ZD500 Series™ User’s Guide Thermal Transfer Printer P1062653-002 Rev.
ii © 2013 ZIH Corp. The copyrights in this manual and the software and/or firmware in the 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.
iii 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.
iv 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.
v 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.
vi 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.
vii 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.
viii Environmental Management Environmental Management Do not dispose of this product in unsorted municipal waste. This product is recyclable, and should be recycled according to your local standards. For more information, please see our website at: Web address: www.zebra.
Contents Compliance and Regulatory Statements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Environmental Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii • Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
x Contents Connecting your Printer to a Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USB Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Adjusting the Print Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Print Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Movable Black Mark Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xii Contents Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power-On Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Quality Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 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.
2 Introduction ZD500 Series™ Thermal Printers 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.
Introduction ZD500 Series™ Thermal Printers Your printer, when connected to a host computer, functions as a complete system for printing labels, receipts, forms, and tags. Many printer settings may also be controlled by your printer’s driver or label design software. Refer to the driver or software documentation for more information. To create label formats, refer to your programming guides or label design applications such as the free label and form design software: ZebraDesigner™.
4 Introduction What’s in the Box? 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. Ribbon Core Documentation and Software USB Cable 3in (76.2 mm) I.D.
Introduction Printer Features 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 Control Panel Release Latches Fan-Fold Media Entry Slot Release Latches Interface Connectors 1/16/2014 DC Power Power Receptacle Switch ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
6 Introduction Printer Features Figure 2 • Printer Features Continued Printhead Ribbon Roll Holders Take Up Spindles Supply Spindles Ribbon Trailer Sensor (hidden from view) Roll Holders and Media Guides Media Guide Stop Adjustment Movable Black Mark Sensor Web (Gap) Sensor Dispenser Option Platen Roller RFID Antenna (inside) Head-Up Sensor (inside) Dispenser Door (open) Label Taken Sensor P1062653-002 Rev.
Introduction Printer Features Figure 3 • Printer Features - Cutter Option Media Cutter (Option) 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
8 Introduction Control Panel Control Panel The control panel indicates the printer’s operating status and allows the user to control basic printer operation. Figure 4 • ZD500 Series™ Control Panel 1 2 12 3 4 11 10 9 8 7 6 5 1 STATUS light 2 The PAUSE button starts or stops printer operation when pressed. 3 The FEED button forces the printer to feed one blank label each time the button is pressed. 4 The CANCEL button cancels print jobs when the printer is paused.
Introduction Control Panel 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.
10 Introduction Control Panel Display Menu and Status Icons 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 P1062653-002 Rev.
Introduction Printer Control Panel Display 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).
12 Introduction Printer Control Panel Display 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.
Introduction Printer Control Panel Display Table 2 • Navigation User Menus XXXXXXX 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. XXX 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.
14 Introduction Control Panel Menu Map Control Panel Menu Map Home Menu Items Printer Ready Menu Item also in other Menus V74.xx.xxZ Printer Option. May not be present.
2 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.
16 Setup Select a Location for the Printer 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.
Setup Attaching Power Attaching Power Important • Set up your printer so that you can handle the power cord easily if needed. To make certain the printer cannot carry electrical current, you must separate the power cord from the power supply receptacle or AC electrical outlet. Caution • Never operate the printer and power supply in an area where they can get wet. Serious personal injury could result! 1. Make sure the printer’s power switch is in the off position (down). 2.
18 Setup Preparing and Handling Media 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.).
Setup Setting the Printer Menu and Report Display Language 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.
20 Setup Loading Roll Media 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.
Setup Loading Roll Media 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.
22 Setup Loading Roll Media 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. Under 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.
Setup Loading Transfer Ribbon 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.
24 Setup Loading Transfer Ribbon 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.
Setup Loading Transfer Ribbon 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. 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
26 Setup Loading Transfer Ribbon 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.
Setup Test Printing with Configuration Report Printouts 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.
28 Setup Connecting your Printer to a Computer 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.
Setup Connecting your Printer to a Computer 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. .
30 Setup Connecting your Printer to a Computer 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.
Setup Connecting your Printer to a Computer 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).
