Zebra ZE500 User Guide PDF

Zebra® ZE500™ Series
User Guide
P1051584-003 Rev. A
© 2014 ZIH Corp. The copyrights in this manual and the software and/or firmware in the print engine described
therein are owned by ZIH Corp. and Zebra’s licensors. Unauthorized reproduction of this manual or the software
and/or firmware in the print engine 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.
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 registered trademarks of ZIH Corp. All rights reserved worldwide.
All other brand names, product names, or trademarks belong to their respective holders. For additional trademark
information, please see “Trademarks” on the product CD.
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.
Part Number: P1051584-003 Rev. A

Declaration of Conformity 3
DECLARATION OF CONFORMITY
ZEBRA TECHNOLOGIES CORPORATION

Declares that the following Information Technology Equipment
Zebra ZE500-4 and ZE500-6
complies with the following applicable directives and standards for the
ITE: Heavy Industry environment
Applicable Directives and Supporting Standards:

2004/108/EC EMC Directive, EN55022:2010 Class A,
EN55024:2010EN61000-3-2:2006 + A2:2009, EN61000-3-3:2008,
2006/95/EC LVD Directive, EN60950-1:2006 (2nd Edition) +A11:2009 +A1:2010+A12:2011,
CB Scheme
RLAN Enabled (if equipped)
Applicable Directives and Supporting Standards:

99/5/EC R&TTE Directive, EN 301 489-17 V1.3.2:2008, EN 300 328 V1.8.1:2012
Manufactured for Zebra Technologies Corporation by:

Jabil Circuit (Guangzhou) Ltd No. 1 Branch Company
Lianyun Road 388, Eastern Zone,
Guangzhou Economic &Technological Development District
Guangdong Province, China
The equipment specified conforms to all Directives and Standards listed above effective
as of the date below.
Effective Date: 11 July 2012
3/27/14 ZE500™ User Guide P1051584-003

4 Compliance Information
Compliance Information
FCC Compliance Statement

This device complies with Part 15 of the FCC 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.
Note • This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential installation. This
equipment generates, uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions, 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, which can be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by 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 radio/TV technician for help.
FCC Radiation Exposure Statement

(for print engines with RFID encoders)
This equipment complies with FCC radiation exposure limits set forth for an uncontrolled
environment. This equipment should be installed and operated with minimum distance 20cm
between the radiator and your body.
This transmitter must not be co-located or operating in conjunction with any other antenna or
transmitter.
Canadian DOC Compliance Statement

This Class B digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.
P1051584-003 ZE500™ User Guide 3/27/14

Contents
About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 • Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Print Engine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Print Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Navigating in the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Changing Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Default Password Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operating Parameters on the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Ribbon Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
When to Use Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Coated Side of Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2 • Printer Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Handling the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Unpack and Inspect the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Remove Additional Shipping Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
To Store the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
To Ship the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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6 Contents
Print Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Dimensions and Clearance Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Install the Print Engine in an Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Select a Data Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Data Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Connect the Print Engine to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Load Ribbon and Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3 • Printer Configuration and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Changing Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Print Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Maintenance and Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Language Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Sensor Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Port Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Calibrate the Ribbon and Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Remove Used Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Adjust the Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Transmissive Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Reflective Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Ribbon Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Toggle Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Printhead Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4 • Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Clean the Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Clean the Printhead and Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Replacing Print Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Recycling Print Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
5 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Printing Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
RFID Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
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Contents 7
Miscellaneous Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Print Engine Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
FEED Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
FEED + PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
CANCEL + PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Communication Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6 • Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
A • Applicator Interface Board Reconfiguration . . . . . . . . . . . . . . . . . . . . . . . 145

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Changing Jumper Settings for Isolated Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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8 Contents
Notes • ___________________________________________________________________
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P1051584-003 ZE500™ User Guide 3/27/14

About This Document
This section provides you with contact information, document structure and organization, and
additional reference documents.
Contents
Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3/27/14 ZE500™ User Guide P1051584-003

10 About This Document
Who Should Use This Document
Who Should Use This Document

This User Guide is intended for use by any person who needs to perform routine maintenance,
upgrade, or troubleshoot problems with the print engine.
How This Document Is Organized

The User Guide is set up as follows:
Section Description
Introduction on page 11 This section provides a high-level overview of the
printer and its components.
Printer Setup and Operation This section assists the technician with initial setup
on page 41 and operation of the print engine.
Printer Configuration and Adjustment This section assists you with configuration of and
on page 69 adjustments to the print engine.
Routine Maintenance on page 109 This section provides routine cleaning and
maintenance procedures.
Troubleshooting on page 115 This section provides information about errors that
you might need to troubleshoot. Assorted
diagnostic tests are included.
Specifications on page 141 This section lists general printer specifications,
printing specifications, ribbon specifications, and
media specifications.
Glossary on page 157 The glossary provides a list of common terms.
P1051584-003 ZE500™ User Guide 3/27/14

1
Introduction
This section provides a high-level overview of the printer and its components.
Contents
Print Engine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Print Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control Panel Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Navigating in the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Changing Password-Protected Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Default Password Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operating Parameters on the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Types of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Ribbon Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
When to Use Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Coated Side of Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3/27/14 ZE500™ User Guide P1051584-003

12 Introduction
Print Engine Orientation
Print Engine Orientation

The ZE500 print engines are available in a right-hand configuration (the print mechanism is on
the right) and a left-hand configuration (the print mechanism is on the left).
Figure 1 • Left-Hand (LH) Print Engine

3
2
2 3
Figure 2 • Right-Hand (RH) Print Engine
1 media door
2 control panel
3 power switch
P1051584-003 ZE500™ User Guide 3/27/14

Introduction 13
Print Engine Components
Print Engine Components

Figure 3 shows the components inside the media compartment of a right-hand print engine. A
left-hand unit contains a mirror image of these components. Familiarize yourself with these
components before continuing with the print engine setup procedure.
Figure 3 • Print Engine Components (RH model shown)

a222
12
5
11
10 9 8 7 6
1 ribbon take-up spindle 7 peel roller assembly (hidden when

closed)
2 ribbon supply spindle 8 peel roller latch
3 printhead-release latch 9 media guide
4 printhead assembly (shown open) 10 pinch roller assembly
5 peel bar 11 lower guide post
6 platen roller 12 upper guide post
3/27/14 ZE500™ User Guide P1051584-003

14 Introduction
Control Panel
Control Panel
All controls and indicators for the print engine are located on the control panel (Figure 4). The
power switch is located on top of the control panel.
Figure 4 • Control Panel
1 2 3 4 5 6 7
POWER PAUSE STATUS DATA

8
9
10 11 12 13 14
1 The display shows the print engine’s operating status and allows the user to navigate the menu
system.
2 POWER light On when the print engine is on.
3 PAUSE light On when the print engine is paused.
4 STATUS light Off Normal operation—no print engine errors.
On A print engine error exists. Check the display for more
information.
5 DATA light Off Normal operation. No data being received or
processed.
On The print engine is processing data or is printing. No
data is being received.
Blinking The print engine is receiving data from or sending
status information to the host computer.
6 The PAUSE button starts or stops print engine operation when pressed.
7 The FEED button forces the print engine to feed one blank label each time the button is pressed.
8 The CANCEL button cancels print jobs when the print engine is paused.
9 The CALIBRATE button calibrates the print engine for media length and sensor values.
10 The LEFT ARROW navigates to the previous parameter in the menus.
11 The PLUS (+) button changes the parameter values. Common uses are to increase a value, to scroll
through choices, or to change values while entering the print engine password.
12 The MINUS (-) button changes the parameter values. Common uses are to decrease a value, to scroll
through choices, or to change the cursor position while entering the print engine password.
13 The SETUP/EXIT button enters and exits configuration mode.
14 The RIGHT ARROW navigates to the next parameter in the menus.
P1051584-003 ZE500™ User Guide 3/27/14

Introduction 15
Control Panel Display

The control panel includes a display, where you can view the print engine’s status or change its
operating parameters. In this section, you will learn how to navigate through the menu system
and change values for menu items.
After the print engine completes the power-up sequence, it moves to the Idle Display
(Figure 5).
Figure 5 • Idle Display
1 The printer’s current status

2 Information that you set through Idle
Display on page 86
Navigating in the Display

Table 1 shows the options available for navigating through the parameters in the display.
Table 1 • Navigation
Enter Setup Mode
POWER PAUSE STATUS DATA POWER PAUSE STATUS DATA
At the Idle Display (Figure 5), press SETUP to enter Setup Mode. The printer displays the first parameter.
Scroll through the Parameters

To scroll through the parameters, press the LEFT
POWER PAUSE STATUS DATA ARROW or the RIGHT ARROW.
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16 Introduction
Table 1 • Navigation (Continued)
Perform an action
+ indicates that an action can be performed.
Press PLUS (+) to perform the specified action.

POWER PAUSE STATUS DATA
Change Parameter Values

- and + indicate that a value can be changed.
Press PLUS (+) or MINUS (-) to scroll through the

POWER PAUSE STATUS DATA accepted values.
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Introduction 17
Table 1 • Navigation (Continued)
Exit Setup Mode
POWER PAUSE STATUS DATA POWER PAUSE STATUS DATA
1. While in Setup Mode, press SETUP to exit the operating parameters.

The LCD displays SAVE CHANGES.
2. To return to the parameters, plus the LEFT ARROW.
OR
Press PLUS (+) or MINUS (-) to scroll through the exit options.
PERMANENT Stores values in the print engine even when power is turned off.
TEMPORARY Saves the changes until power is turned off.
CANCEL This option cancels all changes made since you entered Setup mode,
except for changes made to DARKNESS, TEAR OFF,
COMMUNICATION, and LANGUAGE settings, which go into effect as
soon as they are made.
LOAD DEFAULTS Use this option to restore all 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.
LOAD LAST SAVE Loads the values from the last permanent save.
DEFAULT NET Use this option to restore all print server and network settings back to the
factory defaults. Use care when loading defaults because you will need to
reload all settings that you changed manually.
3. Press the RIGHT ARROW to select the displayed choice and exit Setup Mode.
When the configuration and calibration sequence finishes, the print engine returns to the Idle Display.
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18 Introduction
Changing Password-Protected Parameters

Certain parameters, including the communication parameters, are password-protected by
factory default.
Caution • Do not change password-protected parameters unless you have a complete

understanding of the parameters’ functions. If the parameters are set incorrectly, the print
engine may function unpredictably.
The first time that you attempt to change a password-protected parameter, the print engine
displays ENTER PASSWORD. Before you can change the parameter, you must enter the
four-digit numeric password. After you have entered the password correctly, you do not have
to enter it again unless you leave Setup mode by pressing SETUP/EXIT or by turning off (O)
the print engine.
To enter a password for a password-protected parameter, complete

these steps:
1. At the password prompt, use MINUS (-) to change the selected digit position.
2. When you have selected the digit that you wish to change, use PLUS (+) to increase the
selected digit value. Repeat these two steps for each digit of the password.
3. After entering the password, press SELECT.

The parameter you selected to change is displayed. If the password was entered correctly,
you can change the value.
Default Password Value

The default password value is 1234. The password can be changed using the Zebra
Programming Language (ZPL) command ^KP (Define Password) or using the print engine’s
web pages (ZebraNet wired or wireless print server required).
Disable the Password Protection Feature

You can disable the password protection feature so that it no longer prompts you for a
password by setting the password to 0000 via the ^KP ZPL command. To re-enable the
password-protection feature, send the ZPL command ^KPx, where x can be any number from
1 to 9999.
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Introduction 19
Operating Parameters on the Control Panel

Items in this menu are shown in the order in which they appear when you press the RIGHT
ARROW. For more information about these settings, see Print Settings on page 71.
For information about RFID parameters, refer to RFID Programming Guide 2. You can
download the latest copy from http://www.zebra.com/manuals.
Adjust the Print 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.
See Print Darkness on page 71 for more information.
Select the Print Speed

Select the speed for printing a label (given in inches per second).
Slower print speeds typically yield better print quality.
See Print Speed on page 71 for more information.
Set the Slew Speed

The slew speed is the speed at which the printer skips over the
areas in a label format that are blank across the full width of the
image. A faster slew speed may reduce printing time. The print
engine automatically senses when to apply this higher speed.
See Slew Speed on page 71 for more information.
Set the Backfeed Speed

Backfeed refers to the backward motion of the media from the tear-
off or peel-off position to the print position. This motion occurs so
that more of the lead edge of each label can be used for printing.
Reducing backfeed speed can mitigate some issues. In general,
reducing the backfeed speed may improve print quality at the start
of the label. This speed defaults to 2 ips.
See Backfeed Speed on page 72 for more information.
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20 Introduction
Adjust the Tear-Off Position

If necessary, adjust the position of the media over the tear-off bar
after printing.
See Tear-Off Position on page 72 for more information.
Select the Print Mode

Select a print mode that is compatible with your print engine
options.
See Print Mode on page 73 for more information.
Select the Applicator Port Mode

Select the appropriate action for the applicator port, as suggested
by the applicator manufacturer.
See Applicator Port on page 73 for more information.
Select the Start Print Signal

This parameter determines how the print engine reacts to the Start
Print Signal input on pin 3 of the applicator interface connector at
the rear of the print engine.
Important • The Start Print Signal is determined by the

applicator manufacturer. The print engine must use the
correct setting for it to work properly.
See Start Print Signal on page 74 for more information.
Set the Media Type

Select the type of media that you are using.
See Media Type on page 74 for more information.
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Introduction 21
Select the Media Sensor

Select the media sensor that is appropriate for the media that you
are using.
See Sensor Type on page 93 for more information.
Select the Print Method

Specify if ribbon is being used. Thermal Transfer media requires
ribbon for printing while Direct Thermal media does not.
To determine if you need to use ribbon, see When to Use Ribbon
on page 39.
See Print Method on page 74 for more information.
Adjust the Print Width

Specify the width of the labels being used.
See Print Width on page 75 for more information.
Set the 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 print engine assumes that continuous media is loaded, and the
print engine cannot calibrate.
See Maximum Label Length on page 76 for more information.
Set Early Warning for Media and Ribbon

When this feature is enabled, the print engine provides warnings
when the media or ribbon is reaching near the end of the roll.
See Early Warning for Media and Ribbon on page 80 for more
information.
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22 Introduction
Set Number of Labels Per Roll for Early Warning

This value should correspond to the number of labels per roll of the
media that you are using.
information.
* This parameter appears only if Early Warning for Media and

Ribbon is enabled.
Reset Media Counter for Early Warning

Reset the media counter after you replace the media roll.
• If you replaced the media, press PLUS (+) to select YES.
• If you did not replace the media, press MINUS (-) to select NO,
or press the LEFT ARROW or RIGHT ARROW to move to
another parameter.

Ribbon is enabled.
Set Ribbon Length for Early Warning

This value should correspond to the ribbon length for the ribbon
that you are using.
information.

Ribbon is enabled.
Reset Ribbon Counter for Early Warning

Reset the ribbon counter after you replace the roll of ribbon.
• If you replaced the ribbon, press PLUS (+) to select YES.
• If you did not replace the ribbon, press MINUS (-) to select
NO, or press the LEFT ARROW or RIGHT ARROW to
move to another parameter.

Ribbon is enabled.
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Introduction 23
Set Early Warning for Maintenance

When this feature is enabled, the print engine provides warnings
when the printhead needs to be cleaned.
See Early Warning for Maintenance on page 80 for more
information.
Set Printhead Cleaning Interval*

When Early Warning for Maintenance is enabled, set this value to
the length of the media or ribbon roll that you are using.
See Printhead Cleaning Interval on page 80 for more information.
* This parameter appears only if Early Warning for Maintenance

is enabled.
Reset Printhead Cleaning Counter for Early Warning*

• If you received the message WARNING CLEAN PRINTHEAD,
clean the printhead, and then press PLUS to select YES to reset
the Early Warning for Maintenance printhead cleaning counter.
• If you have not cleaned the printhead, press MINUS to select
NO.

is enabled.
Set Printhead Life Expectancy*

When Early Warning for Maintenance is enabled, set this value to
the number of inches of media that the printhead is expected to
print.
See Printhead Life Expectancy on page 80 for more information.

is enabled.
Reset New Printhead Counter for Early Warning*

• If you received the message WARNING REPLACE HEAD,
replace the printhead, and then press PLUS (+) to select YES to
reset the Early Warning for Maintenance printhead replacement
counter.
• If you have not replaced the printhead, press MINUS (-) to
select NO.

is enabled.
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24 Introduction
View the Non-Resettable Counter

This parameter displays the total length of media that the printer
has printed.
See Non-Resettable Counter on page 81 for more information.
View User-Controlled Counter 1

has printed since this counter was last reset.
See User-Controlled Counters on page 81 for more information.
View User-Controlled Counter 2

has printed since this counter was last reset.
See User-Controlled Counters on page 81 for more information.
Print Counter Readings

Prints a label that lists the odometer readings for the following:
• the non-resettable counter
• the two user-controlled counters
• the Early Warning for Maintenance counters, which indicate
when the printhead was last cleaned and the printhead life (If
the Early Warning for Maintenance feature is disabled, the
counters related to it do not print.)
See Print Counter Readings on page 81 for more information.
Print Font List

This option prints a label that lists the available fonts in the print
engine, including standard print engine fonts plus any optional
fonts. Fonts may be stored in RAM or Flash memory.
See Print Information on page 82 for more information.
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Introduction 25
Print Bar Code List

This option prints a label that lists the available bar codes in the
print engine. Bar codes may be stored in RAM or Flash memory.
Print Image List

This option prints a label that lists the available images stored in
the print engine’s RAM, Flash memory, or optional memory card.
Print Format List

This option prints a label that lists the available formats stored in
the print engine’s RAM, Flash memory, or optional memory card.
Print Configuration Label

This option prints a configuration label (see Figure 12
on page 132), which lists the current print engine configuration.
Print Network Configuration Label

This option prints a configuration label (see Figure 13
on page 132), which lists the settings for any print server that is
installed.
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26 Introduction
Print All Labels

This option prints labels that list the available fonts, bar codes,
images, formats, and the current print engine and network
configurations.
Initialize Flash Memory

This option erases all previously stored information from Flash
memory.
1. If prompted for a password, enter the printer password. For
instructions, see Changing Password-Protected Parameters
on page 18.
The display shows INITIALIZE FLASH?
2. Press PLUS (+) to select YES.
The display shows ARE YOU SURE?.
3. Do you want to continue?
• Press MINUS (-) to select NO to cancel the request and return
to the INITIALIZE FLASH prompt.
• Press PLUS (+) to select YES and begin initialization.
When initialization is complete, the control panel displays
INITIALIZING COMPLETED.
Note • Initializing memory can take several minutes.

