’ ( ) button. Navigate to the ‘SENSORS’ ( ) menu button

and press the ‘Select’ () button. Use the ‘Left’ () and ‘Right’ () navigation arrows to

browse to the ‘PRINT METHOD’. Use the Up () and Down () arrows to select DIRECT

THERMAL or THERMAL TRANS (transfer) media.

Types of Media

Your printer can use various types of media:

•Standard media—Most standard (non-continuous) media uses an adhesive backing that

sticks individual labels or a continuous length of labels to a liner.

•Continuous roll media—Most continuous roll media is direct thermal media (similar to

FAX paper) and is used for receipt or ticket style printing.

•Tag sto ck—Tags are usually made from a heavy paper (up to 0.0075in./0.19mm thick).

Tag stock does not have adhesive or a liner, and it is typically perforated between tags.

For more information on basic media types, see Table 15.

The printer typically uses roll media, but you can use fan-fold or other continuous media too.

Use the correct media for the type of printing you require. When printing without a ribbon, you

must use direct thermal media. When using ribbon, you must use thermal transfer media.

Determining Thermal Media Types

Thermal transfer media requires ribbon for printing while direct thermal media does not.

To determine if ribbon must be used with a particular media, perform a media scratch test.

To perform a media scratch test, complete these steps:

1. Scratch the print surface of the media with a finger nail or pen cap. Press firmly and

quickly while dragging it across the media surface. Direct thermal media is chemically

treated to print (expose) when heat is applied. This test method uses friction heat to expose

the media.

2. Did a black mark appear on the media?

Important • Zebra strongly recommends the use of Zebra-brand supplies for continuous

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 http://www.zebra.com/howtobuy.

Note - Zebra does not offer RFID media for sale at this time.

If a black mark... Then the media is...

Does not appear on the media Thermal transfer. A ribbon is required.

Appears on the media Direct thermal. No ribbon is required.

Print Operations

Types of Media

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Table 15 • Types of Media Roll and Fanfold Media

Media Type How It Looks Description

Non-Continuous

Roll Media

Roll media is wound on a core that can be 0.5 to 1.5 in. (12.7 to

38.1 mm) in diameter. Labels have adhesive backing that sticks

them to a liner, and they are separated by gaps, holes, notches, or

black marks. Tags are separated by perforations. Individual labels

are separated by one or more of the following methods:

•Web media separates labels by gaps, holes, or notches.

•Black mark media uses pre-printed black marks on the back

side of the media to indicate label separations.

•Perforated media has perforations that allow the labels or tags

to be separated from each other easily. The media may also

have black marks or other separations between labels or tags.

Non-Continuous

Fanfold Media

Fan-Fold media is folded in a zigzag pattern. Fanfold media can

have the same label separations as non-continuous roll media.

The separations would fall on or near the folds.

Continuous

Roll Media

Roll media is wound on a core that can be 0.5 to 1.5 in. (12.7 to

38.1 mm) in diameter. Continuous roll media does not have gaps,

holes, notches, or black marks to indicate label separations. This

allows the image to be printed anywhere on the label. A cutter

can be used to cut apart individual labels. With continuous media,

use the transmissive (gap) sensor so the printer can detect when

the media runs out.

Print Operations

Media Loading

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Media Loading

Use the 3 inch Core Adapters for media mounted on a 3 inch I.D. (Inner Diameter) rolls. The

maximum outside diameter of the roll is 5 inches.

Attaching the 3 inch Core Adapters

1. Open the printer.

2. Open the media roll holder. For easier access, the media guide stop adjustment can be

turned toward the front of the printer to lock open the media roll holders for easier access

to those roll holders.

3. Snap the core adapters onto the media roll holders. The hole on the adapter align with the

roll holder roll mount. the extended part of the adapter goes under the media guide in the

front of the media roll holder.

Print Operations

Media Loading

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Loading 3 inch I.D. Media rolls

1. With the printer open and the 3 inch media core adapters installed, open the media roll

holders.

2. Place the media roll on the hangers on the top of the core adapters and let the media guides

close to hold the roll. Note you may need turn the media guide stop adjustment toward the

rear of the printer to allow the media roll holders to fully close on the media roll.

Print Operations

Media Loading

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Removing the 3 inch Core Adapters

1. Open the printer and remove any media from the printer.

2. Push the locking tab on the backside of the core adapter. Push it up and towards the middle

of the printer. The core adapter will pop off the media roll holder.

3. Remove the other core adapter the same way.

Print Operations

Ribbon Overview

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Ribbon Overview

Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is

transferred to the media during the thermal transfer process. The media determines whether

you need to use ribbon and how wide the ribbon must be. When ribbon is used, it must be as

wide as or wider than the media being used. If the ribbon is narrower than the media, areas of

the printhead are unprotected and subject to premature wear.

When to Use Ribbon

Thermal transfer media requires ribbon for printing while direct thermal media does not.

Direct thermal media should never be used with ribbon. Bar codes and graphics can get

distorted. To determine if ribbon must be used with a particular media, perform a media

scratch test.

Coated Side of Ribbon

Ribbon can be wound with the coated side on the inside or outside. This printer can only use

ribbon that is coated on the outside. If you are unsure which side of a particular roll of ribbon

is coated, perform an adhesive test or a ribbon scratch test to determine which side is coated.

To determine which side of a ribbon is coated, complete these steps:

Ribbon Test with Adhesive

If you have labels available, perform the adhesive test to determine which side of a ribbon is

coated. This method works well for ribbon that is already installed.