32 Setup Connecting your Printer to a Computer Ethernet Cable (RJ45 Connector) Ethernet Status/Activity Indicators LED Status Description Both OFF No Ethernet link detected Green 100 Mbps link detected Green with the Amber flickering on and off Amber 100 Mbps link and Ethernet activity detected 10 Mbps link detected Amber with the Green flickering on and off 10 Mbps link and Ethernet activity detected Green LED Amber LED Print Server - Default User ID and Password There are some features that
Setup ZebraNet® Internal Wireless Print Server Option 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. Important • A wireless option board must be installed on your printer before you can configure the printer to communicate using the wireless radio option.
34 Setup Configure Using the Connectivity Wizard 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.
Setup Configure Using the Connectivity Wizard 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.
36 Setup Configure Using the Connectivity Wizard 7. Select the type of printer you are using and then click Next. The wizard prompts for the wireless IP information. P1062653-002 Rev.
Setup Configure Using the Connectivity Wizard 8. Enable the DHCP (dynamic) or static IP option. 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. 9. Click Next. The Wireless Settings window opens.
38 Setup Configure Using the Connectivity Wizard 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 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.
Setup Configure Using the Connectivity Wizard 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. 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
40 Setup Configure Using the Connectivity Wizard 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 P1062653-002 Rev.
Setup Configure Using the Connectivity Wizard 15. Determine if you will send the script immediately, or save it for use at a later time. 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.
42 Setup Configure Using the Connectivity Wizard 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. 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.
Setup Bluetooth Option Configuration 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.
44 Setup Bluetooth Option Configuration 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.
Setup Bluetooth Option Configuration 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.
46 Setup Bluetooth Option Configuration 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.
Setup Bluetooth Option Configuration 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.
48 Setup Bluetooth Option Configuration 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.
Setup After Your Printer is Connected 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.
50 Setup After Your Printer is Connected 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.
3 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.
52 Printer Configuration Changing Printer Settings SETTINGS Menu Table 7 • SETTINGS Menu Print Darkness Print Speed Media Type Print Method 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.
Printer Configuration Changing Printer Settings Table 7 • SETTINGS Menu (Continued) 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.
54 Printer Configuration Changing Printer Settings Table 7 • SETTINGS Menu (Continued) Print Mode Select a print mode that is compatible with your printer options.
Printer Configuration Changing Printer Settings Table 7 • SETTINGS Menu (Continued) 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.
56 Printer Configuration Changing Printer Settings TOOLS Menu Table 8 • TOOLS MENU Print 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: • • • • • • • • P1062653-002 Rev. A SETTINGS—prints the printer configuration report. NETWORK—prints the settings for any print server that is installed.
Printer Configuration Changing Printer Settings Table 8 • TOOLS MENU (Continued) LCD Contrast Idle Display Power-Up Action 1/16/2014 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 Select the information shown on the printer’s display when the printer is idle.
58 Printer Configuration Changing Printer Settings Table 8 • TOOLS MENU (Continued) Head-Close Action P1062653-002 Rev. A 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.
Printer Configuration Changing Printer Settings Table 8 • TOOLS MENU (Continued) Load Defaults Manual Calibration 1/16/2014 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.
60 Printer Configuration Changing Printer Settings Table 8 • TOOLS MENU (Continued) Communication Use this diagnostics tool to cause the printer to output the hexadecimal values for all Diagnostics Mode data received by the printer. For more information, see Communication Diagnostics Test on page 139. Enable ZBI Run a ZBI Program Stop a ZBI Program P1062653-002 Rev. A DISABLED ENABLED Accepted values: • • Related ZPL command(s): ~JD to enable, ~JE to disable SGD command used: device.
Printer Configuration Changing Printer Settings NETWORK Menu Table 9 • NETWORK Menu WIRED or WLAN IP Address WIRED or WLAN Subnet Mask WIRED or WLAN Gateway 1/16/2014 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).
62 Printer Configuration Changing Printer Settings Table 9 • NETWORK Menu (Continued) WIRED or WLAN IP Protocol WIRED or WLAN MAC Address ESSID P1062653-002 Rev. A 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.
Printer Configuration Changing Printer Settings Table 9 • NETWORK Menu (Continued) Channel Signal 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.
64 Printer Configuration Changing Printer Settings Table 9 • NETWORK Menu (Continued) Reset Network P1062653-002 Rev. A 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.
Printer Configuration Changing Printer Settings 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 RFID Calibrate 1/16/2014 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.
66 Printer Configuration Changing Printer Settings Table 10 • RFID Menu (Continued) 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.
Printer Configuration Changing Printer Settings Table 10 • RFID Menu (Continued) 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.