See Initialize Flash Memory on page 82 for more information.
Print a Sensor Profile

Use this menu item to print a sensor profile.
See Print a Sensor Profile on page 82 for more information.
Calibrate the Media and Ribbon Sensors

Use this menu item to adjust the sensitivity of the media and
ribbon sensors.
See Media and Ribbon Sensor Calibration on page 85 for more
information. For instructions on how to perform a calibration
procedure, see Calibrate the Ribbon and Media Sensors
on page 97.
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Introduction 27
Set Parallel Communications

Select the communications port that matches the one being used by
the host computer.
See Parallel Communications on page 94 for more information.
Set Serial Communications

Select the communications port that matches the one being used by
the host computer.
See Parallel Communications on page 94 for more information.
Set the Baud Rate

Select the baud value that matches the one being used by the host
computer.
See Baud Rate on page 95 for more information.
Set the Data Bits Value

Select the data bits value that matches the one being used by the
host computer.
See Data Bits on page 95 for more information.
Set the Parity Value

Select the parity value that matches the one being used by the host
computer.
See Parity on page 95 for more information.
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28 Introduction
Set the Host Handshake Protocol Value

Select the handshake protocol that matches the one being used by
the host computer.
See Host Handshake on page 96 for more information.
Set the Zebra Protocol Value

Protocol is a type of error checking system. Depending on the
selection, an indicator may be sent from the print engine to the host
computer signifying that data has been received. Select the
protocol that is requested by the host computer.
See Protocol on page 96 for more information.
Set the Network ID

This parameter assigns a unique number to the print engine when
the print engine is operating in an RS422/485 multi-drop network
environment (an external RS422/485 adapter is required). This
gives the host computer the means to address a specific print
engine. This does not affect TCP/IP or IPX networks. Set a unique
network ID number for this print engine.
See Network ID on page 96 for more information.
Enable Communication Diagnostics Mode

Use this diagnostics tool to cause the printer to output the
hexadecimal values for all data received by the printer.
See Communication Diagnostics Mode on page 85 for more
information.
Set the Control Character Value

Set the control prefix character to match what is used in your label
formats.
See Control Character on page 91 for more information.
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Introduction 29
Set the Format Command Prefix Value

Set the format command prefix character to match what is used in
your label formats.
See Command Character on page 92 for more information.
Set the Delimiter Character Value

Set the delimiter character to match what is used in your label
formats.
See Delimiter Character on page 92 for more information.
Set the ZPL Mode

Select the ZPL mode that matches what is used in your label
formats.
See ZPL Mode on page 92 for more information.
Set the Ribbon Tension

Select the ribbon tension setting that is appropriate for the width or
type of media being printed. HIGH can be used for most media.
The correct setting is determined by a combination of the ribbon
width and the ribbon length (Table 5). If necessary, use a lower
value for narrow media or for glossy media.
See Ribbon Tension on page 77 for more information.
Set the Power-Up Action

Set the action for the printer to take during the power-up sequence.
See Power-Up Action on page 83 for more information.
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30 Introduction
Set the Head-Close Action

Set the action for the printer to take when you close the printhead.
See Head-Close Action on page 83 for more information.
Set the Backfeed Sequence

This parameter sets when label backfeed occurs after a label is
removed in some print modes. It has no effect in Rewind mode.
This setting is superseded by ~JS when received as part of a label
format.
See Backfeed Sequence on page 77 for more information.
Adjust the Label Top Position

This parameter adjusts the print position vertically on the label.
Positive numbers adjust the label top position farther down the
label (away from the printhead) by the specified number of dots.
Negative numbers adjust the position up the label (toward the
printhead).
See Label Top Position on page 78 for more information.
Adjust the 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.
See Label Left Position on page 78 for more information.
Set the Head Test Count*

The ZE500-6 print engine periodically performs a test of the
printhead functionality. This parameter establishes how many
labels are printed between these internal tests.
* This menu item appears only on ZE500-6 print engines.
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Introduction 31
Set Applicator Error Signal When Print Engine Pauses

When this option is enabled and the print engine is paused, the
print engine sets the applicator error state.
See Error on Pause on page 78 for more information.
Set the Ribbon Low Mode

The Ribbon Low feature determines if the print engine will
generate a warning when the amount of ribbon left on the roll gets
low.
See Ribbon Low Mode on page 79 for more information.
Set the Ribbon Low Output

When the Ribbon Low feature is enabled, this parameter
determines if the output signal on Pin 9 is HIGH or LOW.
See Ribbon Low Output on page 79 for more information.
Set the Reprint Mode

When reprint mode is enabled, you can reprint the last label printed
either by issuing certain commands or by pressing the LEFT
ARROW on the control panel.
See Reprint Mode on page 79 for more information.
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32 Introduction
View Sensor Settings

The following parameters are automatically set during the
calibration procedure and should be changed only by a qualified
service technician.
Select Format Conversion Scaling Factor

Selects the bitmap scaling factor. The first number is the original
dots per inch (dpi) value; the second, the dpi to which you would
like to scale.
See Format Conversion on page 85 for more information.
Select the Idle Display

Select the information shown on the printer’s display when the
printer is idle.
See Idle Display on page 86 for more information.
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Introduction 33
Set the Real-Time Clock (RTC) Date

This parameter allows you to set the date to display in the Idle
Display.
See RTC Date on page 86 for more information.
Set the Real-Time Clock (RTC) Time

This parameter allows you to set the date to display in the Idle
Display.
See RTC Time on page 86 for more information.
Run the Specified ZBI Program*

• To run the ZBI program selected by the previous menu item,
press PLUS (+).
• If you did not replace the ribbon, press MINUS (-) to select
CANCEL, or press the LEFT ARROW or RIGHT ARROW
to move to another parameter.
See Run a ZBI Program on page 86 for more information.
* This menu item appears only if ZBI is enabled on your printer

and no ZBI program is running.
Select the Primary Network Device

This parameter determines which device should be considered
primary in the active device selection.
See Primary Network on page 87 for more information.
View if IP Settings Are Loaded from the Printer or Print

Server
This parameter tells whether to use the print engine’s or the print
server’s LAN/WLAN settings at power-up. The default is to use
the print engine’s settings.
See Load from External Device on page 87 for more information.
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34 Introduction
View the Active Print Server*

This menu item displays which print server is being used. This tells
which device’s settings such as IP protocol and IP address are
being displayed under those menu items.
* This menu item, which cannot be modified from the control

panel, appears only if a wired or wireless print server is
installed in your printer.
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.
See IP Protocol on page 88 for more information.
* This menu item appears only if a wired or wireless print server

is installed in your printer.
Set the Printer’s IP Address*

View and, if necessary, change the printer’s IP address.
Changes are saved only if IP PROTOCOL is set to PERMANENT.
To allow any saved changes to take effect, use RESET NETWORK
on page 35 to reset the print server.
See IP Address on page 88 for more information.

Set the Subnet Mask*

View and, if necessary, change the subnet mask.
See Subnet Mask on page 89 for more information.

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Introduction 35
Set the Default Gateway*

View and, if necessary, change the default gateway.
See Default Gateway on page 89 for more information.

View the MAC Address*

View the Media Access Control (MAC) address of the print server
that is installed in the printer (wired or wireless).
See MAC Address on page 89 for more information.

panel, appears only if a wired or wireless print server is
installed in your printer.
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.
See ESSID on page 90 for more information.

panel, appears only if a wireless print server is installed in your
printer.
Reset the Network Settings*

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.
See Reset Network on page 90 for more information.

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36 Introduction
Specify the Password Level

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.
See Password Level on page 86 for more information.

Select the Display Language

If necessary, change the language that the printer displays.
See Language on page 91 for more information.
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.
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Introduction 37
Types of Media
Types of 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 print engine and to
prevent premature printhead wear. To purchase supplies, go to
http://www.zebra.com/howtobuy.
Your print engine can use various types of media:

• Standard media—Most standard media uses an adhesive backing that sticks individual
labels or a continuous length of labels to a liner. Standard media can come on rolls or in a
fanfold stack (Table 2).
• Tag stock—Tags are usually made from a heavy paper. Tag stock does not have adhesive
or a liner, and it is typically perforated between tags. Tag stock can come on rolls or in a
fanfold stack (Table 2).
• Radio frequency identification (RFID) “smart” media—RFID
media can be used in a printer that is equipped with an RFID
reader/encoder. RFID labels are made from the same materials and
adhesives as non-RFID labels. Each label has an RFID transponder
(sometimes called an “inlay”), made of a chip and an antenna,
embedded between the label and the liner. The shape of the transponder varies by
manufacturer and is visible through the label. All “smart” labels have memory that can be
read, and many have memory that can be encoded.
Important • Transponder placement within a label depends on the transponder type and
the printer model. Make sure that you are using the correct “smart” media for your printer.
For more information, refer to the RFID Programming Guide 2. A copy of the manual is
available at http://www.zebra.com/manuals or on the user CD that came with your print
engine. For transponder placement details, go to http://www.zebra.com/transponders.
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38 Introduction
Types of Media
Table 2 • Roll and Fanfold Media
Media Type How It Looks Description

Non-Continuous Roll media is wound on a 3-in. (76-mm) core. Individual
Roll Media labels or tags 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 is folded in a zigzag pattern. Fanfold media can

Fanfold Media have the same label separations as non-continuous roll media.
The separations would fall on or near the folds.
Continuous Roll media is wound on a 3-in. (76-mm) core.

Roll Media 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. Sometimes a cutter
is used to cut apart individual labels.
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Introduction 39
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.
When to Use Ribbon

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 rapidly with your fingernail.
2. Did a black mark appear on the media?
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.
Coated Side of Ribbon

Ribbon can be wound with the coated side on the inside or outside (Figure 6). This print
engine 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.
Figure 6 • Ribbon Coated on Outside or Inside

Outside Inside
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40 Introduction
Ribbon Overview
Adhesive Test
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?
If ink from the ribbon... Then...

Adhered to the label The ribbon is coated on the outside and can be
used in this printer.
Did not adhere to the label The ribbon is coated on the inside and cannot
be used in this print engine.
To verify this, repeat the test on the other
surface of the roll of ribbon.
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 in this printer.
Did not leave a mark on the The ribbon is coated on the inside and cannot
paper be used in this print engine.
To verify this, repeat the test on the other
surface of the roll of ribbon.
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2
Printer Setup and
Operation
This section assists the technician with initial setup and operation of the print engine.
Contents
Handling the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Unpack and Inspect the Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Remove Additional Shipping Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
To Store the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
To Ship the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Print Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Dimensions and Clearance Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Install the Print Engine in an Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Select a Data Communication Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Data Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Connect the Print Engine to a Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Load Ribbon and Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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42 Printer Setup and Operation
Handling the Print Engine

This section describes how to handle your print engine.
Unpack and Inspect the Print Engine
Important • Zebra Technologies is not responsible for any damage incurred during the
shipment of the equipment and will not repair this damage under warranty.
When you receive the print engine, do the following:
1. Immediately unpack the print engine.
2. Check all exterior surfaces for damage.
3. Raise the media door, and inspect the media compartment for damage to components.
4. If you discover shipping damage during inspection, do the following:

• Immediately notify the shipping company, and file a damage report.
• Keep all packaging material for shipping company inspection.
• Notify your authorized Zebra reseller.
Remove Additional Shipping Materials

1. If your print engine includes the optional applicator port, complete this step. If it does not,
continue with step 2.
Caution • The print engine ships with the following caution label over the optional
applicator port:
Applying external power when the print engine is configured for internal power will
damage your print engine.
For +5V non-isolated mode (internal power):

a. No configuration is necessary. Remove the caution sticker from the applicator
port.
b. Continue with step 2.
For +5V to +28V isolated mode (external power):

a. The jumpers on the applicator interface board must be reconfigured. See
Applicator Interface Board Reconfiguration on page 145 for instructions.
b. Remove the caution sticker from the applicator port.
c. Continue with step 2.
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Printer Setup and Operation 43
2. Remove the metal spacer that ships next to the printhead-release latch. (Right-hand unit
shown.)
a. Cut the cable tie (1) that secured the printhead-release latch during shipping.
b. Rotate the printhead-release latch to expose the metal spacer.
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c. Remove the metal spacer.
d. Rotate the printhead-release latch to the closed position.
3. Cut and remove other cable ties that were used in the media compartment (if any).
P1051584-003 ZE500™ User Guide 3/27/14

To Store the Print Engine

If you are not placing the print engine into immediate operation, repackage it using the original
packing materials. You may store the print engine under the following conditions:
• Temperature: –40°F to 140°F (–40° to 60°C)
• Relative humidity: 5% to 85% non-condensing
To Ship the Print Engine

Save all packing materials in case you need to ship the print engine in the future.
To ship the print engine, do the following:
1. Turn off (O) the print engine, and disconnect all cables.
2. Remove any media, ribbon, or loose objects from the print engine interior.
3. Close the printhead.
4. Carefully pack the print engine into the original container or a suitable alternate container
to avoid damage during transit. A shipping container can be purchased from Zebra if the
original packaging has been lost or destroyed.
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Print Engine Installation

This section provides basic information for mounting the print engine into an applicator. The
illustrations in this section show the print engine from different angles and include dimensions
and clearance needs.
Requirements
Stability When the print engine is mounted, the complete assembly must be physically
stable. When the print engine is loaded with ribbon and media, the equipment must not
become physically unstable.
Ventilation and Temperature Provide ventilation for the print engine mounting enclosure
to remove heat and ensure uninterrupted, trouble-free operation of the print engine. Ambient
air temperature surrounding the print engine must not exceed the following:
• Temperature: 32° to 105°F (0° to 41°C)
• Relative humidity: 20% to 95% non-condensing
Power Requirements Consider the current rating of the print engine during installation.
When power is applied to the print engine and the enclosing equipment, an overload condition
must not be created.
Grounding Requirements Maintain reliable grounding of the print engine. Pay particular
attention to the AC power supply connections so that earth ground is maintained through the
AC power input connector.
Clearance for Cables and Connectors Allow ample space at the rear of the print engine
for electronic connectors and dressing of the following cables: IEC power cord, serial and/or
parallel host communication cable, optional host communication cable (Ethernet), and the
discrete signal (applicator) interface cable.
Power Cord Requirements The IEC power cord does not have a strain relief on the print
engine. If the operating characteristics of the applicator include vibration or strain on the
power cord, provide an appropriate clamping mechanism to avoid unintentional disconnection
of the power cord from the print engine.
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Dimensions and Clearance Needs

This section shows measurements relevant when installing the ZE500 print engine in an
applicator.
Front View (Right-Hand Print Engine Shown)

5 mounting screws
- 0.218 in. (5.5 mm) through
- counterbore 0.350 in. x 0.197 in. (8.9 x 5 mm) deep
- socket head cap screw (M5)
0.669 in.
(17 mm)
18°
0.532 in
(13.50 mm) 0.335 in.
0.721 in (8.50 mm)
(18.31 mm)
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Rear View
9.648 in.
(245 ± 0.1 mm)
0.445 in.
(11.3 mm)
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Top View
16.62 in. (422.1 mm)
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Side View—ZE500-4 Print Engine
First print
element
Mainframe
12.13 in 0.613 in.
(15.6 mm)
(308.2 mm)
0.52 in.
(13.2 mm)
Ribbon and
media edge
1.454 in. (37 mm)

15.89 in.
(403.7 mm)
12.73 in.
(323.2 mm)
7.34 in.
(186.5 mm)
14.95 in. (379.73 mm)

19.87 in. (504.7 mm)
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Side View—ZE500-6 Print Engine
First print
element
Mainframe
0.613 in.
(15.6 mm)
0.52 in.
(13.2 mm)
Ribbon and
media edge
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Install the Print Engine in an Applicator

This section provides the basic instructions for installing the print engine into an applicator.
Caution • If the print engine is installed improperly, it could fall out of the applicator and
cause injury. The center mounting bolt and four mounting screws must be installed and
secured. See Figure 7 for the location of the bolt and screws.
To install the print engine into an applicator, complete these steps:
1. See Figure 7. Install the center mounting bolt into the center hole on the applicator.
2. Carefully place the keyhole on the center mounting bolt.
Note • The keyhole and the center mounting bolt are designed to support the print engine
and assist in installing and removing the four mounting screws.
3. Install the four corner mounting screws to secure the print engine to the applicator.
Figure 7 • Front View of Print Engine in Applicator