To perform an adhesive test, complete these steps:

1. Peel a label from its liner.

2. Press a corner of the sticky side of the label to the outer surface of the roll of ribbon.

3. Peel the label off of the ribbon.

4. Observe the results. Did flakes or particles of ink from the ribbon adhere to the label?

Outside Inside

If ink from the ribbon... Then...

Adhered to the label The ribbon is coated on the outside and can be used with

the printer.

Did not adhere to the label The ribbon is coated on the inside and can not be used in

the printer.

Print Operations

Ribbon Overview

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Ribbon Scratch Test

Perform the ribbon scratch test when labels are unavailable.

To perform a ribbon scratch test, complete these steps:

1. Unroll a short length of ribbon.

2. Place the unrolled section of ribbon on a piece of paper with the outer surface of the

ribbon in contact with the paper.

3. Scratch the inner surface of the unrolled ribbon with your fingernail.

4. Lift the ribbon from the paper.

5. Observe the results. Did the ribbon leave a mark on the paper?

If the ribbon... Then...

Left a mark on the paper The ribbon is coated on the outside and can be used with

the printer.

Did not leave a mark on the

paper

The ribbon is coated on the inside and can not be used in

the printer.

Print Operations

Replacing Supplies

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Replacing Supplies

If labels or ribbon 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 label or ribbon roll, press the Feed

button to restart.

Always use high quality, approved labels, tags and ribbons. If adhesive backed labels are used

that don’t lay flat on the backing liner, the exposed edges may stick to the label guides and

rollers inside the printer, causing the label to peel off from the liner and jam the printer.

Permanent damage to the printhead may result if a non-approved ribbon is used as it may be

wound incorrectly for the printer or contain chemicals corrosive to the printhead.

Adding a New Transfer Ribbon

If ribbon runs out in the middle of a print job, the indicator lights red and the printer waits for

you to add a fresh roll.

1. Keep the power on as you change ribbon.

2. Open the top cover, then cut the used ribbon so you can remove the cores.

3. Load a new ribbon roll and empty ribbon core. If necessary, review the Ribbon Loading

steps. Note: Do Not Use ribbon cores with damaged notch. The notches should have

square corners.

4. Close the top cover.

5. Press the Feed button to restart printing.

Replacing a Partially Used Transfer Ribbon

To remove used transfer ribbon, perform the following steps.

1. Cut the ribbon from the take-up roll.

2. Remove the take-up roll and discard used ribbon.

3. Remove the supply roll and tape the end of any fresh ribbon to prevent it from

unwrapping. When reinstalling a partially used supply roll, tape the cut end onto the

empty take-up roll.

Print Operations

Adjusting the Print Width

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Adjusting the Print Width

Print width must be set when:

• You are using the printer for the first time.

• There is a change in media width.

Print width may be set by:

• The Windows printer driver or application software such as ZebraDesigner™.

• Using the control panel. Navigate as follows:

• Press the menus ‘Home’ ( ) button. Navigate to the ‘SETTINGS’ ( ) menu

button and press the ‘Select’ () button. Use the ‘Right’ () navigation arrow to

browse to ‘PRINT WIDTH’.Use the ‘Up’ () and ‘Down’ () navigation arrows to

change the print width. The print with is expressed in dots/pixels.

• Controlling printer operations with ZPL programming; refer to the Print Width (^PW)

command (consult your ZPL Programming Guide).

Adjusting the Print Quality

Print quality is influenced by the heat (density) setting of the printhead, the print speed, and the

media in use. Experiment with these settings to find the optimal mix for your application. Print

quality can be set with the Zebra Setup Utility’s ‘Configure Print Quality’ routine.

The relative darkness (or density) setting can be controlled by:

• Using the control panel. Navigate as follows:

• Press the menus ‘Home’ ( ) button. Navigate to the ‘SETTINGS’ ( ) menu

button and press the ‘Select’ () button. Use the ‘Right’ () navigation arrow to

browse to ‘DARKNESS’. Use the ‘Up’ () and ‘Down’ () navigation arrows to

change the darkness setting.

• The Set Darkness (~SD) ZPL command (consult your ZPL Programming Guide).

If you find that the print speed needs to be adjusted, use:

• The Windows printer driver or application software such as ZebraDesigner™.

• The Print Rate (^PR) command (consult your ZPL Programming Guide).

Use the printer’s ‘Print Quality Report’ (also know as FEED Self Test) to print a range of

labels used to allow you to identify changes to print DARKNESS and SPEED settings to

optimize general print and bar code quality. See the Print Quality Report on page 135 for

details.

Note • Media manufactures may have specific recommendations for speed settings for your

printer and the media. Some media types have lower maximum speeds than your printer’s

maximum speed.

Print Operations

Media Sensing

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Media Sensing

The ZD500 Series™ printer media controls are set via a control panel setting or by sending

commands to the printer.

The printer’s media settings can be verified by printing a Printer Configuration label. See the

Test Printing with Configuration Report Printouts on page 27 for more details.

The maximum distance that the automatic media type detection and sensing will check can be

reduced by using the ZPL Maximum Label Length command (^ML). It is recommended that

this distance be set to no less than two times the longest label being printed. If the largest label

being printed was a 4 by 6 inch label, then the maximum label (media) length detection

distance can be reduced from the default distance of 39 inches down to 12 inches.

Table 16 • Media Settings

Menu Item Setting

MEDIA TYPE SETTINGS Menu on page 52 for media sensing method

TEAR OFF SETTINGS Menu on page 52 for setting the media

position after printing or a feed action.