68 Printer Configuration Changing Printer Settings Table 10 • RFID Menu (Continued) RFID Void Counter RFID Tag Calibration P1062653-002 Rev. A 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 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.
Printer Configuration Changing Printer Settings LANGUAGE Menu Table 11 • LANGUAGE Menu Language ZPL Override 1/16/2014 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.
70 Printer Configuration Changing Printer Settings Table 11 • LANGUAGE Menu (Continued) Command Character Control Character Delimiter Character ZPL Mode 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.
Printer Configuration Changing Printer Settings SENSOR Menu Table 12 • SENSOR Menu Sensor Type Label Sensor Take Label 1/16/2014 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. TRANSMISSIVE REFLECTIVE Accepted values: • • Related ZPL command(s): ^JS SGD command used: device.
72 Printer Configuration Changing Printer Settings PORTS Menu Table 13 • PORTS Menu Baud Rate Data Bits Parity P1062653-002 Rev. A Set the Baud Rate Select the baud value that matches the one being used by the host computer. 115200 57600 38400 28800 19200 14400 9600 4800 Accepted values: • • • • • • • • Related ZPL command(s): ^SC SGD command used: comm.
Printer Configuration Changing Printer Settings Table 13 • PORTS Menu (Continued) Host Handshake Parallel Mode Set the Host Handshake Protocol Value Select the handshake protocol that matches the one being used by the host computer. • • • Related ZPL command(s): ^SC SGD command used: comm.handshake Printer web page: View and Modify Printer Settings > Serial Communications Setup Set the parallel port to allow two-way or one-way host to printer communication.
74 Printer Configuration Changing Printer Settings BLUETOOTH Menu Table 14 • BLUETOOTH Menu Bluetooth Address Mode Discovery Connected BT Spec Version Min. Security Mode P1062653-002 Rev. A Displays the printer’s Bluetooth Device Address Accepted values: N/A SGD command used: bluetooth.address Displays the Bluetooth connection pair printer’s device type - Slave (typical) or Master.
Printer Configuration Manual Calibration - Media 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.
76 Printer Configuration RFID Calibration 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.
4 Print Operations This section provides media and print handling, font and language support, and the setup of less common printer configurations. 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
78 Print Operations Determining Printer Configuration 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.
Print Operations Types of Media 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.
80 Print Operations Types of Media Table 15 • Types of Media Roll and Fanfold Media Media Type Non-Continuous Roll Media How It Looks Description 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.
Print Operations Media Loading 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.
82 Print Operations Media Loading 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. P1062653-002 Rev.
Print Operations Media Loading 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. 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
84 Print Operations Ribbon Overview 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.
Print Operations Ribbon Overview 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.
86 Print Operations Replacing Supplies 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.
Print Operations Adjusting the Print Width 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.
88 Print Operations Media Sensing Media Sensing The ZD500 Series™ printer media controls are set via a control panel setting or by sending commands to the printer. Table 16 • Media Settings Setting Menu Item 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.
Print Operations Using the Movable Black Mark Sensor 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.
90 Print Operations Using the Movable Black Mark Sensor 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).
Print Operations Using the Movable Black Mark Sensor 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). 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
92 Print Operations Using the Movable Black Mark Sensor 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.
Print Operations Printing on Fan-Fold Media 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. Fan-Fold Media Path 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.
94 Print Operations Printing on Fan-Fold Media 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.
Print Operations Printing with Externally Mounted Roll Media 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.
96 Print Operations Fonts and Your Printer 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.
Print Operations Fonts and Your Printer 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.
98 Print Operations Fonts and Your Printer Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _______________
5 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. 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
100 Printer Options Label Dispenser Option 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.
Printer Options Label Dispenser Option 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. 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
102 Printer Options Label Dispenser Option 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. P1062653-002 Rev.
Printer Options Cutter Option 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.
104 Printer Options Cutter Option 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.
Printer Options Cutter Option 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. Under Media Guides 6. Close the printer. Press down until the cover snaps closed. 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
106 Printer Options ZebraNet® Internal Wireless Print Server Option 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.
Printer Options Bluetooth Option 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.
108 Printer Options Bluetooth Option 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.
6 Maintenance This section provides routine cleaning and maintenance procedures. 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
110 Maintenance Cleaning Cleaning When you clean the printer, use one of the following supplies that best suits your needs: 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 You can obtain cleaning supplies at www.zipzebra.com. The cleaning process takes just a couple of minutes using the steps outlined below.