1
2
4
3
1 Mounting screws (four total)

2 Keyhole
3 Center mounting bolt (shown inside hole on applicator)
4 Applicator
P1051584-003 ZE500™ User Guide 3/27/14

Select a Data Communication Interface

You may connect your print engine to a computer using one or more of the available
connections. The standard connections are shown in Figure 8. A ZebraNet wired or wireless
print server option or a parallel port may also be present on your print engine.
Figure 8 • Communication Interfaces
parallel port
USB port
wired Ethernet port
serial port
1 applicator port
Table 3 on page 54 provides basic information about data communication interfaces that you
can use to connect your print engine to a computer. You may send label formats to the print
engine through any data communication interface that is available. Select an interface that is
supported by both your print engine and your computer or your Local Area Network (LAN).
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Caution • Ensure that the print engine power is off (O) before connecting data
communications cables. Connecting a data communications cable while the power is on (I)
may damage the print engine.
Table 3 • Data Communication Interfaces
Standard or
Interface Description
Option
RS-232 Serial Standard Limitations and Requirements
• Maximum cable length of 50 ft (15.24 m).
• You may need to change print engine parameters to match the
host computer.
• You need to use a null-modem adaptor to connect to the print
engine if using a standard modem cable.
Connections and Configuration The baud rate, number of
data and stop bits, the parity, and the XON/XOFF or DTR control
must match those of the host computer.
USB Standard Limitations and Requirements
• Maximum cable length of 16.4 ft (5 m).
• No print engine parameter changes required to match the host
computer.
Connections and Configuration No additional
configuration is necessary.
8-bit Parallel data Standard Limitations and Requirements
interface • Maximum cable length of 10 ft (3 m).
• Recommended cable length of 6 ft (1.83 m).
• No print engine parameter changes required to match the host
computer.
• A wired or wireless print server (if installed) takes up this port
on the print engine.
Connections and Configuration No additional
configuration is necessary.
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Table 3 • Data Communication Interfaces (Continued)
Standard or
Option
Applicator Option Limitations and Requirements The applicator interface is
used to control the print engine from an external device (usually a
label applicator).
Connections and Configuration The print engine ships with
the following caution label over the optional applicator port:
• For +5V non-isolated mode (internal power), no configuration

is necessary.
• For +5V to +28V isolated mode (external power), the jumpers
on the applicator interface board must be reconfigured. See
Applicator Interface Board Reconfiguration on page 145.
Caution • Do not apply external power until after the
applicator interface board is reconfigured for isolated mode.
Applying external power when the print engine is configured
for internal power will damage your print engine.
Wired Ethernet print Option Limitations and Requirements
server • Can print to the print engine from any computer on your LAN.
• Can communicate with the printer through the print engine’s
web pages.
• The printer must be configured to use your LAN.
• A parallel connection or a wireless print server (if installed)
takes up this port on the print engine.
Caution • Be careful not to plug a USB cable into a wired

Ethernet print server connector on the print engine because
doing so will damage the Ethernet connector.
Connections and Configuration Refer to the ZebraNet
Wired and Wireless Print Servers User Guide for configuration
instructions. A copy of this manual is available at
http://www.zebra.com/manuals or on the user CD that came with
your print engine.
Note • To use this connection, you may need to remove a
factory-installed plug that is designed to keep someone
from accidentally plugging a USB connector into this port.
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Table 3 • Data Communication Interfaces (Continued)
Standard or
Option
Wireless print server Option Limitations and Requirements
• Can print to the print engine from any computer on your
Wireless Local Area Network (WLAN).
• Can communicate with the printer through the print engine’s
web pages.
• The print engine must be configured to use your WLAN.
• A parallel connection or a wired print server (if installed) takes
up this port on the print engine.
Configuration Refer to the ZebraNet Wired and Wireless Print
Servers User Guide for configuration instructions. A copy of this
manual is available at http://www.zebra.com/manuals or on the
user CD that came with your print engine.
Data Cables
You must supply all data cables for your application.
Ethernet cables do not require shielding, but all other data cables must be fully shielded and
fitted with metal or metallized connector shells. Unshielded data cables may increase radiated
emissions above the regulated limits.
To minimize electrical noise pickup in the cable:

• Keep data cables as short as possible.
• Do not bundle the data cables tightly with the power cords.
• Do not tie the data cables to power wire conduits.
P1051584-003 ZE500™ User Guide 3/27/14

Connect the Print Engine to a Power Source

The AC power cord must have a three-prong female connector on one end that plugs into the
mating AC power connector at the rear of the print engine. If a power cable was not included
with your print engine, refer to Power Cord Specifications on page 58.
Caution • For personnel and equipment safety, always use an approved three-conductor
power cord specific to the region or country intended for installation. This cord must use an
IEC 320 female connector and the appropriate region-specific three-conductor grounded
plug configuration.
To connect the print engine to a power source, complete these steps:
1. Plug the female end of the A/C power cord into the A/C power connector on the back of
the print engine.
2. Plug the male end of the A/C power cord into an appropriate power outlet.
115 V AC
230 V AC
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3. Turn on (I) the print engine.
The print engine boots up and performs a self-test.
Power Cord Specifications
Caution • For personnel and equipment safety, always use an approved three-conductor
power cord specific to the region or country intended for installation. This cord must use an
IEC 320 female connector and the appropriate region-specific, three-conductor grounded
plug configuration.
Depending on how your print engine was ordered, a power cord may or may not be included.
If one is not included or if the one included is not suitable for your requirements, see Figure 9
and refer to the following guidelines:
• The overall cord length must be less than 9.8 ft. (3 m).
• The cord must be rated for a minimum of 10 A, 250 V.
• The chassis ground (earth) must be connected to ensure safety and reduce electromagnetic
interference.
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Figure 9 • Power Cord Specifications
3
1
1 AC power plug for your country—This should bear the certification

mark of at least one of the known international safety organizations
(Figure 10).
2 3-conductor HAR cable or other cable approved for your country.
3 IEC 320 connector—This should bear the certification mark of at
least one of the known international safety organizations (Figure 10).
4 Length ≤ 9.8 ft. (3 m). Rating 10 Amp minimum, 250 VAC.
Figure 10 • International Safety Organization Certification Symbols
3/27/14 ZE500™ User Guide P1051584-003

Load Ribbon and Media

Use the instructions in this section to load ribbon (if used) and media in a ZE500™ print
engine. Ribbon is used with thermal transfer labels. For direct thermal labels, do not load
ribbon in the print engine. To determine if ribbon must be used with a particular media, see
When to Use Ribbon on page 39.
Caution • While performing any tasks near an open printhead, remove all rings, watches,
hanging necklaces, identification badges, or other metallic objects that could touch the
printhead. You are not required to turn off the printer power when working near an open
printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose
all temporary settings, such as label formats, and you must reload them before you resume
printing.
Important • Use ribbon that is wider than the media to protect the printhead from wear.
Ribbon must be coated on the outside. See Coated Side of Ribbon on page 39 for more
information.
To load ribbon and media, complete these steps:
Loading Ribbon
1.
Caution • The printhead may be hot and could cause severe burns. Allow the
printhead to cool.
Rotate the printhead-release latch to the open position.
LH RH
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2. Position the ribbon roll with the loose end unrolling in the direction shown.
LH RH
3. Place the roll of ribbon on the ribbon supply spindle. Push the roll back as far as it will go.
LH RH
4. Place an empty ribbon core on the ribbon take-up spindle. Push the core back as far as it
will go.
LH RH
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5.
printhead to cool.
Thread the ribbon under the lower ribbon guide roller (1), under the printhead
assembly (2), and then over the upper ribbon guide roller (3).
3 3
1 1
2 2
LH RH
6. Wind the ribbon around the core on the ribbon take-up spindle.
LH RH
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Loading Media
7. Load media on the media supply reel of the applicator (refer to the applicator’s
documentation for more information).
8. Press the release button on the pinch roller assembly. Allow the assembly to pivot upward.
LH RH
9. Slide the media guide all the way out.
LH RH
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10. Thread the media under the upper guide post (1), below the pinch roller assembly (2), and
under the printhead assembly (3).
2 1 1 2
3 3
LH RH
11. Extend approximately 30 in. (75 cm) of media past the peel bar. Remove and discard the
labels from the liner on this exposed media.
RH
LH
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12. Slide in the media guide until it just touches the edge of the media.
LH RH
13. Press down on the pinch roller assembly until it locks closed.
LH RH
14. Rotate the printhead-release latch to the closed position.
LH RH
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15. Raise the peel roller latch so that the peel roller assembly pivots downward.
LH RH
16. Thread the liner around the peel bar, under the platen roller, and through the peel roller
assembly.
Important • If the applicator has an air tube, route the liner between the air tube and the
peel bar. Do not thread the liner over the air tube.
LH RH
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17. Rotate the peel roller assembly up until it locks into the closed position.
LH RH
18. Thread the liner around the take-up spindle of the applicator (refer to the applicator’s
documentation for more information).
19. Close the media door.
20. If desired, perform the CANCEL Self Test on page 149 to verify that your printer is able to
print.
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Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
P1051584-003 ZE500™ User Guide 3/27/14

3
Printer Configuration
and Adjustment
This section assists you with configuration of and adjustments to the print engine.
Contents
Changing Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Print Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Maintenance and Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Language Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Sensor Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Port Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Calibrate the Ribbon and Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Remove Used Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Adjust the Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Transmissive Media Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Reflective Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Ribbon Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Toggle Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Printhead Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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70 Printer Configuration and Adjustment
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:
• ZPL and Set/Get/Do (SGD) commands (See the Zebra® Programming Guide for more
information.)
• The printer’s control panel display (See Control Panel Display on page 15 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.)
This section contains the following subsections:

• Print Settings on page 71
• Maintenance and Diagnostic Tools on page 80
• Network Settings on page 87
• Language Settings on page 91
• Port Settings on page 94
For information about RFID parameters, see the RFID Programming Guide 2.
Note • You can download the latest copy of the referenced manuals from
http://www.zebra.com/manuals.
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Printer Configuration and Adjustment 71
Print Settings
Table 4 • Print Settings

Print Set the darkness to the lowest setting that provides good print quality. If you set the darkness
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 FEED Self Test on page 134 to determine the best darkness setting.
Accepted values: 0.0 – 30.0
Related ZPL command(s): ^MD, ~SD
SGD command used: print.tone
Control panel menu item: DARKNESS on page 19
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: • ZE500-4 203 dpi: 2–12 ips
• ZE500-4 300 dpi: 2–12 ips
• ZE500-6 203 dpi: 2–12 ips
• ZE500-6 300 dpi: 2–10 ips
Related ZPL command(s): ^PR
SGD command used: media.speed
Control panel menu item: PRINT SPEED on page 19
Print Speed
Slew Speed The slew speed is the speed at which the printer skips over the areas in a label format that
are blank across the full width of the image. A faster slew speed may reduce printing time.
The print engine automatically senses when to apply this higher speed.
• ZE500-4 300 dpi: 2–12 ips
• ZE500-6 203 dpi: 2–12 ips
• ZE500-6 300 dpi: 2–10 ips
SGD command used: none
Control panel menu item: SLEW SPEED on page 19
Printer web page: none
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Table 4 • Print Settings (Continued)

Backfeed Backfeed refers to the backward motion of the media from the tear-off or peel-off position to
Speed the print position. This motion occurs so that more of the lead edge of each label can be used
for printing. Reducing backfeed speed can mitigate some issues. In general, reducing the
backfeed speed may improve print quality at the start of the label. This speed defaults to
2 ips.
• ZE500-4 300 dpi: 2–12 ips
• ZE500-6 203 dpi: 2–12 ips
• ZE500-6 300 dpi: 2–10 ips
Control panel menu item: BACKFEED SPEED on page 19
Tear-Off If necessary, adjust the position of the media over the tear-off bar after printing.
Position • 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).
1
2
1 Media direction
2 Factory-set tear line location at position 000
Accepted values: –120 to 120

Related ZPL command(s): ~TA
Control panel menu item: TEAR OFF on page 20
Tear Off
P1051584-003 ZE500™ User Guide 3/27/14


Print Mode Select a print mode that is compatible with your print engine options.
Accepted values: • APPLICATOR—The print engine prints a label when
it receives a signal from the applicator.
• TEAR OFF—The print engine prints label formats as
it receives them. The print engine operator can tear off
the printed labels any time after they print.
• STREAM—The print engine prints a batch of labels
with backfeed occurring only at the start and end of
the batch instead of between individual labels. This
setting increases label throughput in batch printing.
• REWIND—The print engine prints without pausing
between labels. The media is wound onto a core after
printing.
• RFID—The print engine does not backfeed between
labels. When the last label prints, the print engine
waits 1 second for another label format before feeding
the last printed label to the tear-off position. Use this
mode when printing multiple RFID labels in Tear-Off
mode to improve throughput time.
Related ZPL command(s): ^MM
SGD command used: media.printmode
Control panel menu item: PRINT MODE on page 20
Print Mode
Applicator Select the appropriate action for the applicator port, as suggested by the applicator
Port manufacturer.
Accepted values: • OFF: The applicator port is off.
• MODE 1: Asserts the ~END_PRINT signal low while
the print engine is moving the label forward.
• MODE 2: Asserts the ~END_PRINT signal high
while the print engine is moving the label forward.
• MODE 3: Asserts the ~END_PRINT signal low for
20 milliseconds when a label has been completed and
positioned. Not asserted during continuous printing
modes.
• MODE 4: Asserts the ~END_PRINT signal high for
20 milliseconds when a label has been completed and
positioned. Not asserted during continuous printing
modes.
Related ZPL command(s): ^JJ
SGD command used: device.applicator.end_print
Control panel menu item: APPLICATOR PORT on page 20
Printer web page: View and Modify Printer Settings > Advanced Setup >
Applicator
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Start Print This parameter determines how the print engine reacts to the Start Print Signal input on
Signal pin 3 of the applicator interface connector at the rear of the print engine.
Important • The Start Print Signal is determined by the applicator manufacturer.
The print engine must use the correct setting for it to work properly.
Accepted values: • PULSE MODE—Labels print when the signal

transitions from HIGH to LOW or LOW to HIGH, as
specified by the SGD command
device.applicator.start_print.
• LEVEL MODE—Labels print as long as the signal is
asserted LOW.
Control panel menu item: START PRINT SIG on page 20
Start Print Sig
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 NON-CONTINUOUS for various non-continuous media, the print engine
feeds media to calculate the label length.
See Types of Media on page 47 for more information.
Accepted values: • CONTINUOUS
• NON-CONTINUOUS
Related ZPL command(s): ^MN
Control panel menu item: MEDIA TYPE on page 20
Printer web page: View and Modify Printer Settings > Media Setup >
Media Type
Print Method Specify if ribbon is being used. Thermal Transfer media requires ribbon for printing while
Direct Thermal media does not.
To determine if you need to use ribbon, see When to Use Ribbon on page 39.
Accepted values: • THERMAL TRANS
• DIRECT THERMAL
Related ZPL command(s): ^MT
Control panel menu item: PRINT METHOD on page 21
Print Method
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Print Width Specify the width of the labels being used.
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: minimum: 2 dots
maximum:
• ZE500-4 203 dpi: 832 dots
• ZE500-4 300 dpi: 1228 dots
• ZE500-6 203 dpi: 1344 dots
• ZE500-6 300 dpi: 1984 dots
Related ZPL command(s): ^PW
Control panel menu item: PRINT WIDTH on page 21
Print Width
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Maximum Set the maximum label length to a value that is at least 1.0 in. (25.4 mm) greater than the
Label Length actual label length plus the interlabel gap. If you set the value to one that is smaller than the
label length, the print engine assumes that continuous media is loaded, and the print engine
cannot calibrate.
For example, if the label length is 6.0 inches (152 mm) including the interlabel gap, set the
parameter for at least 7.0 inches (178 mm).
1
3
1 Label length (including interlabel gap)

2 Interlabel gap
3 Set the maximum label length to approximately
this value
Accepted values: 0 to the maximum label length supported by the printer

Related ZPL command(s): ^ML
Control panel menu item: MAXIMUM LENGTH on page 21
Maximum Length
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Ribbon Select the ribbon tension setting that is appropriate for the width or type of media being
Tension printed. HIGH can be used for most media. The correct setting is determined by a
combination of the ribbon width and the ribbon length (Table 5). If necessary, use a lower
value for narrow media or for glossy media.
Table 5 • Ribbon Tension Settings
Ribbon Length
Ribbon Width
300 Meters 450 Meters 600 Meters
3 to 5 in. LOW LOW LOW
(76 to 127 mm)
4 to 6 in. LOW LOW or MEDIUM LOW or MEDIUM
(102 to 152 mm)
5 to 7 in. LOW or MEDIUM MEDIUM MEDIUM or HIGH
(127 to 178 mm)
Accepted values: • HIGH