PRINT MODE SETTINGS Menu on page 52 to set media handling after

printing or a feed action.

LABEL LENGTH MAX SETTINGS Menu on page 52 (see below for description).

POWER UP ACTION TOOLS Menu on page 56 to set what the media does on

power up.

HEAD CLOSE ACTION TOOLS Menu on page 56 to set what the media does when

the printer is closed.

MANUAL CALIBRATION Manual Calibration - Media on page 75 for the procedure

to automatically adjust the printer for typical label media.

TOOLS Menu on page 56 to start the manual calibration

process.

SENSOR PROFILE Sensor Profile on page 140 to observe and possibly

change media sensing for hard to calibrate media that for

example ‘has printing on the liner’ or ‘has pre-printe’

media‘ that can interfere with a manual calibration.

Print Operations

Using the Movable Black Mark Sensor

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Using the Movable Black Mark Sensor

The movable black mark sensor allows the printer to use media with black marks or notches

(holes) on the back side of the media (or media liner) that are not located in the center of the

media.

The movable sensor’s second functional feature is adjustable transmissive web (gap) sensing

to positions that match legacy Zebra® desktop printer sensor locations and in between. This

provides for use of some non standard media variations or irregularly shaped media.

The movable black mark sensor can not properly sense continuous media or labels (for inter-

label gap sensing) if the sensor is not in the default sensing area for web (gap) sensing. See

Adjusting the Movable Sensor for Web (Gap) Sensing on page 92

Movable

Black Mark Sensor

Off Center

Black Mark Sensing Only

Default - Web (GAP) Sensing

Standard Operating Position

Alignment

Key

Print Operations

Using the Movable Black Mark Sensor

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Adjusting the Movable Sensor for Black Marks or Notches

The black mark sensor looks for non-reflective surfaces such as black marks, black lines,

notches or holes in the media which do not reflect the sensor’s beam back to the sensor’s

detector. The sensor and it’s black mark detector are next to each other under the sensor cover

(dark plastic cover is translucent to the sensor’s non-visible light).

The sensor can be adjusted by two methods:

1) Preferred - Aligning the movable sensor’s alignment arrow to the right side of a black mark

or notch located in the center or left side of the printer, or

2) Align the center of the sensor cover under the oval notch or a right hand black mark (or

notch).

The sensor should be set as far as possible from the edge of media. The media can move from

side to side and notches cut into the side of the media can become damaged.

Load the media. Before closing the printer, adjust the moveable black mark sensor as follows:

1. Flip the media back over the roll to expose the black marks or notches on the backside

(non printing side) of the media.

Black Marks

Print Operations

Using the Movable Black Mark Sensor

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2. Slide the movable sensor from the center default position to align with the black marks.

The arrow on the movable sensor should line up with the right edge of the black mark.

This is true for marks or notches located on either side of the media (left side shown).

Print Operations

Using the Movable Black Mark Sensor

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Adjusting the Movable Sensor for Web (Gap) Sensing

The movable sensor supports the web/gap positions used by the legacy Zebra® desktop printer

models and for some non standard media configurations. Printer’s with typical web (gap)

sensing in the fixed center position or the movable sensor’s set to the default position are offset

from the center of the printer to allow for gap sensing of labels that are side by side on a roll -

see below.

Web (Gap) sensing with the movable sensor can only function when the sensor’s alignment

arrow points to any position on the alignment key. The sensor must be aligned with the labels

(or other media) to sense the gap between the labels. The example above shows where the

sensor is set if center aligned positioning is used. It will miss sensing labels with a 2-up label

configuration and with the sensor in the ‘default’ position, it will be able to the detect labels

and the gaps between them.

• Default — Zebra Models: G-Series™ fixed position sensors, LP/TLP 2842™,

LP/TLP 2844™, LP/TLP 2042™

• Center Aligned — Zebra Model: LP/TLP 2742™

Default Gap

Sensing Position

Adjustment Range - Left to Right

DefaultCenter Aligned

Print Operations

Printing on Fan-Fold Media

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Printing on Fan-Fold Media

Printing on fan-fold media requires you to adjust the media guide’s stop position.

1. Open the top cover.

2. Adjust the media guide stop position with the green thumb wheel. Use a piece of the fan-

fold media to set the stop position. Rotate the wheel toward you to open the guides wider.

Rotate the wheel away from you to make the media guide narrower.

Fan-Fold

Media Path

Print Operations

Printing on Fan-Fold Media

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3. Insert the media through the slot at the rear of the printer.

4. Run the media between the media guide and roll holders.

5. Close the top cover.

After printing or feeding 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 guides may need further adjustment. If this does not correct

the problem, then the media can be routed over the two roll holding pins on the media guide.

An empty roll core of the same width as the stack of the fan-fold media can be placed between

the roll holders to provide additional support for thin media.

Print Operations

Printing with Externally Mounted Roll Media

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Printing with Externally Mounted Roll Media

The printer accommodates externally mounted roll media similar to the printer’s support of

fan-fold media. The printer requires the media roll and stand combination to have a low initial

inertia to pull the media off the roll.

Zebra at this time does not offer an external media option for the ZD500 Series™ printer.

Externally Mounted Roll Media Considerations:

• The media ideally should enter the printer directly behind the printer through the fan-fold

media slot in the rear of the printer. See Printing on Fan-Fold Media on page 93 for media

• Lower the print speed to decrease the chance of motor stalls. The roll typically has the

highest inertia when trying to start the roll moving. Larger media roll diameters require the

printer to have more torque applied to get the roll moving.