Maintenance Cleaning 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). 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. When you load new media, you can also clean the printhead. 1. Rub the cleaning pen across the dark area of the printhead.
112 Maintenance Cleaning 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.
Maintenance Cleaning 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. .
114 Maintenance Cleaning 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.
Maintenance Cleaning 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.
116 Maintenance RTC Battery 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.
Maintenance Replacing the Printhead Replacing the Printhead If you need to replace the printhead, read the procedure and review the removal and installation steps before actually replacing the printhead. Caution • 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.
118 Maintenance Replacing the Printhead 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. P1062653-002 Rev.
Maintenance Replacing the Printhead 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. 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
120 Maintenance Replacing the Printhead 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. P1062653-002 Rev.
Maintenance Replacing the Printhead 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. Post Slot Tab Spring Post Spring Slot Spring Slot 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
122 Maintenance Replacing the Printhead 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.
7 Troubleshooting This section provides troubleshoots procedures. 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
124 Troubleshooting Error Messages 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 HEAD OPEN CLOSE HEAD STATUS light steady red MEDIA OUT LOAD MEDIA Possible Cause Recommended Solution The printhead is not fully closed. Close the printhead completely. The printhead open sensor is not working properly.
Troubleshooting Error Messages Table 1 • Error Messages (Continued) Display/ Indicator Lights Possible Cause 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. HEAD COLD PRINTING HALTED THERMISTOR REPLACE PRINTHEAD STATUS light steady yellow The printer shows one of these messages or cycles between them.
126 Troubleshooting Printing Issues 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.
Troubleshooting Printing Issues Table 2 • Printing Issues (Continued) Issue Possible Cause Recommended Solution 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.
128 Troubleshooting Printing Issues Table 2 • Printing Issues (Continued) Issue Possible Cause 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. Vertical image or label drift The bar code printed on a label does not scan. P1062653-002 Rev. A Recommended Solution Clean the printhead and platen roller.
Troubleshooting Ribbon Problems Ribbon Problems Table 3 identifies problems that may occur with ribbon, the possible causes, and the recommended solutions. Table 3 • Ribbon Problems Problem Possible Cause Recommended Solution Broken or melted ribbon Darkness setting too high. 1. Reduce the darkness setting. SeeSETTINGS Menu on page 52 - DARKNESS for how to change the darkness setting. 2. Clean the printhead thoroughly.
130 Troubleshooting Communications Problems Communications Problems Table 4 identifies problems with communications, the possible causes, and the recommended solutions. Table 4 • Communications Problems Problem Possible Cause Recommended Solution A label format was sent to the printer but was not recognized. The DATA light does not flash. The communication parameters are incorrect. Check the printer driver or software communications settings (if applicable).
Troubleshooting Miscellaneous Issues Miscellaneous Issues Table 3 identifies miscellaneous issues with the printer, the possible causes, and the recommended solutions. Table 5 • Miscellaneous Printer Problems Problem Possible Cause Recommended Solution The control panel display shows a language that I cannot read The language parameter was changed through the control panel or a firmware command. 1. On the control panel display, scroll to LANGUAGE Menu. 2. Press OK to access the items in this menu. 3.
132 Troubleshooting RFID Troubleshooting RFID Troubleshooting Many RFID hardware problems can be corrected or diagnosed by performing a ‘Manual Calibration - Media’ on the printer (Manual Calibration - Media on page 75) followed by a ‘RFID Calibration’ (RFID Calibration on page 76) on your chosen RFID media. These two operations are the first place to troubleshoot problems with RFID operations. Does the printer sense basic media characteristics (length, gap, etc.
Troubleshooting Printer Diagnostics Printer Diagnostics Diagnostic reports, calibrations procedures, restoring factory defaults and other diagnostics provide specific information about the condition of the printer. The procedures sample printouts and provide specific information that helps determine the operating conditions for the printer. Important • Use full-width media when performing self tests. If your media is not wide enough, the test labels may print on the platen roller.
134 Troubleshooting Printer Diagnostics Configuration Report The Configuration Report (CANCEL self test) prints a set of printer and network configuration reports. To perform the configuration, complete these steps: 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.
Troubleshooting Printer Diagnostics Print Quality Report Different types of media may require different darkness settings. This section contains a simple but effective method for determining the ideal darkness for printing bar codes that are within specifications. During the Print Quality Report (FEED self test), a series of labels are printed at different darkness settings at two different print speeds. The relative darkness and the print speed are printed on each label.