• MEDIUM
• LOW
Related ZPL command(s): ^JW
Control panel menu item: RIBBON TENSION on page 29
Backfeed This parameter sets when label backfeed occurs after a label is removed in some print
Sequence modes. It has no effect in Rewind mode. This setting is superseded by ~JS when received
as part of a label format.
Accepted values: • AFTER (backfeed occurs immediately after the last
label is completed)
• OFF (no backfeed)
• BEFORE (backfeed occurs before the forward motion
of the first label)
• DEFAULT
Related ZPL command(s): ~JS
Control panel menu item: BACKFEED on page 30
Backfeed
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Label Top This parameter adjusts the print position vertically on the label. Positive numbers adjust the
Position label top position farther down the label (away from the printhead) by the specified number
of dots. Negative numbers adjust the position up the label (toward the printhead).
Related ZPL command(s): ^LT
Control panel menu item: LABEL TOP on page 30
Label Top
Label Left If necessary, shift the print position horizontally on the label. Positive numbers move the left
Position 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.
Related ZPL command(s): ^LS
Control panel menu item: LEFT POSITION on page 30
Left Position
Head Test The ZE500-6 print engine periodically performs a test of the printhead functionality. This
Count parameter establishes how many labels are printed between these internal tests.
Accepted values: 0000 (disables the test) to 9999
Related ZPL command(s): ^JT
Control panel menu item: HEAD TEST COUNT on page 30
Head Test Count
Error on When this option is enabled and the print engine is paused, the print engine sets the
Pause applicator error state.
Accepted values: • ENABLED
• DISABLED
Control panel menu item: ERROR ON PAUSE on page 31
Error on Pause
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Ribbon Low The Ribbon Low feature determines if the print engine will generate a warning when the
Mode amount of ribbon left on the roll gets low.
When the Ribbon Low feature is off, the output signal (Pin 9) does not function, the LOW
RIBBON warning is not displayed, and the print engine continues to print until it runs out of
ribbon.
When the Ribbon Low feature is enabled, output signal (Pin 9) on the applicator port is
functional. When the amount of ribbon on the supply spindle gets low, the output signal
asserts to provide a RIBBON LOW warning. Set the output signal to assert HIGH or LOW.
Accepted values: • ENABLED
• DISABLED
Control panel menu item: RIBBON LOW MODE on page 31
Ribbon Low When the Ribbon Low feature is enabled, this parameter determines if the output signal on
Output Pin 9 is HIGH or LOW.
Accepted values: • ACTIVE HIGH
• ACTIVE LOW
Related ZPL command(s): none
SGD command used: device.applicator.ribbon_low
Control panel menu item: RIBBON LOW OUTPUT on page 31
Reprint When reprint mode is enabled, you can reprint the last label printed by pressing and holding
Mode PAUSE + CANCEL on the printer’s control panel.
Accepted values: • ON
• OFF
Related ZPL command(s): ^JZ
Control panel menu item: REPRINT MODE on page 32
Printer web page: N/A
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Maintenance and Diagnostic Tools
Table 6 • Maintenance and Diagnostic Tools

Early Warning When this feature is enabled, the print engine provides warnings when the media or
for Media and ribbon is reaching near the end of the roll.
Ribbon
Accepted values: MEDIA DISABLED, MEDIA ENABLED
Related ZPL command(s): ^JH
Control panel menu item: EARLY WARNING MEDIA on page 21
Printer web page: View and Modify Printer Settings > General Setup
> Early Warning (Media)
Early Warning When this feature is enabled, the print engine provides warnings when the printhead
for Maintenance needs to be cleaned.
Accepted values: MAINT. OFF, MAINT. ON
Control panel menu item: EARLY WARNING MAINTENANCE on page 23
> Early Warning (Maintenance)
Printhead When Early Warning for Maintenance is enabled, set this value to the length of the
Cleaning Interval media or ribbon roll that you are using.
When the printhead reaches the set length, WARNING CLEAN PRINTHEAD appears on
the control panel display. If the alert function is enabled, the print engine generates an
alert.
Accepted values: 0 M/0 FT to 450M/1476 FT in 50 M increments
Control panel menu item: HEAD CLEANING on page 23
> Head Cleaning
Printhead Life When Early Warning for Maintenance is enabled, set this value to the number of inches
Expectancy of media that the printhead is expected to print.
When the printhead reaches the set length, WARNING REPLACE HEAD appears on the
control panel display. If the alert function is enabled, the print engine generates an alert.
Accepted values: 0 M/0 FT to 450M/1476 FT in 50 M increments
Control panel menu item: HEAD LIFE on page 23
> Head Life
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Table 6 • Maintenance and Diagnostic Tools (Continued)

Non-Resettable The non-resettable counter gives the total length of media that the printer has printed.
Counter You can use firmware commands to change the unit of measure for this counter.
Related ZPL command(s): ^MA (for changing unit of measure)
Control panel menu item: NONRESET CNTR on page 24
User-Controlled Two user-controlled counters give the total length of media that the printer has printed
Counters since the last time the counter was reset. You can use firmware commands to change the
unit of measure and reset the counters.
Related ZPL command(s): ^MA (for changing unit of measure)
~RO (for resetting counters)
SGD command used: odometer.media_marker_count1
odometer.media_marker_count2
Control panel menu item: RESET CNTR1 on page 24
RESET CNTR2 on page 24
Print Counter Prints a label that lists the odometer readings for the following:
Readings • the non-resettable counter
• the two user-controlled counters
• the Early Warning for Maintenance counters, which indicate when the printhead
was last cleaned and the printhead life (If the Early Warning for Maintenance
feature is disabled, the counters related to it do not print.)
Related ZPL command(s): ~HQ
Control panel menu item: PRINT METERS on page 24
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Print Print the specified information on one or more labels.
Information • FONTS—Prints the available fonts in the print engine, including standard print
engine fonts plus any optional fonts. Fonts may be stored in RAM or Flash memory.
• BAR CODES—Prints the available bar codes in the print engine. Bar codes may be
stored in RAM or Flash memory.
• IMAGES—Prints the available images stored in the print engine’s RAM, Flash
memory, or optional memory card.
• FORMATS—Prints the available formats stored in the printer’s RAM, Flash
memory, or optional memory card.
• SETUP—Prints the printer configuration label.
• NETWORK—Prints the settings for any print server that is installed.
• ALL—Prints the previous six labels.
Related ZPL command(s): Printer configuration: ~WC
Network: ~WL
Others: ^WD
Control panel menu item: LIST FONTS on page 24
LIST BAR CODES on page 25
LIST IMAGES on page 25
LIST FORMATS on page 25
LIST SETUP on page 25
LIST NETWORK on page 25
LIST ALL on page 26
Printer web page: View and Modify Printer Settings >
Print Listings on Label
Print a Sensor Shows the sensor settings compared to actual sensor readings.
Profile To interpret the results of the sensor profile, see Sensor Profile on page 139.
Related ZPL command(s): ~JG
Control panel menu item: SENSOR PROFILE on page 26
Print Listings on Label
Initialize Flash This option erases all previously stored information from Flash memory.
Memory Caution • This option completely erases the Flash memory.
Related ZPL command(s): ^JB
Control panel menu item: INIT FLASH MEM. on page 26
Printer web page: View and Modify Printer Settings > Advanced
Setup > Format Memory
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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
Control panel menu item: MEDIA POWER UP on page 29
Printer web page: View and Modify Printer Settings > Calibration
Head-Close Set the Head-Close Action
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
Control panel menu item: HEAD CLOSE on page 30
Printer web page: View and Modify Printer Settings > Calibration
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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
Control panel menu item: Available as options when exiting Setup Mode. See
Exit Setup Mode on page 17.
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
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Media and Calibrate the printer to adjust the sensitivity of the media and ribbon sensors.
Ribbon Sensor For complete instructions on how to perform a calibration procedure, see Calibrate the
Calibration Ribbon and Media Sensors on page 97.
Accepted values: N/A
Related ZPL command(s): ~JC
Control panel menu item: MEDIA AND RIBBON CALIBRATE on page 26
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.
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 138.
Accepted values: • DISABLED
• ENABLED
Related ZPL command(s): ~JD to enable, ~JE to disable
Control panel menu item: COMMUNICATIONS on page 28
Format Selects the bitmap scaling factor. The first number is the original dots per inch (dpi)
Conversion value; the second, the dpi to which you would like to scale.
Accepted values: • NONE
• 150 → 300
• 150 → 600
• 200 → 600
• 300 → 600
Control panel menu item: FORMAT CONVERT on page 32
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Idle Display Select the information shown on the printer’s display when the printer is idle.
Accepted values: • FIRMWARE (FW) VERSION
• MM/DD/YY 24 HR
• M/DD/YY 12 HR
• DD/MM/YY 24 HR
• DD/MM/YY 12 HR
Control panel menu item: IDLE DISPLAY on page 32
RTC Date This parameter allows you to set the date to display in the Idle Display.
Related ZPL command(s): ^ST
Control panel menu item: RTC DATE on page 33
RTC Time This parameter allows you to set the time to display in the Idle Display.
Related ZPL command(s): ^ST
Control panel menu item: RTC TIME on page 33
Password Level This parameter allows you to select whether certain factory-selected menu items or all
menu items are password protected.
Accepted values: • SELECTED ITEMS
• ALL ITEMS
Control panel menu item: PASSWORD LEVEL on page 36
Run a ZBI If you have ZBI 2.0 installed, you may choose to run a ZBI program that you have
Program downloaded to your printer.
Related ZPL command(s): ^JI, ~JI
SGD command used: zbi.control.run
Control panel menu item: Run the Specified ZBI Program* on page 33
Printer web page: Directory Listing
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Network Settings
Table 7 • Network Settings

Primary Network Select the Primary Network Device
This parameter determines which device should be considered primary in the active
device selection.
Accepted values: • WIRED
• WIRELESS
Related ZPL command(s): ^NC
SGD command used: ip.primary_network
Control panel menu item: PRIMARY NETWORK on page 33
Load from View if IP Settings Are Loaded from the Printer or Print Server
External Device This parameter tells whether to use the print engine’s or the print server’s LAN/WLAN
settings at power-up. The default is to use the print engine’s settings.
Accepted values: • YES
• NO
Related ZPL command(s): ^NP
Control panel menu item: LOAD FROM EXT? on page 33
Active Print View the Active Print Server
Server This menu item displays which print server is being used. This tells which device’s
settings such as IP protocol and IP address are being displayed under those menu items.
Accepted values: • WIRELESS indicates that the wireless print server
is active.
• INTERNAL WIRED indicates that the internal
wired print server is active.
• EXTERNAL WIRED indicates that an external
wired print server is active.
• NONE indicates that one of the network options is
installed but is not active. When NONE is shown
for this menu item, the device-specific items such
as IP protocol and IP address will not display.
Control panel menu item: ACTIVE PRINTSRVR on page 34
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Table 7 • Network Settings (Continued)

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
external_wired.ip.protocol
Wireless: wlan.ip.protocol
Control panel menu item: IP PROTOCOL on page 34
Network Communications Setup >
TCP/IP Settings > IP Protocol
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
on page 90).
Accepted values: 000 to 255 for each field
SGD command used: Wired: internal_wired.ip.addr
external_wired.ip.addr
Wireless: ip.addr, wlan.ip.addr
Control panel menu item: IP ADDRESS on page 34
TCP/IP Settings > IP Address
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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 on page 90).
SGD command used: Wired: internal_wired.ip.netmask
external_wired.ip.netmask
Wireless: wlan.ip.netmask
Control panel menu item: SUBNET MASK on page 34
TCP/IP Settings > Subnet Mask
Default 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 on page 90).
SGD command used: Wired: internal_wired.ip.gateway
external_wired.ip.gateway
Wireless: wlan.ip.gateway
Control panel menu item: DEFAULT GATEWAY on page 35
TCP/IP Settings > Default Gateway
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).
SGD command used: Wired: internal_wired.mac_addr
external_wired.mac_addr
Wireless: wlan.mac_addr
Control panel menu item: MAC ADDRESS on page 35
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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)
SGD command used: wlan.essid
Control panel menu item: ESSID on page 35
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.
Related ZPL command(s): ~WR
SGD command used: device.reset
Control panel menu item: RESET NETWORK on page 35
Printer web page: Print Server Settings >
Factory Print Server Settings
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Language Settings
Table 8 • Language Settings

Language If necessary, change the language that the printer displays.
This change affects the words shown on the following:
• status and error messages
• the printer parameters
• the printer configuration label, the network configuration label, and other labels that you
can select to print through the user menus (This does not apply to Japanese, Korean,
Simplified Chinese, or Traditional Chinese. Labels for those languages print in English.)
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: ENGLISH, SPANISH, FRENCH, GERMAN, ITALIAN,

NORWEGIAN, PORTUGUESE, SWEDISH, DANISH,
SPANISH 2, DUTCH, FINNISH, JAPANESE,
KOREAN, SIMPLIFIED CHINESE, TRADITIONAL
CHINESE, RUSSIAN, POLISH, CZECH, ROMANIAN
Related ZPL command(s): ^KL
Control panel menu item: LANGUAGE on page 36
Language
Control Set the Control Prefix Character Value
Character The print engine 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
Control panel menu item: CONTROL PREFIX on page 28
Printer web page: View and Modify Printer Settings > ZPL Control
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Table 8 • Language Settings (Continued)

Command Set the Format Command Prefix Value
Character The format command prefix is a two-digit hex value used as a parameter place marker in
ZPL/ZPL II format instructions. The print engine looks for this hex character to indicate the
start of a ZPL/ZPL II format instruction.
Set the format command prefix 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 print engine 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.
Related ZPL command(s): ^CC or ~CC
Control panel menu item: FORMAT PREFIX on page 29
Delimiter Set the Delimiter Character Value
Character 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.
Related ZPL command(s): ^CD or ~CD
Control panel menu item: DELIMITER CHAR on page 29
ZPL Mode Set the ZPL Mode
Select the ZPL mode that matches what is used in your label formats.
This print engine accepts label formats written in either ZPL or ZPL II, eliminating the need
to rewrite any ZPL formats that already exist. The print engine 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
Control panel menu item: ZPL MODE on page 29
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Sensor Settings
Table 9 • Sensor Settings

Sensor Type Select the Media Sensor
Select the media sensor that is appropriate for the media that you are using.
Accepted values: • WEB
• MARK
Related ZPL command(s): ^JS
Control panel menu item: SENSOR TYPE on page 21
Printer web page: View and Modify Printer Settings > Media Setup
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Port Settings
Table 10 • Port Settings

Parallel Set Parallel Communications
Communications Select the communications port that matches the one being used by the host computer.
Accepted values: • BIDIRECTIONAL
• UNIDIRECTIONAL
Control panel menu item: PARRALEL COMM. on page 27
Serial Communications Setup
Serial Set Serial Communications
Communications Select the communications port that matches the one being used by the host computer.
Accepted values: • RS232
• RS422/485
• RS485 MULTIDROP
Note • Select RS232 if you are using an
external adapter to enable RS422/485
operation.
Control panel menu item: SERIAL COMM. on page 27
Serial Communications Setup >
Serial Comm.
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Table 10 • Port Settings (Continued)

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
• 2400
• 1200
• 600
• 300
Related ZPL command(s): ^SC
SGD command used: comm.baud
Control panel menu item: BAUD on page 27
Serial Communications Setup > Baud
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
SGD command used: comm.data_bits
Control panel menu item: DATA BITS on page 27
Serial Communications Setup > Data Bits
Parity Set the Parity Value
Select the parity value that matches the one being used by the host computer.
• EVEN
• ODD
SGD command used: comm.parity
Control panel menu item: PARITY on page 27
Serial Communications Setup > Parity
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Table 10 • Port Settings (Continued)

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
Control panel menu item: HOST HANDSHAKE on page 28
Serial Communications Setup >
Host Handshake
Protocol Protocol is a type of error checking system. Depending on the selection, an indicator
may be sent from the print engine to the host computer signifying that data has been
received. Select the protocol that is requested by the host computer.
• ZEBRA
• ACK_NAK
Note • ZEBRA is the same as ACK_NAK,
except that ZEBRA response messages are
sequenced. If ZEBRA is selected, the print
engine must use DSR/DTR for host
handshake protocol.
Control panel menu item: PROTOCOL on page 28
Serial Communications Setup > Protocol
Network ID This parameter assigns a unique number to the print engine when the print engine is
operating in an RS422/485 multi-drop network environment (an external RS422/485
adapter is required). This gives the host computer the means to address a specific print
engine. This does not affect TCP/IP or IPX networks. Set a unique network ID number
for this print engine.
Accepted values: 000 to 999
Related ZPL command(s): ^NI
Control panel menu item: NETWORK ID on page 28
Serial Communications Setup > Network ID
P1051584-003 ZE500™ User Guide 3/27/14

Calibrate the Ribbon and Media Sensors

Use the procedure in this section to calibrate the printer, which adjusts the sensitivity of the
media and ribbon sensors.
• For issues that may be resolved by sensor calibration, see Printing Issues on page 116.
• For a summary of the options for initiating calibration, see Media and Ribbon Sensor
Calibration on page 85.
Important • Follow the calibration procedure exactly as presented. All of the steps must be
performed even if only one of the sensors requires adjustment. You may press and hold
CANCEL at any step in this procedure to cancel the process.
To perform sensor calibration, complete these steps:
1. With the printer in the Ready state, initiate media and ribbon calibration through the print
engine’s display:
a. Navigate to the following parameter. See Control Panel Display on page 15 for
information about using the control panel.
b. Press RIGHT SELECT to select START.
The printer does the following:

• The STATUS light and SUPPLIES light flash yellow once.
• The PAUSE light blinks yellow.
• The control panel displays:
LOAD BACKING
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2.
printhead to cool.
LH RH
3. Extend approximately 8 in. (203 mm) of media past the peel bar. Remove and discard the
labels from the liner on this exposed media.
RH
LH
P1051584-003 ZE500™ User Guide 3/27/14

4. Pull the media back into the print engine so that only the liner is between the media
sensors.
5. Press PLUS (+) to continue.