• The media should move smoothly and freely. The media should not slip, skip, jerk, bind

and then move, etc. when mounted on your media stand.

• The printer should not touch the media roll.

• The printer should not slip or lift up off the operating surface.

Sending Files to the Printer

Graphics, fonts and programming files can be sent to the printer from the Microsoft Windows

operating systems by using the Zebra Setup Utilities (and driver), ZebraNet™ Bridge or

Zebra® ZDownloader found on the user's CD or at www.zebra.com.

Print Operations

Fonts and Your Printer

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Fonts and Your Printer

The ZD500 Series™ printer supports your language and font requirements with a variety of

internal fonts, on-board font scaling, international font sets and character code page support,

Unicode support, and font download.

The printer’s font capabilities are programming language dependent. 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. ZPL programming guide describes and documents

the fonts, code pages, character access, listing fonts, and limitations for their respective printer

programming languages. See the printer programming guides for information on Text, Fonts

and Character support.

The printer includes utilities and application software that support font download into the

printer for both printer programming languages.

Identifying Fonts in Your Printer

Fonts and memory are shared by the programming languages in the printer. Fonts can be

loaded in many memory areas in the printer. ZPL programming can recognize EPL and ZPL

fonts. EPL programming can only recognize EPL fonts. See the respective programmer guides

for more information on fonts and printer memory.

ZPL Fonts:

• To manage and download fonts for ZPL print operation, use the Zebra Setup utility or

ZebraNet™ Bridge.

• To display all of the fonts loaded in your printer, send the printer the ZPL command ^WD.

See the ZPL Programmers Guide for details.

• Bitmap fonts in the various printer memory areas are identified by the .FNT file

extension in ZPL.

• Scalable fonts are identified with the .TTF, .TTE or .OTF file extensions in ZPL.

EPL does not support these fonts.

Localizing the Printer with Code Pages

The ZD500 Series™ printer supports two sets of language, region and character sets for

permanent fonts loaded into the printer for each printer programming language, ZPL and EPL.

The printer supports localization with common international character map code pages.

• For ZPL code page support, including Unicode, see the ^CI command in the ZPL

programmer’s guide.

Print Operations

Fonts and Your Printer

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Asian fonts and Other Large Font Sets

Asian language 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.

In order to address multiple languages with a single font set, Unicode was invented. A

Unicode font supports one or more code points (relate these to code page character maps) and

is accessed in a standard method that resolves character mapping conflicts. The ZPL

programming language supports Unicode. Both of the printer’s programming languages

support the large pictographic double-byte character Asian font sets.

The number of fonts that can be downloaded is dependent upon the amount of available flash

memory not already in use and the size of the font to be downloaded.

Some Unicode fonts are large such as MS (Microsoft) Arial Unicode font (23 MB) available

from Microsoft or the Andale font (22 MB) offered by Zebra. These large font sets typically

support a large number of languages as well.

Getting Asian Fonts

Asian bitmap font sets are downloaded into the printer by the user or integrator. The ZPL fonts

are purchased separately from the printer. EPL Asian Fonts are available for free to download

from the Zebra Web site.

• Simplified and Traditional Chinese

• Japanese — JIS and Shift-JIS mappings

• Korean including Johab

•Thai

Print Operations

Fonts and Your Printer

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Notes • ___________________________________________________________________

__________________________________________________________________________

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Printer Options

This section covers the common printer options and accessories with brief descriptions and

how to get you started using or configuring your printer option or accessory.

Printer Options

Label Dispenser Option

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Label Dispenser Option

The factory installed label dispenser option allows you to print a label with backing

(liner/web) being removed from the label as it prints, ready for application. When printing

multiple labels, removing the dispensed (peeled) label notifies the printer to print and dispense

the next label.

To use dispenser-mode correctly, use your printer driver to activate the label (taken) sensor

along with these typical label settings which include but are not limited to length, non-

continuous (gap), and web (liner). Otherwise, you must send the ZPL programming

commands to the printer.

When programming in ZPL, you can use the following command sequences shown below

and refer to your ZPL Programming Guide for more information on ZPL programming.

^XA ^MMP ^XZ

^XA ^JUS ^XZ

1. Load your labels into the printer. Close the printer and press the Feed button until a

minimum of 4 inches or 100 millimeters of exposed labels exit the printer. Remove the

exposed labels from the liner.

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Printer Options

Label Dispenser Option

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2. Lift the liner over the top of the printer and open the dispenser door.

3. Insert the label liner between the dispenser door and the printer body.

Printer Options

Label Dispenser Option

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4. Close the dispenser door.

5. Press the Feed button to advance the media.

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 printer will stack and eject peeled labels.

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Printer Options

Cutter Option

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Cutter Option

The printer supports a factory installed media cutter option for full width cutting of label liner,

tag or receipt media. These cutter options are all supported in a single cutter housing design.

The type of cutter option installed in your printer can be verified by printing a printer

configuration status label. The cutter options are:

•A medium duty cutter for cutting label liner and light tag media (LINER/TAG)

Maximum Paper Weight (thickness): up to 180 g/m2 (0.0077 in.)

Life*: 2 million cuts: 0.5 mil to 5 mil stock (10-120 g/m2)

1 million cuts: 5 mil to 7.5 mil stock (120-180 g/m2)

750,000 cuts: 7.5 mil to 10 mil (180-200 g/m2)

* - Exceeding the maximum media weight (density/hardness) and thickness will

shorten the cutters usable life or can cause the cutter to fail (jam or other error).