136 Troubleshooting Printer Diagnostics 4. See Figure 2 and Table 6. Inspect the test labels and determine which one has the best print quality for your application. If you have a bar code verifier, use it to measure bars/spaces and calculate the print contrast. If you do not have a bar code verifier, use your eyes or the system scanner to choose the optimal darkness setting based on the labels printed in this self test.
Troubleshooting Printer Diagnostics Table 6 • Judging Bar Code Quality (Continued) Print Quality Description “In-spec” The “in-spec” bar code can only be confirmed by a verifier, but it should exhibit some visible characteristics. • The normal bar code will have complete, even bars and clear, distinct spaces. • The rotated bar code will have complete, even bars and clear, distinct spaces. Although it may not look as good as a slightly dark bar code, the bar code will be “in-spec.
138 Troubleshooting Printer Diagnostics Reset Printer Factory Defaults Performing this resets the printer configuration to the factory default values for the nonnetwork printer settings. Perform a sensor calibration after this procedure. (See Manual Calibration - Media on page 75.) To perform a Reset Printer Factory Defaults procedure (FEED + PAUSE Self Test), complete these steps: 1. Turn off (O) the printer. 2. Press and hold FEED + PAUSE while turning on (I) the printer. 3.
Troubleshooting Printer Diagnostics Communication Diagnostics Test The communication diagnostics test is a troubleshooting tool for checking the interconnection between the printer and the host computer. When the printer is in diagnostics mode, it prints all data received from the host computer as straight ASCII characters with the hex values below the ASCII text. The printer prints all characters received, including control codes such as CR (carriage return).
140 Troubleshooting Printer Diagnostics Sensor Profile Use the sensor profile image (which will extend across several actual labels or tags) to troubleshoot the following situations: • The printer experiences difficulty in determining gaps (web) between labels. • The printer incorrectly identifies preprinted areas on a label as gaps (web). • The printer cannot detect ribbon. With the printer in the Ready state, print a sensor profile in one of these ways: Using the buttons on the control panel a.
Troubleshooting Printer Diagnostics Media Sensor Profile (Figure 4) The line labeled MEDIA (1) on the sensor profile indicates the media sensor readings. The media sensor threshold settings is indicated by WEB (2). The media out threshold is indicated by OUT (3).The upward spikes (4) indicate gaps between labels (the web), the lines between the spikes (5) indicate where labels are located, and the numbered line at the top (6) provides measurement in dots from the start of the printout.
142 Troubleshooting Printer Diagnostics Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________
A Appendix: Interface Wiring This section provides wiring diagrams for typical interface cables that do not have a single standardized configuration. 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
144 Appendix: Interface Wiring Serial Port Interface Serial Port Interface Pin 1 2 3 4 5 6 7 8 9 Description Not used RXD (receive data) input to the printer TXD (transmit data) output from the printer DTR (data terminal ready) output from the printer -- controls when the host may send data Chassis ground DSR (data set ready) input to the printer RTS (request to send) output from the printer -- always in the ACTIVE condition when the printer is turned on CTS (clear to send) - Not used by the printer +5 V
B Appendix: Dimensions This section provides external printer dimensions. 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
146 Appendix: Dimensions External ZD500 Series™ Printer Dimensions External ZD500 Series™ Printer Dimensions 7.90 in 200.7 mm 7.48 in 190 mm 2.46 in 62.5 mm 10.05 in 255.1 mm 14.02 in 356 mm n 3i m 9.5 2 m 24 13.6 in 345 mm 4.05 in 103 mm 10.05 in 255.1 mm P1062653-002 Rev. A 0.52 in 13.
Appendix: Dimensions External ZD500 Series™ Printer Dimensions 7.48 in 190 mm 1.84 in 46.8 mm 3.82 in 97 mm 3.27 in 83 mm Label Dispenser 7.90 in 200.7 mm 7.48 in 190 mm 3.1 in 78.5 mm 10.35 in 262.5 mm 10.96 in 278.3 mm Cutter 7.90 in 200.7 mm 7.48 in 190 mm 2.91 in 74 mm 11.20 in 284.6 mm 1/16/2014 ZD500 Series™ Thermal Transfer Printer User’s Guide P1062653-002 Rev.
148 Appendix: Dimensions External ZD500 Series™ Printer Dimensions Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________