The control panel displays:
REMOVE RIBBON
6. Remove the ribbon (if used).
7. Rotate the printhead-release latch to the closed position, and close the media door.
LH RH
8. Press PAUSE to begin the media calibration process.

The control panel displays:
CALIBRATING
PLEASE WAIT
When the process is complete, the control panel displays:
RELOAD ALL
9. Rotate the printhead-release latch to the open position.
LH RH
10. Reload the media and ribbon (if used).
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11. Rotate the printhead-release latch to the closed position.
LH RH
13. Press PAUSE to enable printing.
P1051584-003 ZE500™ User Guide 3/27/14

Remove Used Ribbon
Remove Used Ribbon

Remove used ribbon from the ribbon take-up spindle each time you change the roll of ribbon.
To remove used ribbon, complete these steps:
1. Has the ribbon run out?
If the ribbon... Then

Ran out Continue with step 2.
Did not run out a. Cut or break the ribbon before the ribbon take-up spindle.
LH RH
b. Continue with step 2.
2. Slide the core with the used ribbon off of the ribbon take-up spindle.
LH RH
3. Discard the used ribbon. You may reuse the empty core from the ribbon supply spindle by
moving it to the ribbon take-up spindle.
3/27/14 ZE500™ User Guide P1051584-003

Adjust the Sensors
Adjust the Sensors

This section describes how to adjust the sensors.
Transmissive Media Sensor

The transmissive media sensor finds “start of label” indicators, such as notches or holes in the
media or interlabel gaps. This sensor consists of a light source (positioned below the media)
and a light sensor (positioned above the media).
To position the sensor, complete these steps:
1. Refer to Figure 11. Slide the sensor position indicator on the pinch roller assembly to
move the media sensor.
2. How does the current media indicate the start of labels?
If the media... Then...

Has notches or holes Align the sensor with the notch or hole in the media.
between labels
Uses interlabel gaps Position the sensor approximately at the center of the media
width.
Figure 11 • Media Sensor Adjustment (Right-Hand Unit Shown)
1 Sensor position indicator

2 Pinch roller assembly
P1051584-003 ZE500™ User Guide 3/27/14

Adjust the Sensors
Reflective Media Sensor

Some types of media have black marks printed on the underside of the media liner, which act
as “start of label” indicators. The reflective media sensor senses these black marks. The
position of this sensor is not adjustable. If you use this type of media, refer to Media
Specifications on page 144 for information about black mark requirements.
Ribbon Sensor
The ribbon sensor is mounted in a fixed position, and no adjustment is required.
3/27/14 ZE500™ User Guide P1051584-003

Toggle Positioning
Toggle Positioning
Proper toggle positioning is important for proper print quality.
Caution • Observe proper electrostatic safety precautions when handling any

static-sensitive components such as circuit boards and printheads.
To adjust the toggles, complete these steps:
1. Print some labels at 2 in. (51 mm) per second by running the PAUSE Self Test (see PAUSE
Self Test on page 133).
2. While printing labels, use the control panel to lower the darkness setting until the labels
are printing gray instead of black (see Print Darkness on page 71).
3.
printhead to cool.
Loosen the locking nut at the top of each toggle assembly.
4. Position the toggles approximately 1/4 of the way in from each edge of the media.
5. Tighten the locking nuts.
P1051584-003 ZE500™ User Guide 3/27/14

Toggle Positioning
6. Print additional labels at 2 in. (51 mm) per second by again running the PAUSE Self Test.
(Press and hold PAUSE while turning on (I) the printer.)
7. Do both sides of the label print at the same level of gray?
If… Then…
Yes The toggles are positioned correctly. Increase the darkness setting to the
optimum level for the media being used.
No a. Readjust the position of the toggle or toggles toward the side that printed
lighter.
b. Print additional labels at 2 in. (51 mm) per second by again running the
PAUSE Self Test. (Press and hold PAUSE while turning on (I) the printer.)
c. Repeat this step until both sides of the label print at the same level of gray.
d. Increase the darkness setting to the optimum level for the media being used.
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Printhead Pressure Adjustment

Before adjusting the printhead pressure, check that the toggles are positioned correctly. See
Toggle Positioning on page 104.
Printhead life and drive system life (belts and bearings) can be maximized by using the lowest
pressure that produces the desired print quality without allowing the ribbon or media to
slip.You may need to adjust the printhead pressure in the following instances:
• if there is noticeable bleed or swelling in the printed image (too much pressure)
• if there are voids (too little pressure)
• if the darkness setting (burn duration) is set properly, but printing is too light (too little
pressure)
• if the ribbon slips (too little pressure)

To adjust printhead pressure, complete these steps:
1. As needed throughout this procedure, refer to the PAUSE Self Test on page 133 to print
test labels.
2. Refer to Print Darkness on page 71 to set the darkness value (burn duration) appropriately
for your media and ribbon.
3. Loosen the locking nut on the toggle assembly.
P1051584-003 ZE500™ User Guide 3/27/14

4.
printhead to cool.
As a starting point for adjustment, set the position of the adjusting nut (1) and the
locking nut (2) so that when the locking nut is tightened, it is approximately 5/16 in.
(8 mm) from the yoke (3).
3
5/16 in. 2
(8 mm)
1
5. Move the adjusting nut until the print quality is acceptable. Use the lowest pressure that
provides the desired print quality.
• To increase printhead pressure, move the adjusting nut downward.
• To decrease printhead pressure, move the adjusting nut upward.
6. To lock the toggle pressure, tighten the locking nut against the adjusting nut.
3/27/14 ZE500™ User Guide P1051584-003

Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
P1051584-003 ZE500™ User Guide 3/27/14

4
Routine Maintenance
This section provides routine cleaning and maintenance procedures.
Contents
Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Clean the Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Clean the Printhead and Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Replacing Print Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Recycling Print Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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110 Troubleshooting
Cleaning Schedule
Cleaning Schedule
Cleaning your print engine regularly maintains print quality and may extend the life of the
print engine. The recommended cleaning schedule is shown in Table 11. See the following
pages for specific procedures.
Caution • Use only the cleaning agents indicated. Zebra is not responsible for damage
caused by any other fluids being used on this print engine.
Table 11 • Recommended Print Engine Cleaning Schedule
Area Method Interval
Printhead Solvent* Perform these procedures at the following times:

Platen roller Solvent* • When CLEAN HEAD NOW appears.
• Direct Thermal Print Mode: After every roll of
Pinch roller Solvent* labels or 500 ft (150 m) of fanfold labels.
Peel roller Solvent* • Thermal Transfer Print Mode: After every roll
(1500 ft or 450 m) of ribbon.
Transmissive media sensor Air blow
Reflective media sensor Air blow
Media path Solvent*
Ribbon sensor Air blow
Door-open sensors Air blow Monthly and as needed
Tear-off/peel-off bar Solvent*
* Use Preventative Maintenance kit (part number 47362) or a solution of 90% isopropyl alcohol and
10% deionized water.
Clean the Exterior

Clean the outside surfaces of the print engine with a lint-free cloth. Use a mild detergent
solution or desktop cleaner sparingly, as needed.
Caution • Do not use harsh or abrasive cleaning agents or solvents.
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Troubleshooting 111
Clean the Media Compartment
Clean the Media Compartment

Remove any accumulated dirt and lint from the interior of the print engine using a soft bristle
brush and/or vacuum cleaner. This area should be inspected every time a new ribbon is loaded.
Clean the Printhead and Rollers

Clean the printhead, platen roller, pinch roller, and peel roller according to the schedule in
Table 11 on page 110. Clean the printhead more often if you see inconsistent print quality,
such as voids or light print. Clean the rollers if you see media movement problems.
To clean the printhead and rollers, complete these steps:

1. Turn Off (O) the print engine.
2.
printhead to cool.
LH RH
3. Remove the media and ribbon from the print engine.
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112 Troubleshooting
Clean the Printhead and Rollers
4. Using Preventative Maintenance kit (part number 47362) or a solution of 90% isopropyl
alcohol and 10% deionized water on a cotton swab, wipe the print elements from end to
end. Allow the solvent to evaporate.
1 2
1 Printhead elements (gray strip)

2 Cotton swab
3 Platen Roller
5. Use a lint-free cloth moistened with alcohol to clean the platen roller, pinch roller, and
peel roller. Rotate the rollers while cleaning.
6. Reload the ribbon and media (if used).
Note • If print quality does not improve after you perform this procedure, clean the printhead
with Save-a-Printhead cleaning film. Call your authorized Zebra distributor for more
information.
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Routine Maintenance 113
Replacing Print Engine Components
Replacing Print Engine Components

Some print engine components, such as the printhead and platen roller, may wear out over time
and can be replaced easily. Regular cleaning may extend the life of some of these components.
See Cleaning Schedule on page 110 for the recommended cleaning intervals.
Ordering Replacement Parts

For optimal printing quality and proper printer performance across our product line, Zebra
strongly recommends the use of genuine Zebra™ supplies as part of the total solution.
Specifically, the ZE500 print engines are designed to work only with genuine Zebra™
printheads, thus maximizing safety and print quality.
Contact your authorized Zebra reseller for part ordering information, or see Contacts
on page 27 for contact addresses and telephone numbers.
Recycling Print Engine Components

The majority of this print engine’s components are recyclable. The print engine’s main logic
board may include a battery that you should dispose of properly.
Do not dispose of any print engine components in unsorted municipal waste. Please dispose
of the battery according to your local regulations, and recycle the other print engine
components according to your local standards. For more information, see
http://www.zebra.com/environment.
Lubrication
No lubrication is needed for this print engine.
Caution • Some commercially available lubricants will damage the finish and the
mechanical parts if used on this print engine.
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114 Routine Maintenance
Lubrication
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
P1051584-003 ZE500™ User Guide 3/27/14

5
Troubleshooting
This section provides information about errors that you might need to troubleshoot. Assorted
diagnostic tests are included.
Contents
Printing Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Miscellaneous Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Print Engine Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
FEED Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
FEED + PAUSE Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
CANCEL + PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Communication Diagnostics Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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116 Troubleshooting
Printing Issues
Printing Issues
Table 12 identifies possible issues with printing or print quality, the possible causes, and the
recommended solutions.
Table 12 • Printing Issues
Issue Possible Cause Recommended Solution

General print quality The print engine is set at an For optimal print quality, set the print speed to
issues incorrect print speed. the lowest possible setting for your application
via control panel, the driver, or the software. You
may want to perform the FEED Self Test
on page 134 to determine the optimal settings for
your print engine.
See Print Speed on page 71 for how to change
the print speed.
You are using an incorrect 1. Switch to a different type of media or ribbon
combination of labels and to try to find a compatible combination.
ribbon for your application. 2. If necessary, consult your authorized Zebra
reseller or distributor for information and
advice.
The print engine is set at an For optimal print quality, set the darkness to the
incorrect darkness level. lowest possible setting for your application. You
on page 134 to determine the ideal darkness
setting.
See Print Darkness on page 71 for how to
change the darkness setting.
The printhead is dirty. Clean the printhead. See Clean the Printhead
and Rollers on page 111.
Incorrect or uneven printhead 1. Position the printhead toggles correctly. See
pressure. Toggle Positioning on page 104.
2. Set the printhead pressure to the minimum
needed for good print quality. See Printhead
Pressure Adjustment on page 106.
Loss of printing The platen roller, pinch roller, Clean the printhead and rollers. See Clean the
registration on labels. or peel roller is dirty. Printhead and Rollers on page 111.
Excessive vertical Media guides are positioned Ensure that the media guides are properly
drift in top-of-form improperly. positioned. See Load Ribbon and Media
registration. on page 60.
The media type is set Set the print engine for the correct media type
incorrectly. (gap/notch, continuous, or mark). See Media
Type on page 74.
The media is loaded incorrectly. Load media correctly. See Load Ribbon and
Media on page 60.
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Troubleshooting 117
Printing Issues
Table 12 • Printing Issues (Continued)

Long tracks of Print element damaged. Call a service technician.
missing print on
several labels Wrinkled ribbon. See wrinkled ribbon causes and solutions in
Ribbon Problems on page 119.
Fine, angular gray Wrinkled ribbon. See wrinkled ribbon causes and solutions in
lines on blank labels Ribbon Problems on page 119.
Printing too light or The media or ribbon is not Replace supplies with those recommended for
too dark over the designed for high-speed high-speed operation.
entire label operation.
You are using an incorrect 1. Switch to a different type of media or ribbon
combination of media and to try to find a compatible combination.
ribbon for your application. 2. If necessary, consult your authorized Zebra
reseller or distributor for information and
advice.
You are using ribbon with Direct thermal media does not require ribbon. To
direct thermal media. determine if you are using direct thermal media,
perform the label scratch test in When to Use
Ribbon on page 39.
Smudge marks on The media or ribbon is not Replace supplies with those recommended for
labels designed for high-speed high-speed operation.
operation.
Misregistration/skips The print engine is not Calibrate the print engine. See Calibrate the
labels calibrated. Ribbon and Media Sensors on page 97.
Improper label format. Check your label format and correct it as
necessary.
Misregistration and The platen roller, pinch roller, Clean the printhead and rollers. See Clean the
misprint of one to or peel roller is dirty. Printhead and Rollers on page 111.
three labels Media does not meet Use media that meets specifications. See Media
specifications. Specifications on page 144.
Vertical drift in The print engine is out of Calibrate the print engine. See Calibrate the
top-of-form position calibration. Ribbon and Media Sensors on page 97.
The platen roller, pinch roller, Clean the printhead and rollers. See Clean the
or peel roller is dirty. Printhead and Rollers on page 111.
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118 Troubleshooting
Printing Issues
Table 12 • Printing Issues (Continued)

Vertical image or The print engine is using Set the print engine for the correct media type
label drift non-continuous labels but is (gap/notch, continuous, or mark—see Media
configured in continuous mode. Type on page 74) and calibrate the printer, if
necessary (see Calibrate the Ribbon and Media
Sensors on page 97).
The media sensor is calibrated Calibrate the print engine. See Calibrate the
improperly. Ribbon and Media Sensors on page 97.
The platen roller, pinch roller, Clean the printhead and rollers. See Clean the
or peel roller is dirty. Printhead and Rollers on page 111.
The media or ribbon is loaded Ensure that the media and ribbon are loaded
incorrectly. correctly. See Load Ribbon and Media
on page 60.
Incompatible media. You must use media that meets the printer
specifications. Ensure that the interlabel gaps or
notches are 2 to 4 mm and consistently placed
(see Media Specifications on page 144).
The bar code printed The bar code is not within Perform the FEED Self Test on page 134. Adjust
on a label does not specifications because the print the darkness or print speed settings as necessary.
scan. is too light or too dark.
There is not enough blank Leave at least 1/8 in. (3.2 mm) between the bar
space around the bar code. code and other printed areas on the label and
between the bar code and the edge of the label.
Auto Calibrate failed. The media or ribbon is loaded Ensure that the media and ribbon are loaded
incorrectly. correctly. See Load Ribbon and Media
on page 60.
The sensors could not detect the Calibrate the print engine. See Calibrate the
media or ribbon. Ribbon and Media Sensors on page 97.
The sensors are dirty or Ensure that the sensors are clean and properly
positioned improperly. positioned.
The media type is set Set the print engine for the correct media type
incorrectly. (gap/notch, continuous, or mark). See Media
Type on page 74.
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Troubleshooting 119
Ribbon Problems
Ribbon Problems
Table 13 identifies problems that may occur with ribbon, the possible causes, and the
Table 13 • Ribbon Problems
Problem Possible Cause Recommended Solution

Broken or melted Darkness setting too high. 1. Reduce the darkness setting. See Print
ribbon Darkness on page 71 for how to change the
darkness setting.
2. Clean the printhead thoroughly. See Clean
the Printhead and Rollers on page 111.
The ribbon is coated on the Replace the ribbon with one coated on the
wrong side and cannot be used correct side. For more information, see Coated
in this print engine. Side of Ribbon on page 39.
Ribbon slips or does Ribbon tension is set Change the ribbon tension setting. See Ribbon
not advance correctly incorrectly. Tension on page 77.
Wrinkled ribbon Ribbon was loaded incorrectly. Load the ribbon correctly. See Load Ribbon and
Media on page 60.
Incorrect burn temperature. For optimal print quality, set the darkness to the
lowest possible setting for your application. You
on page 134 to determine the ideal darkness
setting.
See Print Darkness on page 71 for how to
change the darkness setting.
Incorrect or uneven printhead Set the printhead pressure to the minimum
pressure. needed for good print quality. See Printhead
Media not feeding properly; Make sure that media is snug by adjusting the
“walking” from side to side. media guide, or call a service technician.
The printhead or platen roller Call a service technician.
may be installed incorrectly.
The printer does not The printer may have been Calibrate the printer, this time using ribbon, or
detect when the calibrated without ribbon. load printer defaults. See Calibrate the Ribbon
ribbon runs out. Later, ribbon was inserted and Media Sensors on page 97 or Load Defaults
In thermal transfer without the user recalibrating on page 84.
mode, the printer did the printer or loading printer
not detect the ribbon defaults.
even though it is
loaded correctly.
The printer indicates The print engine was not Calibrate the print engine. See Calibrate the
that ribbon is out, calibrated for the label and Ribbon and Media Sensors on page 97.
even though ribbon is ribbon being used.
loaded correctly.
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120 Troubleshooting
RFID Problems
RFID Problems
Table 14 identifies problems that may occur with RFID print engines, the possible causes, and
the recommended solutions. For more information about RFID, refer to the RFID
Programming Guide 2. A copy of the manual is available at http://www.zebra.com/manuals or
on the user CD that came with your print engine.
Table 14 • RFID Problems