•Cut Width: 4.25 inches (108 mm) maximum to 0.75 inches (19 mm) minimum

•Minimum distance between cuts (label length): 1 inch (25.4 mm). Cutting shorter

media lengths between the cuts may cause the cutter to jam or error.

• By default, the cutter operations include a self cleaning preventive maintenance

cleaning cut after every twenty-fifth cut. This feature can be disabled via ZPL or SGD

(Set/Get/DO) programming command (cutter.clean_cutter) but is not

recommended.

Warning • 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 • Tools, cotton swabs, solvents (including alcohol), etc. all may damage or shorten

the cutter’s usable life or cause the cutter to jam.

Printer Options

Cutter Option

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Loading Media with the Cutter Option

1. Open the printer. Remember that you need to pull the release latch levers toward the front

of the printer.

2. Adjust the media sensor’s position for labels or continuous media to the center position. If

the media has black marks (not full width black lines) or notches, then see Adjusting the

Movable Sensor for Black Marks or Notches on page 90

3. Open the media roll holders. Pull the media guides open with your free hand and place the

media roll on the roll holders and release the guides. Orient the media roll so that its

printing surface will be up as it passes over the platen (drive) roller.

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Printer Options

Cutter Option

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4. Thread the media through the cutter’s inside slot so that it extends out of the front of the

printer. Verify the roll turns freely. The roll must not sit in the bottom of the media

compartment. Verify that media’s printing surface is facing up.

5. Push the media under both of the media guides.

6. Close the printer. Press down until the cover snaps closed.

Under Media

Guides

Printer Options

ZebraNet® Internal Wireless Print Server Option

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ZebraNet® Internal Wireless Print Server Option

The ZebraNet® Internal Wireless Print Server (PS) is an optional factory installed device that

connects to Wi-Fi network access point on your network and your ZebraLinkTM-enabled

printer. The print server provides you with a browser interface for printer and print server

settings. If you use the ZebraNetTM Bridge, Zebra® network printer management software,

you can easily access the specialized features of a ZebraLinkTM enabled printer.

Printers with an Internal Wireless Print Server provide the following features:

• A printer status display for alerts, configuration settings and network settings.

• Print server and printer setup using a browser.

• Remote monitoring and configuration capability of the Internal Wireless PS using a

browser.

•Alerts.

• The ability for you to send unsolicited printer status messages via E-mail-enabled

devices.

ZebraNetTM Bridge — ZebraNetTM Bridge is a software program that works with the

10/100 Internal PS and enhances the features of ZebraLink resident within ZPL-based printers.

The features include the following:

•ZebraNet

TM Bridge allows you to locate printers automatically. ZebraNetTM Bridge

searches on parameters such as IP address, subnet, printer model, printer status, and

many other user-defined characteristics.

• Remote Configuration — Manage all your Zebra label printers throughout the

enterprise without having to travel to remote sites or physically handle any printers.

Any Zebra printer connected to the enterprise network can be accessed from the

ZebraNetTM Bridge interface and configured remotely through an easy-to-use

graphical user interface.

• Printer Alerts, Status, Heartbeat Monitoring and event Notification — ZebraNetTM

Bridge lets you configure multiple event alerts per device with different alerts directed

to different people. Receive alerts and notifications by e-mail, cell phone/pager, or

through the ZebraNetTM Bridge Events tab. View alerts by printer or group, and filter

by date/time, severity, or trigger.

• Configure and Copy Printer Profiles — Copy and paste settings from one printer to

another or broadcast them to an entire group. ZebraNet Bridge allows you to copy

printer settings, printer-resident files (formats, fonts, and graphics), and alerts with a

click of the mouse. Create printer profiles — virtual “golden printers” — with desired

settings, objects, and alerts, and clone or broadcast them as if they were real printers,

providing extensive savings in setup time. Printer profiles are also an excellent way to

back up a printer’s configuration for crisis recovery.

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Printer Options

Bluetooth Option

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Bluetooth Option

Bluetooth is an optional factory installed (internal wireless) device that can connect to other

Bluetooth enabled devices and computers. The Bluetooth radio inside ZD500 Series™ printers

complies with Bluetooth Specification 3.0 and supports the Serial Port Profile (SPP), a

Windows virtual serial port. All print jobs sent to the printer on Windows PC’s will be done

through the SPP, which is basically a Bluetooth emulation of an RS-232 serial communication.

This printer option includes a LCD display to provide connection status and configuration

information to assist with installation and connection to a Bluetooth enabled host system.

Microsoft has supported most Bluetooth devices since the release of Windows XP Service

Pack 2 (SP2). Prior to that, Bluetooth devices for earlier versions of Windows required drivers

to be supplied with the device. Windows XP SP2 and above also include ‘Add a Printer’

wizard support for printers. The ZD500 Series™ printer is accessed via a Bluetooth virtual

serial port connection (SPP). The printer only needs Bluetooth 2.0 driver that supports SPP to

be able to communicate with the Windows PC’s Bluetooth devices.

In the Windows environment, the printer requires the ZebraDesigner™ driver to be installed

on the computer to enable printing after Bluetooth communication has been established. Use

the Zebra Setup Utility’s printer install wizards to help you configure your Bluetooth

connection.

Printer Options

Bluetooth Option

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Printer Network Configuration Status Label

ZD500 Series™ printers with the ZebraNet® Internal Wireless Print Server option on-board

print an additional printer configuration status label for information needed to establish and

trouble shoot network printing. The following printout is printed with the ZPL ~WL

command.

The regular printout of the configuration status label has some of the printer’s network settings

such as IP Address, on the lower half of the printout.