The RFID-enabled The print engine is not Manually calibrate the print engine (see Media
print engine voids calibrated for the media being and Ribbon Sensor Calibration on page 85).
every label. used.
You are using an RFID label The ZE500R printer supports only Gen 2 RFID
with a tag type that is not labels. For more information, refer to the RFID
supported by your print engine. Programming Guide 2, or contact an authorized
Zebra RFID reseller.
The print engine is unable to 1. Turn off (O) the print engine.
communicate with the RFID 2. Wait 10 seconds.
reader. 3. Turn on (I) the print engine.
4. If the problem persists, you may have a bad
RFID reader or a loose connection between
the RFID reader and the print engine. Contact
Technical Support or an authorized Zebra
RFID service technician for assistance.
Radio frequency (RF) Do one or more of the following as necessary:
interference from another RF • Move the print engine away from fixed RFID
source. readers or other RF sources.
• Make sure that the media door is closed at all
times during RFID programming.
The settings are incorrect in The software settings override the print engine
your label designer software. settings. Make sure that the software and print
engine settings match.
You are using an incorrect Do one or more of the following as necessary:
programming position, • Check the RFID programming position , or
particularly if the tags being the program position setting in your label
used are within print engine designer software. If the position is incorrect,
specifications. change the setting.
• Restore the RFID programming position back
to the default value.
For more information, refer to the RFID
Programming Guide 2. For transponder
placement details, go to
http://www.zebra.com/transponders.
You are sending RFID ZPL or Check your label formats. For more information,
SGD commands that are refer to the RFID Programming Guide 2.
incorrect.
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Troubleshooting 121
RFID Problems
Table 14 • RFID Problems (Continued)

Low yields. Too many The RFID labels are not within Make sure that the labels meet transponder
RFID tags per roll specifications for the print placement specifications for your printer. See
are voided. engine, which means that the http://www.zebra.com/transponders for
transponder is not in an area transponder placement information.
that can be programmed For more information, refer to the RFID
consistently. Programming Guide 2, or contact an authorized
Zebra RFID reseller.
Incorrect read and write power Change the RFID read and write power levels.
levels for the RFID tag type. For instructions, refer to the RFID Programming
Guide 2.
Radio frequency (RF) Do one or more of the following as necessary:
interference from another RF • Move the print engine away from fixed RFID
source. readers.
• Make sure that the media door is closed at all
times during RFID programming.
The print engine is using Go to http://www.zebra.com/firmware for
outdated print engine firmware updated firmware.
and reader firmware versions.
The print engine The print engine calibrated the 1. Select FEED for the MEDIA POWER UP and
stops at the RFID label length only to the RFID HEAD CLOSE parameters (see Power-Up
inlay. inlay instead of to the interlabel Action on page 83 or Head-Close Action
gap. on page 83).
2. Manually calibrate the print engine (see
Media and Ribbon Sensor Calibration
on page 85).
The DATA light The download was not 1. Turn off (O) the print engine.
flashes indefinitely successful. For best results, 2. Wait 10 seconds.
after you attempt to cycle power on the print engine 3. Turn on (I) the print engine.
download print before downloading any
4. Attempt to download the firmware again.
engine or reader firmware.
firmware. 5. If the problem persists, contact Technical
Support.
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122 Troubleshooting
RFID Problems
Table 14 • RFID Problems (Continued)

RFID parameters do The print engine was powered Wait at least 10 seconds after turning the print
not appear in Setup off (O) and then back on (I) too engine power off before turning it back on.
mode, and RFID quickly for the RFID reader to 1. Turn off (O) the print engine.
information does not initialize properly. 2. Wait 10 seconds.
appear on the print
engine configuration
label. 4. Check for the RFID parameters in Setup
mode or for RFID information on a new
configuration label.
The printer does not
void RFID labels that An incorrect version of print 1. Verify that the correct firmware version is
are not programmed engine or reader firmware was loaded on your printer. For more information,
correctly. loaded on the printer. refer to the RFID Programming Guide 2.
2. Download the correct printer or reader
firmware if necessary.
3. If the problem persists, contact Technical
Support.
The print engine is unable to 1. Turn off (O) the print engine.
communicate with the RFID 2. Wait 10 seconds.
subsystem. 3. Turn on (I) the print engine.
4. If the problem persists, you may have a bad
RFID reader or a loose connection between
the RFID reader and the print engine. Contact
Technical Support or an authorized service
technician for assistance.
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Troubleshooting 123
Error Messages
Error Messages
The control panel displays messages when there is an error. See Table 15 for LCD errors, the
possible causes, and the recommended solutions.
Table 15 • Error Messages
Display/
Possible Cause Recommended Solution
Print Engine Condition
The printhead was replaced with Install a genuine Zebra™ printhead.
one that is not a genuine Zebra™
printhead.
The ERROR light flashes.

The Early Warning for 1. Clean the printhead.
Maintenance feature is enabled, 2. On the control panel, go to the
and the printhead has reached the HEAD CLEANED? menu item.
end of the specified interval for 3. Press PLUS to select YES to reset
cleaning. See Early Warning for the Early Warning for Maintenance
Maintenance on page 80 for more printhead cleaning counter.
information.
The printhead is not fully closed. Close printhead completely.
The head open sensor is not Call a service technician.
working properly.
The print engine stops; the

ERROR light flashes.
The media is not loaded or is Load media correctly. See Load Ribbon
loaded incorrectly. and Media on page 60.
Misaligned media sensor. Check position of the media sensor.
The print engine is set for Install proper media type, or reset print
noncontinuous media, but engine for current media type and
continuous media is loaded. perform calibration.
MEDIA light is on; the
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124 Troubleshooting
Error Messages
Table 15 • Error Messages (Continued)
Display/
In thermal transfer mode, ribbon is Load ribbon correctly. See Load
not loaded or incorrectly loaded. Ribbon and Media on page 60.
In thermal transfer mode, the 1. Load ribbon correctly. See Load
ribbon sensor is not detecting Ribbon and Media on page 60.
ribbon. 2. Calibrate the print engine. See
Calibrate the Ribbon and Media
The print engine stops; the Sensors on page 97.
RIBBON light is on; the In thermal transfer mode, media is 1. Load media correctly. See Load
ERROR light flashes. blocking the ribbon sensor. Ribbon and Media on page 60.
2. Calibrate the print engine. See
Sensors on page 97.
In thermal transfer mode, the print 1. Print a sensor profile. See Print a
engine did not detect the ribbon Sensor Profile on page 82. The
even though it is loaded correctly. ribbon out threshold (1) is likely
too high, above the black area that
indicates where the ribbon is
detected (2).
1
2
2. Calibrate the print engine (see

Sensors on page 97) or load print
engine defaults (see options under
Exit Setup Mode on page 17).
If you are using direct thermal Set the print engine for Direct Thermal
media, the print engine is waiting mode. See Print Method on page 74.
for ribbon to be loaded because it is
incorrectly set for Thermal
Transfer mode.
Ribbon is loaded, but the print Ribbon is not required with direct
engine is set for direct thermal thermal media. If you are using direct
mode. thermal media, remove the ribbon. This
error message will not affect printing.
If you are using thermal transfer media,
which requires ribbon, set the print
The RIBBON light is on; the engine for Thermal Transfer mode. See
ERROR light flashes. Print Method on page 74.
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Troubleshooting 125
Error Messages
Display/
The printhead has a faulty Call a service technician.
thermistor.
The ERROR light flashes.
Caution • An improperly connected printhead data or power cable

can cause this error message. The printhead may be hot enough to
cause severe burns. Allow the printhead to cool.
The printhead temperature is Continue printing while the printhead

approaching its lower operating reaches the correct operating
limit. temperature. If the error remains, the
The print engine prints while environment may be too cold for
the ERROR light flashes. proper printing. Relocate the print
engine to a warmer area.
The printhead data cable is not
Caution • Turn off (O) the print engine
properly connected. before performing this procedure.
Failure to do so can damage the
printhead.
1. Turn off (O) the print engine.
2. Disconnect and reconnect the data
cable to the printhead.
3. Ensure that the cable connector is
fully inserted into the printhead
connector.

thermistor.
Caution • The printhead may be hot enough to cause severe

burns. Allow the printhead to cool.
The printhead is over temperature. Allow the print engine to cool. Printing
automatically resumes when the
printhead elements cool to an
The print engine stops; the acceptable operating temperature.
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126 Troubleshooting
Error Messages
Display/
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

Caution • Turn off (O) the print engine
properly connected. before performing this procedure.
Failure to do so can damage the
printhead.
2. Disconnect and reconnect the data
cable to the printhead.
3. Ensure that the cable connector is
fully inserted into the printhead
connector.

thermistor.

ERROR light is on; the print
engine cycles through these
three messages.
The print engine is defragmenting
Caution • Do NOT turn off the print
memory. engine power during defragmenting.
Doing so can damage the print engine.
Allow the print engine to finish

defragmenting. If you get this error
message frequently, check your label
The print engine stops.
formats. Formats that write to and erase
memory frequently may cause the
printer to defragment often. Using
properly coded label formats usually
minimizes the need for defragmenting.
If this error message does not go away,
contact Technical Support. The print
engine requires service.
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Troubleshooting 127
Error Messages
Display/
There is not enough memory to Free up some of the print engine’s
perform the function specified on memory by adjusting the label format
the second line of the error or print engine parameters. One way to
message. 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 Print Width
on page 75.
Ensure that the device, such as a
FLASH memory card, is installed and
not write protected or full.
Ensure that the data is not directed to a
device that is not installed or is
unavailable.
Call a service technician.
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128 Troubleshooting
Communications Problems
Communications Problems
Table 16 identifies problems with communications, the possible causes, and the recommended
solutions.
Table 16 • Communications Problems

A label format was sent to The communication Check the print engine driver or software
the print engine but was parameters are incorrect. communications settings (if applicable).
not recognized. The DATA If you are using serial communication, check
light does not flash. the serial port settings. See Port Settings
on page 94.
If you are using serial communication, make
sure that you are using a null modem cable or a
null modem adapter.
Check the printer’s handshake protocol setting.
The setting used must match the one being
used by the host computer. See Set the Host
Handshake Protocol Value on page 96.
If a driver is used, check the driver
communication settings for your connection.
A label format was sent to The serial communication Ensure that the flow control settings match.
the print engine. Several settings are incorrect. Check the communication cable length. See
labels print, then the print Table 3 on page 54 for requirements.
engine skips, misplaces,
misses, or distorts the Check the print engine driver or software
image on the label. communications settings (if applicable).
A label format was sent to The prefix and delimiter Verify the prefix and delimiter characters. See
the print engine but was characters set in the print Set the Control Prefix Character Value
not recognized. The DATA engine do not match the on page 91 and Set the Delimiter Character
light flashes but no ones in the label format. Value on page 92.
printing occurs. Incorrect data is being sent Check the communication settings on the
to the print engine. computer. Ensure that they match the print
engine settings.
If the problem continues, check the label
format.
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Troubleshooting 129
Miscellaneous Issues
Table 17 identifies miscellaneous issues with the print engine, the possible causes, and the
Table 17 • Miscellaneous Print Engine Problems

The control panel The language parameter was 1. On the control panel display, press SETUP.
display shows a changed through the control 2. Press LEFT ARROW once to move to the
language that I panel or a firmware command. LANGUAGE parameter.
cannot read
3. Use PLUS (+) or MINUS (-) to scroll
through the language selections. 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.
4. Select the language that you want to display.
The display is missing The display may need Call a service technician.
characters or parts of replacing.
characters
Changes in Some parameters are set 1. Check the parameters and change or reset if
parameter settings incorrectly. necessary.
did not take effect 2. Turn the print engine off (O) and then on (I).
A firmware command (such as Refer to the Programming Guide for ZPL, ZBI,
device.command_override) Set-Get-Do, Mirror, and WML or call a service
turned off the ability to change technician.
the parameter.
A firmware command changed
the parameter back to the
previous setting.
If the problem persists, there Call a service technician.
may be a problem with the
main logic board.
Non-continuous The print engine was not Calibrate the printer. See Calibrate the Ribbon
labels are being calibrated for the media being and Media Sensors on page 97.
treated as continuous used.
labels. The print engine is configured Set the print engine for the correct media type
for continuous media. (gap/notch, continuous, or mark). See Media
Type on page 74.
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130 Troubleshooting
Table 17 • Miscellaneous Print Engine Problems (Continued)

All indicator lights Internal electronic or firmware Call a service technician.
are on, nothing is on failure.
the display (if the
printer has a display),
and the print engine
locks up.
The print engine Main logic board failure. Call a service technician.
locks up while
running the
Power-On Self Test.
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Troubleshooting 131
Print Engine Diagnostics

Self tests and other diagnostics provide specific information about the condition of the print
engine. The self tests produce sample printouts and provide specific information that helps
determine the operating conditions for the print engine.
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. To prevent this from happening, check
the print width, and ensure that the width is correct for the media that you are using.
Each self test is enabled by pressing a specific control panel key or combination of keys while
turning on (I) the print engine power. Keep the key(s) pressed until the first indicator light
turns off. The selected self test automatically starts at the end of the Power-On Self Test.
Note •
• When performing these self tests, do not send data to the print engine from the host.
• If your media is shorter than the label to be printed, the test label continues on the next
label.
• When canceling a self test prior to its actual completion, always reset the print engine by
turning it off (O) and then on (l).
Power-On Self Test

A Power-On Self Test (POST) is performed each time the print engine is turned on (l). During
this test, the control panel lights (LEDs) turn on and off to ensure proper operation. At the end
of this self test, only the STATUS LED remains lit. When the Power-On Self Test is complete,
the media is advanced to the proper position.
To initiate the Power-On Self Test, complete these steps:

The POWER LED illuminates. The other control panel LEDs and the LCD monitor the
progress and indicate the results of the individual tests. All messages during the POST
display in English; however, if the test fails, the resulting messages cycle through the
international languages as well.
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132 Troubleshooting
CANCEL Self Test

The CANCEL self test prints a printer configuration label and a network configuration label.
For other ways to print these labels, see Print Information on page 82.
To perform the CANCEL Self Test, complete these steps:
2. Press and hold CANCEL while turning on (I) the print engine. Hold CANCEL until the
first control panel light turns off.
The printer prints a printer configuration label (Figure 12) and then a network
configuration label (Figure 13).
Figure 12 • Sample Printer Figure 13 • Sample Network

Configuration Label Configuration Label
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Troubleshooting 133
PAUSE Self Test

This self test can be used to provide the test labels required when making adjustments to the
print engine’s mechanical assemblies or to determine if any printhead elements are not
working. Figure 14 shows a sample printout.
To perform a PAUSE self test, complete these steps:
2. Press and hold PAUSE while turning on (I) the print engine. Hold PAUSE until the first
control panel light turns off.
• The initial self test prints 15 labels at the print engine’s slowest speed, and then
automatically pauses the print engine. Each time PAUSE is pressed, an additional 15
labels print. Figure 14 shows a sample of the labels.
Figure 14 • PAUSE Test Label
• While the print engine is paused, pressing CANCEL alters the self test. Each time
PAUSE is pressed, 15 labels print at 6 in. (152 mm) per second.
• While the print engine is paused, pressing CANCEL again alters the self test a second
time. Each time PAUSE is pressed, 50 labels print at the print engine’s slowest speed
• While the print engine is paused, pressing CANCEL again alters the self test a third
time. Each time PAUSE is pressed, 50 labels print at 6 in. (152 mm) per second.
• While the print engine is paused, pressing CANCEL again alters the self test a fourth
time. Each time PAUSE is pressed, 15 labels print at the print engine’s maximum
speed.
3. To exit this self test at any time, press and hold CANCEL.
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134 Troubleshooting
FEED Self Test

Different types of media may require different darkness settings. This section contains a
simple but effective method for determining the ideal darkness for printing bar codes that are
within specifications.
During the FEED self test, labels are printed at different darkness settings at two different print
speeds. The relative darkness and the print speed are printed on each label. The bar codes on
these labels may be ANSI-graded to check print quality.
During this test, one set of labels is printed at 2 ips, and another set is printed at 6 ips. The
darkness value starts at three settings lower than the print engine’s current darkness value
(relative darkness of –3) and increase until the darkness is three settings higher than the current
darkness value (relative darkness of +3).
To perform a FEED self test, complete these steps:
1. Print a configuration label to show the print engine’s current settings.
3. Press and hold FEED while turning on (I) the print engine. Hold FEED until the first
control panel light turns off.
The print engine prints a series of labels (Figure 15) at various speeds and at darkness
settings higher and lower than the darkness value shown on the configuration label.
Figure 15 • FEED Test Label
4. See Figure 16 and Table 18. 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.
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Troubleshooting 135
Figure 16 • Bar Code Darkness Comparison
Table 18 • Judging Bar Code Quality
Print Quality Description