The printer’s IP address is needed to identify and configure the printer for operations on your

network. See the ZebraNet® Internal Wireless Print Server manual for more information.

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Maintenance

This section provides routine cleaning and maintenance procedures.

Maintenance

Cleaning

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Cleaning

When you clean the printer, use one of the following supplies that best suits your needs:

You can obtain cleaning supplies at www.zipzebra.com.

The cleaning process takes just a couple of minutes using the steps outlined below.

Cleaning Supplies Order

Quantity Intended Purpose

Cleaning pens (105950-035) Set of 12 Clean printhead

Cleaning swabs (105909-057) Set of 25 Clean media path, guides and sensors

Printer Part Method Interval

Printhead Let the printhead to cool for a minute, then use a

new cleaning pen to swab the dark line on the

printhead cleaning from the center to the outside

edges of the printhead.

See Cleaning the Printhead on page 111

When using ribbon:

after every roll of

ribbon; when using

direct thermal: after

every roll of media.

Platen roller Remove the platen roller to clean. Clean the

roller thoroughly with 90% medical-grade

alcohol and a cleaning swab or lint-free cloth.

See Platen Cleaning and Replacement

on page 114

As needed.

Peel bar Clean it thoroughly with 90% medical-grade

alcohol and a fiber-free cleaning swab.

Let alcohol dissipate and the printer dry

completely.

Media path

Cutter Option The cutter blade mechanism does not require

maintenance cleaning. DO NOT Clean the blade

or mechanism with solvents or WD-40. This

blade has a special coating to resist adhesives

and wear.

Exterior Water-dampened cloth. As needed.

Interior Gently brush out printer.

Caution • Adhesives and media material can over time transfer onto the printer

components along the media path including the platen and printhead. This build-up can

accumulate dust and debris. Failure to clean the printhead, media path and platen roller

could result in inadvertent loss of labels, label jams and possible damage to the printer.

Important • Using too much alcohol can result in contamination of the electronic

components requiring a much longer drying time before the printer will function properly.

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Maintenance

Cleaning

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Cleaning the Printhead

Always use a new cleaning pen on the printhead (an old pen carries contaminants from its

previous uses that may damage the printhead).

When you load new media, you can also clean the printhead.

1. 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 printhead

outside of media path.

2. Wait one minute before closing the printer.

Caution • The printhead becomes hot while printing. To protect from damaging the

printhead and risk of personal injury, avoid touching the printhead. Use only the cleaning

pen to perform maintenance.

Maintenance

Cleaning

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Media Path Cleaning

Use a cleaning swab to remove debris, dust or crust that has built-up on the holders, guides and

media path surfaces.

1. Use the alcohol in the cleaning swab to soak the debris to break up the adhesive.

2. Wipe the ridges to remove accumulated debris.

3. Wipe the inside edges of both edge guides to remove any built-up residue.

4. Wait one minute before closing the printer.

Discard the cleaning swab after use.

Media

Guides

Ridges

Platen

Peel

Bar

Pinch

Roller

Ridges

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Maintenance

Cleaning

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Sensor Cleaning

Dust can accumulate on the media sensors.

1. Gently brush away dust; if necessary, use a dry swab to brush away dust. If adhesives or

other contaminates remain, use an alcohol moistened swab to break it up.

2. Use a dry swab to remove any residue that may be left from the first cleaning.

3. Repeat steps 1 and 2 as required until all residue and streaks are removed from the sensor.

Black-Line

Sensor

Ribbon Trailer

Sensor

Label Taken

Sensor

Gap

Sensor

Maintenance

Cleaning

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Platen Cleaning and Replacement

The standard platen (drive roller) normally does not require cleaning. Paper and liner dust can

accumulate without effecting print operations. Contaminates on the platen roller can damage

the printhead or cause the media to slip or stick when printing. Adhesive, dirt, general dust,

oils and other contaminates should be cleaned immediately off the platen.

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.

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). 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.

Platen Bearings

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Maintenance

Cleaning

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3. Lift the platen out of the printer’s bottom frame.

4. Clean the platen with the alcohol moistened swab. Clean from the center out. Repeat this

process until the 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 contaminates.

Adhesives and oils, for example, may be thinned by the initial cleaning but not completely

removed.

5. Install the platen in the printer. Discard the cleaning swabs after use - do not reuse.

6. Make sure the bearings and drive gear are on the shaft of the platen.

Maintenance

RTC Battery

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7. Align the platen with the gear to the left and lower it into the printer’s bottom frame.

8. Rotate the platen bearing latch release tabs down on the right and left sides towards the

rear of the printer and snap them into place.

Allow the printer to dry for one minute before closing the dispenser door, media cover or

loading labels.

Other Printer Maintenance

There are no user level maintenance procedures beyond those detailed in this section. See the

Troubleshooting on page 123 for more information on diagnosing printer and print problems.

RTC Battery

The RTC (Real-Time Clock) battery is not operator replaceable. See a Zebra authorized

service technician to replace the battery.

Fuses

There are no replaceable fuses in the ZD500 Series™ printer or power supply.

Caution • The printer has a three volt lithium battery. You can discern a low or flat battery if

the printer provides a consistently delayed date stamp. Battery replacement must be performed

by a qualified service technician. Only use a Zebra approved replacement battery.

Important • Recycle batteries according to local your guidelines and regulations. Wrap the

battery when disposing (or storing) to avoid a short circuit.

DO NOT short circuit the battery. Short circuiting the battery may result in heat

generation, fire or bursting.

DO NOT heat, disassemble or dispose of battery in fire.

117

Maintenance

Replacing the Printhead

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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.

Before following the steps in this procedure, open the printer by pulling the release latches

forward then lifting the top cover.

Printhead Removal

1. Open the printer. Remove any transfer ribbon from the printer.

2. Use a small flat bladed screwdriver to remove the ribbon guide. Gently pry the guide

right-side tab from the ribbon frame. Pull the left side of the ribbon guide out.

Caution • 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.

Caution • Turn the printer power off and unplug the power cord before replacing the

printhead.

Ribbon Guide

(and printhead cover)

Maintenance

Replacing the Printhead

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3. Use a blunt tipped tool to press the release tab on the right side and then the left side of the

printhead. The tool diameter can be from 0.10 to 0.15 inches (2.5 to 3.8 mm).

Insert the tool into the ribbon frame's printhead release access (the round) opening. Push

the release tab and gently pull the printhead bracket down.

119

Maintenance

Replacing the Printhead

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

4. Gently but firmly pull the two printhead cable bundles’ connectors off of the printhead.

5. Gently but firmly pull the green ground wire off the printhead.

Maintenance

Replacing the Printhead

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Replacing the Printhead

1. Push the left side printhead connector into the printhead. The connector is keyed to only

insert one way.

2. Connect the green ground wire to the printhead.

3. Push the right side printhead wire connector onto the printhead.

4. Check that the ground wire and wire bundles are still connected to the printhead.

121

Maintenance

Replacing the Printhead

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

5. Insert the printhead bracket’s the tab into slot in the ribbon frame assembly. Align the

printhead spring slots to the five posts and snap the printhead into the ribbon frame.

Slot

Post

Spring

Slot

Tab

Spring

Slot

Spring

Post

Maintenance

Replacing the Printhead

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6. Place the left hand side of the ribbon guide into the ribbon frame. Swing the right side of

the ribbon guide into the slot and snap it into position.

7. Verify that the printhead moves up and down freely when pressure is applied and remains

locked when released.

8. 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. See Cleaning the

Printhead on page 111.

9. Reload media. Plug in the power cord, turn on the printer and print a status report to

ensure proper function. See Test Printing with Configuration Report Printouts on page 27.

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Troubleshooting

This section provides troubleshoots procedures.

Troubleshooting

Error Messages

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Error Messages

The control panel displays messages when there is an error. See Table 1 for errors, the possible

causes, and the recommended solutions.

Table 1 • Error Messages

Display/

Indicator Lights Possible Cause Recommended Solution

STATUS light steady red

The printhead is not fully

closed.

Close the printhead

completely.

The printhead open sensor is

not working properly.

Call a service technician to

replace the sensor.

STATUS light steady red

The media is not loaded or is

loaded incorrectly.

Load media correctly.

Misaligned media sensor. Check the position of the

media sensor.

The printer is set for

noncontinuous media, but

continuous media is loaded.

1. Install the proper media

type, or reset printer for the

current media type.

2. Calibrate the printer. See

Manual Calibration -

Media on page 75.

STATUS light steady red

In thermal transfer mode:

•the end of the ribbon roll

has been detected.

Replace the empty ribbon with

a new roll.

STATUS light flashing red

The printhead damaged,

replace incorrectly, or was

replaced with one that is not a

genuine Zebra™ printhead.

Install a genuine Zebra™

printhead.

STATUS light steady yellow

Caution • The printhead may be hot enough to cause

severe burns. Allow the printhead to cool.

The printhead is over

temperature.

Allow the printer to cool.

Printing automatically resumes

when the printhead elements

cool to an acceptable operating

temperature.

If this error persists, consider

changing where the printer is

located or using a slower print

speed.

HEAD OPEN

CLOSE HEAD

MEDIA OUT

LOAD MEDIA

ALERT

RIBBON OUT

PH NOT AUTHENTICATED

REPLACE PRINTHEAD

PRINT HEAD OVERTEMP

PRINTING HALTED

125

Troubleshooting

Error Messages

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

STATUS light steady yellow

The printer shows one of these messages

or cycles between them.

Caution • An improperly connected printhead data or

power cable can cause these error messages. The

printhead may be hot enough to cause severe burns.

Allow the printhead to cool.

The printhead data cable is not

properly connected.

Call a service technician to

hook up the printhead

properly.

The printhead has a faulty

thermistor.

Call a service technician to

replace the printhead.

The printhead temperature is

approaching its lower

operating limit.

Continue printing while the

printhead reaches the correct

operating temperature. If the

error remains, the environment

may be too cold for proper

printing. Relocate the printer

to a warmer area.

STATUS light steady red

Caution • The cutter blade is sharp. Do not touch or

rub the blade with your fingers.

The cutter blade is in the

media path. Cutter maybe

obstructed (jammed).

The cutting blade is stopped.

Needs service if cycling power

or running cut cycles with the

SGD cutter.clean_cutter

command can not clear the

obstruction. See the ZPL

Programming Guide for more

information..

There is not enough memory

to perform the function

specified on the second line of

the error message.

Free up some of the printer’s

memory by adjusting the label

format or printer parameters.

One way to free up memory is

to adjust the print width to the

actual width of the label

instead of leaving the print

width set to the default. See

SETTINGS Menu on page 52 -

PRINT WIDTH.

Ensure that the data is not

directed to a device that is not

installed or is unavailable.

If the problem persists, call a

service technician.