Too dark Labels that are too dark are fairly obvious. They may be
readable but not “in-spec.”
• The normal bar code bars increase in size.
• The openings in small alphanumeric characters may fill in
with ink.
• Rotated bar code bars and spaces run together.
Slightly dark Slightly dark labels are not as obvious.
• The normal bar code will be “in-spec.”
• Small character alpha numerics will be bold and could be
slightly filled in.
• The rotated bar code spaces are small when compared to
the “in-spec” code, possibly making the code unreadable.
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136 Troubleshooting
Table 18 • 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.”
• In both normal and rotated styles, small alphanumeric
characters look complete.
Slightly light Slightly light labels are, in some cases, preferred to slightly
dark ones for “in-spec” bar codes.
• Both normal and rotated bar codes will be in spec, but
small alphanumeric characters may not be complete.
Too light Labels that are too light are obvious.
• Both normal and rotated bar codes have incomplete bars
and spaces.
• Small alphanumeric characters are unreadable.
5. Note the relative darkness value and the print speed printed on the best test label.
6. Add or subtract the relative darkness value from the darkness value specified on the
configuration label. The resulting numeric value is the best darkness value for that specific
label/ribbon combination and print speed.
7. If necessary, change the darkness value to the darkness value on the best test label.
8. If necessary, change the print speed to the same speed as on the best test label.
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Troubleshooting 137
FEED + PAUSE Self Test

Performing this self test temporarily resets the print engine configuration to the factory default
values. These values are active only until power is turned off unless you save them
permanently in memory. If the factory default values are permanently saved, a sensor
calibration procedure must be performed. (See Calibrate the Ribbon and Media Sensors
on page 97.)
To perform a FEED and PAUSE self test, complete these steps:
2. Press and hold FEED + PAUSE while turning on (I) the print engine.
3. Hold FEED + PAUSE until the first control panel light turns off.
The print engine configuration is reset to the factory default values. No labels print at the
end of this test.
CANCEL + PAUSE Self Test

Performing this self test temporarily resets the network configuration to the factory default
values. These values are active only until power is turned off unless you save them
permanently in memory.
To perform a CANCEL and PAUSE self test, complete these steps:
2. Press and hold CANCEL + PAUSE while turning on (I) the print engine.
3. Hold CANCEL + PAUSE until the first control panel light turns off.
The printer’s network configuration is reset to the factory default values. No labels print at
the end of this test.
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138 Troubleshooting
Communication Diagnostics Test

The communication diagnostics test is a troubleshooting tool for checking the interconnection
between the print engine and the host computer. When the printer is in diagnostics mode, it
prints all data received from the host computer as straight ASCII characters with the hex
values below the ASCII text. The print engine prints all characters received, including control
codes such as CR (carriage return). Figure 17 shows a typical test label from this test.
Note • The test label prints upside-down.
Figure 17 • Communication Diagnostics Test Label
To use communication diagnostics mode, complete these steps:
1. Set the print width equal to or less than the label width being used for the test. See Print
Width on page 75 for more information.
2. Set the DIAGNOSTICS MODE option to ENABLED. For methods, see Communication
Diagnostics Mode on page 85.
The printer enters diagnostics mode and prints any data received from the host computer
on a test label
3. Check the test label for error codes. For any errors, check that your communication
parameters are correct.
Errors show on the test label as follows:
• FE indicates a framing error.
• OE indicates an overrun error.
• PE indicates a parity error.
• NE indicates noise.
4. Turn the print engine off (O) and then back on (I) to exit this self test and return to normal
operation.
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Troubleshooting 139
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 a. Turn off (O) the print engine.

the control panel b. Press and hold FEED + CANCEL while turning on (I) the
print engine.
c. Hold FEED + CANCEL until the first control panel light
turns off.
Using ZPL a. Send the ~JG command to the printer. See the Zebra
Programming Guide for more information about this
command.
Using the control panel a. On the control panel display, navigate to the following
menu items item. See Control Panel Display on page 15 for
information about using the control panel and accessing
the menus.
b. Press PLUS (+) to select PRINT.
Compare your results to the examples shown in this section. If the sensitivity of the sensors
must be adjusted, calibrate the printer (see Calibrate the Ribbon and Media Sensors
on page 97).
Ribbon Sensor Profile (Figure 18) The bars (1) on the sensor profile indicate the ribbon
sensor readings. The ribbon sensor threshold setting is indicated by the word RIBBON (2). If
the ribbon readings are below the threshold value, the print engine does not acknowledge that
ribbon is loaded.
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140 Troubleshooting
Figure 18 • Sensor Profile (Ribbon Section)
Media Sensor Profile (Figure 19) The media sensor readings are shown as bars and flat
areas on the sensor profile (Figure 19). The bars (1) indicate gaps between labels (the web),
and the low areas (2) indicate where labels are located. If you compare the sensor profile
printout to a blank length of your media, the bars should be the same distance apart as the gaps
on the media. If the distances are not the same, the print engine may be having difficulty
determining where the gaps are located.
The media sensor threshold settings are shown by the words MEDIA (3) for the media
threshold and WEB (4) for the web threshold. Use the numbers to the left of the sensor
readings to compare the numeric readings to the sensor settings.
Figure 19 • Sensor Profile (Media Section)
1 2
3 4
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6
Specifications
This section lists general printer specifications, printing specifications, ribbon specifications,
and media specifications.
Contents
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Ribbon Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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142 Specifications
General Specifications
General Specifications
Model ZE500-4 ZE500-6

Height 11.8 in. (300 mm) 11.8 in. (300 mm)
Width 9.6 in. (245 mm) 9.6 in. (245 mm)
Depth 14.95 in. (380 mm) 17.23 in (438 mm)
Weight 34 lb (15.4 kg) 38 lb (17.3 kg)
Electrical Universal power supply with power-factor correction
100–240 VAC, 47-63 Hz
Temperature Operating Thermal Transfer: 40° to 104°F (5° to 40°C)
Direct Thermal: 32° to 104°F (0° to 40°C)
Storage –40° to 160°F (–40° to 71°C)
Relative Operating 20% to 85%, non-condensing
Humidity Storage 5% to 95%, non-condensing
Communication Interfaces • High-speed bidirectional parallel interface, IEEE 1284:Compatibility
mode, EPC, Nibble mode.
• High-speed serial interfaces:
• RS-232C with DB9F connector
• Configurable baud rate (300-115,200), parity, data bits, and stop bits
• Software (XON/XOFF) or hardware (DTR/DSR) communication
handshake protocols
• USB 2.0
• ZebraNet 10/100 Print Server
• ZebraNet b/g Print Server
• Applicator interface with DB15F connector
+5V I/O and +24V to +28V I/O versions available
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Specifications 143
Printing Specifications
Printing Specifications
Print resolution 203 dpi (dots per inch) (8 dots/mm)

300 dpi (12 dots/mm)
Dot size (nominal) 203 dpi 0.0049 in. x 0.0052 in.
(width x length) (0.125 mm x 0.132 mm)
300 dpi 0.0033 in. x 0.0043 in.
(0.084 mm x 0.110 mm)
Maximum print width ZE500-4 4.1 in. (104 mm)
ZE500-6 6.6 in. (168 mm)
Programmable constant ZE500-4 2.0 in. (51 mm) through 12 in. (305 mm) per second
print speeds in 1-inch (25 mm) increments
ZE500-6, 203 dpi 2.0 in. (51 mm) through 12 in. (305 mm) per second
in 1-inch (25 mm) increments
ZE500-6, 300 dpi 2.0 in. (51 mm) through 10 in. (203 mm) per second
in 1-inch (25 mm) increments
Ribbon Specifications
Ribbon wound coated side out

Ribbon width* ZE500-4 1.0 to 4.2 in. (25 to 107 mm)
ZE500-6 3.0 to 7.1 in. (76 to 180 mm)
Maximum ribbon length 1970 feet (600 m)
Maximum ribbon roll outside diameter 4.0 in. (102 mm)
size inside diameter 1.0 in. (25 mm)
* Zebra recommends using ribbon that is at least as wide as the media to protect the printhead from wear.
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144 Specifications
Media Specifications
Media Specifications
Model ZE500-4 ZE500-6

Minimum label length Applicator mode, 0.50 in.* (12.7 mm*) 3.0 in. (76.2 mm)
backfeed on
Applicator mode, 0.25 in.* (6.4 mm*) 1.0 in. (25.4 mm)
backfeed off
Stream mode 0.50 in.* (12.7 mm*) 3.0 in. (76.2 mm)
Rewind mode 0.25 in.* (6.4 mm*) 1.0 in. (25.4 mm)
“loose loop” “loose loop”
Tear-off mode, 0.50 in.* (12.7 mm*) 3.0 in. (76.2 mm)
backfeed on
Tear-off mode, 0.25 in.* (6.4 mm*) 1.0 in. (25.4 mm)
backfeed off
RFID mode ** N/A
Media width (label and Minimum 0.625 in.* (16 mm*) 3.0 in. (76 mm)
liner) Maximum 4.5 in.* (114 mm*) 7.1 in. (180 mm)
RFID labels ** N/A
Media thickness Minimum 0.0053 in (0.135 mm) 0.003 in (0.076 mm)
(includes liner, if any) Maximum 0.010 in. (0.254 mm) 0.012 in. (0.305 mm)
Inter-label gap Minimum 0.079 in.* (2 mm*) 0.079 in. (2 mm)
Preferred 0.118 in.* (3 mm*) 0.118 in. (3 mm)
Maximum 0.157 in.* (4 mm*) 0.157 in. (4 mm)
RFID labels ** N/A
Ticket/tag notch size (width x length) 0.25 x 0.12 in. (6 x 3 mm)
Hole diameter 0.125 in. (3 mm)
Black mark length (parallel to inside media edge) 0.12 to 0.43 in. (3 to 11 mm)
Black mark width (perpendicular to inside media > 0.43 in. (> 11 mm)
edge)
Black mark location within 0.040 in. (1 mm) of inside media edge
Density, in Optical Density Units (ODU) > 1.0 ODU
(black mark media)
Maximum media density (black mark media) 0.5 ODU
* Does not apply to RFID labels.
** This parameter varies for each transponder type.
P1051584-003 ZE500™ User Guide 3/27/14

A
Applicator Interface Board
Reconfiguration
The print engine ships with the following caution label over the optional applicator port:
• For +5V non-isolated mode (internal power), no configuration is necessary.

• For +5V to +28V isolated mode (external power), the jumpers on the applicator interface
board must be reconfigured. Follow the instructions in this section.
Caution • Do not remove the caution label or apply external power until after the
applicator interface board is reconfigured for isolated mode. Applying external power
when the print engine is configured for internal power will damage your print engine.
Note • The graphics and steps in this procedure are for the right-hand (RH) print engine.
Steps for a left-hand (LH) print engine may be slightly different.
Tools Required
Tools • You may need these tools to complete this procedure:
 Phillips Screwdriver Set  Needle-nose pliers

 Metric Hex Key (Allen Wrench) Set  Torx Key Set
 Antistatic Wriststrap and Mat  Flashlight
3/27/14 ZE500™ User Guide P1051584-003

146 Applicator Interface Board Reconfiguration
Changing Jumper Settings for Isolated Mode
Caution • This installation must be performed by a qualified service technician.
To change from non-isolated mode (internal power) to isolated mode (external

power), complete these steps:
Remove Power and Data Cables
1.
Caution • Observe proper electrostatic safety precautions when handling
Connect yourself to an antistatic device.
2.
Caution • Turn off (O) the print engine and disconnect it from the power source before
performing the following procedure.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
Access the Electronics Compartment and Remove the Applicator Interface

Board
3. Does your applicator (or stand) permit open access to the rear of the print engine?
If you have… Then…

Open access You may swing the print engine open and work on it without
removing the unit from the applicator.
If you wish to remove the unit from the stand at any time, follow
the instructions listed for the Obstructed access type applicator
shown in this table.
a. Go to step 4.
Obstructed access You must remove the print engine from the applicator before you
work on it.
a. Remove the four corner mounting screws securing the print
engine to the applicator.
b. Loosen the center mounting bolt, but do not remove it.
Note • The keyhole and the center mounting bolt are
designed to support the print engine and assist in
installing and removing the four mounting screws.
c. Lift the print engine off the center mounting bolt and place on
a workbench.
P1051584-003 ZE500™ User Guide 3/27/14

Applicator Interface Board Reconfiguration 147
4. Remove the four long mounting screws (1) that secure the electronics cover, and then
slide the electronics cover (2) off of the print engine.
3/27/14 ZE500™ User Guide P1051584-003

5. On the back of the applicator interface board, remove the two mounting screws (1) that
secure the applicator interface board (2) to the back plane of the print engine.
1 2
6. Locate the latch (1) on the side of the print engine.
Note • For right-hand models, the latch is on the right side when you are facing the back
of the print engine. For left-hand models, the latch is on the left side.
7. Press the latch, and then swing the electronics enclosure open.
P1051584-003 ZE500™ User Guide 3/27/14

8. Inside the print engine, locate the applicator interface board.
9. Disconnect the connectors (1) along the accessible edge of the applicator interface board.
Note how the connectors are attached to assist with reattachment later in this procedure.
10. Gently pull the applicator interface board partially away from the back plane of the print
engine.
Note • Avoid disconnecting or pinching any cables inside the electronics enclosure.
3/27/14 ZE500™ User Guide P1051584-003

11. Disconnect the remaining connectors on the applicator interface board and the attached
voltage regulator board.
1
2
11 3
4
10
6
8
7
9
1 Applicator interface board mounting 7 J7: Internal HDMI connector for

plate control panel
2 Applicator interface board 8 Voltage regulator board
3 J3: Applicator interface power cable 9 J1 (on voltage reg. board): Power cable
4 J1: Locking SP comm cable 10 J2: External HDMI connector for
deported control panel
5 J8: Control panel SPI extension 11 J6: Applicator interface cable
(ribbon) cable
6 J9: Door-open sensor cable
12. Remove the applicator interface board from the print engine.
P1051584-003 ZE500™ User Guide 3/27/14

Adjust Jumper Placement for +5V to +28V Isolated Mode
13. Locate the areas marked J4 and J5.
14.
Caution • Do not apply external power until after the board is reconfigured for Isolated
Mode.
Move the jumpers on both J4 and J5 to cover the pins as shown from the default of
Non-Isolated Mode to Isolated Mode. You may use needle-nose pliers, if necessary.
NON-ISOLATED MODE (Default Setting) 1

Internal Supply, +5V
EXT +V
INT +5V INT EXT GND
GND
J4 J5
3
1
4
ISOLATED MODE
External Supply, +5V to +28V
Key EXT +V
INT +5V INT EXT GND
GND
Gray: Jumper position J4 J5
White: Not Connected 3
1 Simulated applicator interface board

2 Pins
3 Labels on the applicator interface board
4 Applicator port
3/27/14 ZE500™ User Guide P1051584-003

Reinsert and Reconnect the Applicator Interface Board
15. Gently insert the applicator interface board into the print engine, and slide it toward the
back plane.
Note • Avoid disconnecting or pinching any cables inside the electronics enclosure.
16. Reconnect the cables that were disconnected in step 9 and step 11. See Figure 20
on page 153 for most of the connector locations.
a. Reconnect the control panel.
Which type of control panel are you using?
If your control panel is… Then…

Standard 1. Connect the HDMI cable to J7 on the applicator
(attached to the top of the interface board.
print engine) 2. Continue with step b.
Deported 1. Reconnect the HDMI cable to J2 on the
(attached away from the print applicator interface board. This connector is
engine) accessible from the back plane.
2. Continue with step b.
b. Connect the locking SP comm cable to J1 on the applicator interface board.
Important • This applicator interface board requires the use of an SP comm cable
with a ferrite. The locking connector is the one closest to the ferrite.
c. Connect the six-pin connector for the power cable to J3 on the applicator interface
board.
d. Connect the four-pin connector (arranged in a line) for the power cable to J1 (1) on
the voltage regulator board.
e. Connect the door-open sensor to J9 on the applicator interface board.
P1051584-003 ZE500™ User Guide 3/27/14

Figure 20 • Applicator Interface Board Connections
9
2
6
4
1 J3: Applicator interface power cable

2 J1: Locking SP comm cable
3 J8: Control panel SPI extension (ribbon) cable
4 J9: Door-open sensor cable
5 J7: Internal HDMI connector for control panel
6 J2: External HDMI connector for deported control panel
7 J5: Jumper
8 J6: Applicator interface cable
9 J4: Jumper
3/27/14 ZE500™ User Guide P1051584-003

17. Align the mounting holes in the applicator interface board with the holes in the back plane
of the print engine.
18. Reinstall the two mounting screws (1) to secure the applicator interface board (2) to the
back plane of the print engine.
2
1
Close the Electronics Enclosure
19. Ensure that all wires are routed properly and are not causing any obstructions, and then
carefully swing the electronics enclosure closed.
20. Slide the electronics cover onto the print engine.
21. Reinstall the four electronics cover mounting screws.
P1051584-003 ZE500™ User Guide 3/27/14