Table 1 • Error Messages (Continued)

Display/

Indicator Lights Possible Cause Recommended Solution

HEAD COLD

PRINTING HALTED

THERMISTOR

REPLACE PRINTHEAD

CUT ERROR

OUT OF MEMORY

STORING GRAPHIC

OUT OF MEMORY

STORING FORMAT

OUT OF MEMORY

STORING BITMAP

OUT OF MEMORY

STORING FONT

Troubleshooting

Printing Issues

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Printing Issues

This section helps you identify possible issues with printing or print quality, the possible

causes, and the recommended solutions.

Table 2 • Printing Issues

Issue Possible Cause Recommended Solution

General print quality

issues - The printed

image does not look

right.

The printhead is dirty. Clean the printhead. See Cleaning the Printhead

on page 111 and Platen Cleaning and

Replacement on page 114

The printer is set at an incorrect

darkness level and/or print

speed.

For optimal print quality, set the darkness to the

lowest possible setting for your for bar codes and

balance that with graphic and text quality in your

application.

Don not set print speeds above the manufacture

maximum rated speed for your media or ribbon.

You may want to perform the Print Quality

Report on page 135 to determine the ideal

darkness and speed settings for your application.

See SETTINGS Menu on page 52 - DARKNESS

for how to change the darkness setting.

See SETTINGS Menu on page 52 - PRINT

SPEED for how to change the print speed.

You are using an incorrect

combination of labels and

ribbon for your application.

1. Switch to a different type of media or ribbon

to try to find a compatible combination.

1. If necessary, consult your authorized Zebra

reseller or distributor for information and

advice.

You maybe using the wrong

power supply.

Verify the printer has the correct 100 Watt power

supply that came with this printer.

The printhead has worn out. Replace the printhead. The printhead is a

consumable item and will wear out due to

friction between the media and printhead.

Using unapproved media may shorten life

or damage your printhead.

The platen may need cleaning

or replacement.

Clean or replace the platen (drive) roller.

127

Troubleshooting

Printing Issues

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

No print on the label. The media may not be direct

thermal media when printing

without ribbon (i.e. thermal

transfer).

See the test procedure Determining Thermal

Media Types on page 79.

The ribbon may not have the

‘ink’ outside wound or

approved for this printer.

See the following ribbon test procedures: Ribbon

Test with Adhesive on page 84 and Ribbon

Scratch Test on page 85.

Media or ribbon has been

loaded incorrectly.

The media printable surface must face up

towards the prinhead. Follow the instructions for

Loading Roll Media on page 20

in the Setup section. For printing using transfer

ribbon, see Loading Transfer Ribbon on page 23.

Loss of printing

registration on labels.

Excessive vertical

drift in top-of-form

registration.

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

the Printhead on page 111 and Platen Cleaning

and Replacement on page 114

The media type is set

incorrectly.

Set the printer for the correct media type

(gap/notch, continuous, or mark). See

SETTINGS Menu on page 52.- MEDIA TYPE

The media is loaded incorrectly. Load media correctly. See Loading Roll Media

on page 20.

Long tracks of

missing print on

several labels

Print element damaged. Call a service technician.

Printing too light or

too dark over the

entire label

The media or ribbon is not

designed for high-speed

operation.

Replace supplies with those recommended for

high-speed operation.

You are using an incorrect

combination of media and

ribbon for your application.

1. Switch to a different type of media or ribbon

to try to find a compatible combination.

2. If necessary, consult your authorized Zebra

reseller or distributor for information and

advice.

You are using ribbon with

direct thermal media.

Direct thermal media does not require ribbon. To

determine if you are using direct thermal media,

perform the label scratch test in When to Use

Ribbon on page 84.

Smudge marks on

labels

The media or ribbon is not

designed for high-speed

operation.

Replace supplies with those recommended for

high-speed operation.

Misregistration/skips

labels

The printer is not calibrated. Calibrate the printer. See Manual Calibration -

Media on page 75.

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

necessary.

Table 2 • Printing Issues (Continued)

Issue Possible Cause Recommended Solution

Troubleshooting

Printing Issues

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Vertical drift in

top-of-form position

The printer is out of calibration. Calibrate the printer. See Manual Calibration -

Media on page 75.

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

Cleaning the Printhead on page 111 and Platen

Cleaning and Replacement on page 114

Vertical image or

label drift

The printer is using

non-continuous labels but is

configured in continuous mode.

Set the printer for the correct media type

(gap/notch, continuous, or mark—see

SETTINGS Menu on page 52.- MEDIA TYPE)

and calibrate the printer, if necessary (see

Manual Calibration - Media on page 75).

The media sensor is calibrated

improperly.

Calibrate the media in the printer. See Manual

Calibration - Media on page 75.

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

Cleaning the Printhead on page 111 and Platen

Cleaning and Replacement on page 114.

The media or ribbon is loaded

incorrectly.

Ensure that the media and ribbon are loaded

correctly. See Loading Roll Media on page 20

and Loading Transfer Ribbon on page 23.

Incompatible media. You must use media that meets the printer

specifications. Ensure that the inter-label gaps or

notches are 2 to 4 mm and consistently placed.

The bar code printed

on a label does not

scan.

The bar code is not within

specifications because the print

is too light or too dark.

Perform the Print Quality Report on page 135.

Adjust the darkness or print speed settings as

necessary.

There is not enough blank

space around the bar code.

Leave at least 1/8 in. (3.2 mm) between the bar

code and other printed areas on the label and

between the bar code and the edge of the label.

Table 2 • Printing Issues (Continued)

Issue Possible Cause Recommended Solution

129

Troubleshooting

Ribbon Problems

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

Ribbon Problems

Table 3 identifies problems that may occur with ribbon, the possible causes, and the

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