Reinstall the Print Engine in the Applicator (If Applicable)
22. To reinstall the print engine into the applicator, carefully place the keyhole on the center
mounting bolt.
Note • The keyhole and the center mounting bolt are designed to support the print engine
and assist in installing and removing the four mounting screws.
23. Replace the four corner mounting screws securing the print engine to the applicator.
24. Tighten the center mounting bolt.
Resume Printer Operation
25. Reconnect the AC power cord and interface cables.
26. Turn on (l) the print engine.
The installation is complete.
3/27/14 ZE500™ User Guide P1051584-003

Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
P1051584-003 ZE500™ User Guide 3/27/14

Glossary
alphanumeric Indicating letters, numerals, and characters such as punctuation marks.
backfeed When the print engine pulls the media and ribbon (if used) backward into the print
engine so that the beginning of the label to be printed is properly positioned behind the
printhead. Backfeed occurs when operating the print engine in Tear-Off and Applicator modes.
bar code A code by which alphanumeric characters can be represented by a series of

adjacent stripes of different widths. Many different code schemes exist, such as the universal
product code (UPC) or Code 39.
black mark A registration mark found on the underside of the print media that acts as a start-
of-label indication for the print engine. (See non-continuous media.)
calibration (of a print engine) A process in which the print engine determines some basic
information needed to print accurately with a particular media and ribbon combination. To do
this, the print engine feeds some media and ribbon (if used) through the print engine and
senses whether to use the direct thermal or thermal transfer print method, and (if using
non-continuous media) the length of individual labels or tags.
configuration The print engine configuration is a group of operating parameters specific to

the print engine application. Some parameters are user selectable, while others are dependent
on the installed options and mode of operation. Parameters may be switch selectable, control
panel programmable, or downloaded as ZPL II commands. A configuration label listing all the
current print engine parameters may be printed for reference.
continuous media Label or tag-stock media that has no notch, gap, or web (media liner
only) to separate the labels or tags. The media is one long piece of material.
core diameter The inside diameter of the cardboard core at the center of a roll of media or
ribbon.
diagnostics Information about which print engine functions are not working that is used for
troubleshooting print engine problems.
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158 Glossary
die-cut media A type of label stock that has individual labels stuck to a media liner. The
labels may be either lined up against each other or separated by a small distance. Typically the
material surrounding the labels has been removed. (See non-continuous media.)
direct thermal A printing method in which the printhead presses directly against the media.
Heating the printhead elements causes a discoloration of the heat-sensitive coating on the
media. By selectively heating the printhead elements as the media moves past, an image is
printed onto the media. No ribbon is used with this printing method. Contrast this with thermal
transfer.
direct thermal media Media that is coated with a substance that reacts to the application of
direct heat from the printhead to produce an image.
dynamic RAM The memory devices used to store the label formats in electronic form while
they are being printed. The amount of DRAM memory available in the print engine determines
the maximum size and number of label formats that can be printed. This is volatile memory
that loses the stored information when power is turned off.
fanfold media Media that comes folded in a rectangular stack. Contrast this with roll media.
firmware This is the term used to specify the print engine’s operating program. This program
is downloaded to the print engine from a host computer and stored in FLASH memory. Each
time the print engine power is turned on, this operating program starts. This program controls
when to feed the media forward or backward and when to print a dot on the label stock.
FLASH memory FLASH memory is non-volatile and maintains the stored information
intact when power is off. This memory area is used to store the print engine’s operating
program. In addition, this memory can be used to store optional print engine fonts, graphic
formats, and complete label formats.
Font A complete set of alphanumeric characters in one style of type. Examples include
CG Times™, CG Triumvirate Bold Condensed™.
ips (inches-per-second) The speed at which the label or tag is printed. Many Zebra print
engines can print from 1 ips to 12 ips.
label An adhesive-backed piece of paper, plastic, or other material on which information is

printed.
label backing (liner) The material on which labels are affixed during manufacture and
which is discarded or recycled by the end-users.
light emitting diode (LED) Indicators of specific print engine status conditions. Each LED
is either off, on, or blinking depending on the feature being monitored.
liquid crystal display (LCD) The LCD is a back-lit display that provides the user with
either operating status during normal operation or option menus when configuring the print
engine to a specific application.
media Material onto which data is printed by the print engine. Types of media include:
tag stock, die-cut labels, continuous labels (with and without media liner), non-continuous
media, fanfold media, and roll media.
P1051584-003 ZE500™ User Guide 3/27/14

Glossary 159
media sensor This sensor is located behind the printhead to detect the presence of media
and, for non-continuous media, the position of the web, hole, or notch used to indicate the start
of each label.
media supply hanger The stationary arm that supports the media roll.
non-continuous media Media that contains an indication of where one label/printed

format ends and the next one begins. Examples are die-cut labels, notched tag-stock, and stock
with black mark registration marks.
non-volatile memory Electronic memory that retains data even when the power to the
print engine is turned off.
notched media A type of tag stock containing a cutout area that can be sensed as a start-of-
label indicator by the print engine. This is typically a heavier, cardboard-like material that is
either cut or torn away from the next tag. (See non-continuous media.)
peel-off A mode of operation in which the print engine peels a printed label away from the
backing and allows the user to remove it before another label is printed. Printing pauses until
the label is removed.
print speed The speed at which printing occurs. For thermal transfer print engines, this
speed is expressed in terms of ips (inches per second).
printhead wear The degradation of the surface of the printhead and/or the print elements
over time. Heat and abrasion can cause printhead wear. Therefore, to maximize the life of the
printhead, use the lowest print darkness setting (sometimes called burn temperature or head
temperature) and the lowest printhead pressure necessary to produce good print quality. In the
thermal transfer printing method, use ribbon that is as wide or wider than the media to protect
the printhead from the rough media surface.
registration Alignment of printing with respect to the top (vertical) or sides (horizontal) of a
label or tag.
ribbon A band of material consisting of a base film coated with wax or resin “ink.” The
inked side of the material is pressed by the printhead against the media. The ribbon transfers
ink onto the media when heated by the small elements within the printhead. Zebra ribbons
have a coating on the back that protects the printhead from wear.
ribbon wrinkle A wrinkling of the ribbon caused by improper alignment or improper

printhead pressure. This wrinkle can cause voids in the print and/or the used ribbon to rewind
unevenly. This condition should be corrected by performing adjustment procedures.
roll media Media that comes supplied rolled onto a core (usually cardboard). Contrast this
with fanfold media.
supplies A general term for media and ribbon.
symbology The term generally used when referring to a bar code.
tag A type of media having no adhesive backing but featuring a hole or notch by which the
tag can be hung on something. Tags are usually made of cardboard or other durable material.
3/27/14 ZE500™ User Guide P1051584-003

160 Glossary
tear-off A mode of operation in which the user tears the label or tag stock away from the
remaining media by hand.
thermal transfer A printing method in which the printhead presses an ink or resin coated
ribbon against the media. Heating the printhead elements causes the ink or resin to transfer
onto the media. By selectively heating the printhead elements as the media and ribbon move
past, an image is printed onto the media. Contrast this with direct thermal.
void A space on which printing should have occurred, but did not due to an error condition
such as wrinkled ribbon or faulty print elements. A void can cause a printed bar code symbol
to be read incorrectly or not at all.
P1051584-003 ZE500™ User Guide 3/27/14

Index
A B
active print server backfeed sequence
how to interpret, 87 how to change, 77
user menu item, 34 user menu item, 30
adhesive test for ribbon coating, 40 backfeed speed
adjustments how to select, 72
label left position, 78 selection, 80
label top position, 78 user menu item, 19
maximum label length, 76 bar codes
media sensors, 102 bar code does not scan, 118
print darkness, 71 bar codes label, 82
print width, 75 darkness comparison during FEED self test, 134
printhead pressure, 106 user menu item, 25
tear-off position, 72 battery disposal, 113
toggle positioning, 104 baud rate
applicator user menu item, 27
characteristics of applicator connection, 55 ways to set, 95
error on pause, 78 bitmap scaling factor, 85
reconfiguration of applicator interface board to black mark media
+5V to +28V isolated mode, 145 described, 38
select applicator mode, 73 selecting media type, 74
specify end print action, 73 setting media type through user menu, 20
start print signal broken ribbon, 119
how to change, 74 buttons on control panel, 14
user menu item, 20
user menu item, 20
3/27/14 ZE500™ User Guide P1051584-003

162 Index
C counters
CALIBRATE button, 14 non-resettable
calibration description, 81
Auto Calibrate failed, 118 user menu item, 24
how to set as head-close action, 83 print odometer readings, 81
how to set as power-up action, 83 how to print, 81
media/ribbon cal user menu item, 24
procedure, 97 user-controlled
user menu item, 26 counter 1 menu item, 24
SHORT CAL counter 2 menu item, 24
how to set for head-close action, 83 how to change, 81
how to set for power-up action, 83 Cutter mode
ways to initiate, 85 how to select, 73
CANCEL button select print mode through user menu, 20
CANCEL self test, 132
location, 14 D
cleaning darkness
exterior of print engine, 110 how to make adjustments, 71
media compartment, 111 print quality too light or too dark, 117
printhead and platen roller, 111 user menu item, 19
recommended schedule, 110 data bits
command character user menu item, 27
user menu item, 29 ways to set, 95
ways to set, 92 data cables, 56
communication diagnostics mode data source
how to initiate, 85 connections, 53
user menu item, 28 date setting, 33
communication interfaces, 53 declaration of conformity, 3
communications diagnostics mode default gateway
overview, 138 user menu item, 35
communications problems, 128 ways to view or set, 89
components of print engine, 13 default password, 18
configuration label default reset, 84
network defragmenting message, 126
ways to print, 82 delimiter character
printer user menu item, 29
ways to print, 82 ways to set, 92
printing using CANCEL self test, 132 diagnostic mode
connect printer to computer or network, 53 how to initiate, 85
connect printer to power source, 57 user menu item, 28
continuous media diagnostics, 131
described, 38 Direct Thermal mode
selecting media type, 74 how to specify, 74
setting media type through user menu, 20 media scratch test, 39
control character disable password protection, 18
user menu item, 28 display
ways to set, 91 location, 14
control panel missing characters, 129
button function, 14 display language
display, 15 how to change from unfamiliar language, 129
error messages, 123 user menu item, 36
navigation, 15 ways to change, 91
P1051584-003 ZE500™ User Guide 3/27/14

Index 163
disposal of printer parts, 113 fonts

door-open sensor fonts label, 82
when to clean, 110 user menu item, 24
format convert
E how to use, 85
user menu item, 32
early warning
format prefix
maintenance
user menu item, 29
how to enable or disable, 80
ways to set format command prefix, 92
printhead life menu item, 23
formats
reset new printhead counter, 23
formats label, 82
reset printhead cleaning counter, 23
user menu item, 25
set printhead cleaning interval, 23
user menu item, 23
media and ribbon G
how to enable or disable, 80 gap/notch
labels per roll, 22 illustrations, 38
reset media counter, 22 selecting media type, 74
reset ribbon counter, 22 sensor selection through user menu, 21
ribbon length, 22 setting media type through user menu, 20
user menu item, 21 ways to select media sensor type, 93
error messages, 123 gateway
error on pause user menu item, 35
how to change, 78 ways to view or set, 89
user menu item, 31
ESSID H
user menu item, 35
head test count
ways to view, 90
how to enable or disable, 78
Ethernet
user menu item, 30
characteristics of a wired connection, 55
head-close action
characteristics of wireless connection, 56
how to change, 83
port location, 53
user menu item, 30
exterior cleaning, 110
host handshake
user menu item, 28
F ways to set, 96
factory defaults
reload parameters, 17 I
restore network settings, 17
idle display
fanfold media
described, 15
described, 38
how to change what displays, 86
FCC radiation exposure limits, 4
user menu item, 32
feed a label
images
how to set as head-close action, 83
images label, 82
how to set as power-up action, 83
user menu item, 25
FEED button
images distorted on labels, 128
FEED and PAUSE self test, 137
indicator lights
FEED self test, 134
combined with error message on ZT230, 123
location, 14
initialize flash memory
flash memory initialization
how to start, 82
how to start, 82
user menu item, 26
user menu item, 26
initiate manual calibration, 85
inspect for shipping damage, 42
3/27/14 ZE500™ User Guide P1051584-003

164 Index
installation load defaults

procedure, 52 how to load printer or print server defaults, 84
requirements, 46 load factory defaults, 17
IP address load IP settings from external device
user menu item, 34 how to use, 87
ways to view or set, 88 user menu item, 33
IP protocol load network defaults, 84
how to change, 88 lubrication, 113
user menu item, 34
IP resolution M
IP protocol
MAC address
how to change, 88
user menu item, 35
user menu item, 34
ways to view, 89
manual calibration
L media/ribbon cal user menu item, 26
label left position procedure, 97
how to adjust, 78 ways to initiate, 85
user menu item, 30 maximum label length
label length how to change, 76
how to adjust maximum value, 76 user menu item, 21
user menu item, 21 media
label shift, 78 black mark, 38
label top position continuous roll media, 38
how to adjust, 78 fanfold, 38
user menu item, 30 non-continuous roll media, 38
label width, 75 perforated, 38
labels did not print, 128 RFID “smart” labels, 37
labels not printing, 128 tag stock, 37
labels per roll for early warning, 22 types of media, 37
language web, 38
how to change from unfamiliar language, 129 media compartment cleaning, 111
user menu item, 36 media path cleaning, 110
ways to change display language, 91 media power up
last saved settings, 84 how to change, 83
LCD error messages, 123 user menu item, 29
left-hand print engine orientation, 12 media scratch test, 39
LENGTH media sensor
how to set as head-close action, 83 adjustments, 102
how to set as power-up action, 83 sensor type user menu item, 21
liability, 2 ways to select, 93
Liner Take-Up mode media sensor calibration
how to select, 73 procedure, 97
select print mode through user menu, 20 user menu item, 26
list bar codes, 25 ways to initiate, 85
list fonts, 24 media type
list formats, 25 how to select, 74
list images, 25 user menu item, 20
list network, 25 melted ribbon, 119
list setup, 25 misregistration of labels, 117
missing print on labels, 117
P1051584-003 ZE500™ User Guide 3/27/14

Index 165
N password
navigation, 15 default, 18
network configuration label disable, 18
user menu item, 25 select password protection level
ways to print, 82 how to set, 86
network ID user menu item, 36
how to change, 96 PAUSE button
user menu item, 28 FEED and PAUSE self test, 137
network settings location, 14
load defaults PAUSE self test, 133
ways to initiate, 84 peel roller
when exiting Setup mode, 17 cleaning, 111
reset network when to clean, 110
user menu item, 35 peel-off bar cleaning, 110
ways to reset, 90 Peel-Off mode
NO MOTION how to select, 73
how to set as head-close action, 83 select print mode through user menu, 20
how to set as power-up action, 83 perforated media, 38
non-continuous media pinch roller
described, 38 cleaning, 111
problem with labels, 129 when to clean, 110
selecting media type, 74 platen roller
cleaning, 111
when to clean, 110
O power
odometers connect to power source, 57
non-resettable counter power cord specifications, 58
description, 81 Power-On Self Test (POST), 131
user menu item, 24 power-up action
print readings how to change, 83
how to print, 81 user menu item, 29
user menu item, 24 primary network
print user-controlled counters, 81 how to select, 87
user-controlled counters user menu item, 33
counter 1 menu item, 24 print configuration label
counter 2 menu item, 24 CANCEL self test, 132
how to change, 81 print darkness setting, 71
ordering replacement parts, 113 print engine components, 13
print engine setup
P dimensions and clearance needs, 47
installation, 46
parallel communications
print information
user menu item, 27
how to print various printer information, 82
ways to set, 94
LIST ALL user menu item, 26
parallel port
print method
characteristics of parallel connection, 54
how to specify, 74
location, 53
user menu item, 21
parity
print mode
user menu item, 27
how to select, 73
ways to set, 95
user menu item, 20
3/27/14 ZE500™ User Guide P1051584-003

166 Index
print quality printer settings

bar code does not scan, 118 applicator port end print action, 73
running FEED self test, 134 backfeed speed, 72
troubleshooting, 116 darkness, 71
print server date, 33
active print server label left position, 78
how to interpret, 87 label top position, 78
user menu item, 34 maximum label length, 76
characteristics of wired connection, 55 media type, 74
characteristics of wireless connection, 56 print method, 74
default gateway print mode, 73
user menu item, 35 print speed, 71
ways to view or set, 89 print width, 75
ESSID reprint mode, 79
user menu item, 35 settings not taking effect, 129
ways to view, 90 slew speed, 71
IP address tear-off position, 72
user menu item, 34 time, 33
ways to view or set, 88 printhead
IP protocol cleaning, 111
how to change, 88 cleaning interval
user menu item, 34 how to specify, 80
MAC address user menu item, 23
user menu item, 35 life expectancy
ways to view, 89 how to specify, 80
network configuration label user menu item, 23
sample label, 132 pressure adjustment, 106
ways to print, 82 when to clean, 110
primary network protocol
user menu item, 33 how to change, 96
reset network settings user menu item, 28
user menu item, 35
ways to reset, 90 R
subnet mask
radiation exposure limits, 4
user menu item, 34
Real-Time Clock (RTC)
ways to view or set, 89
date, 86
print speed
date setting on control panel, 33
how to select, 71
time, 86
user menu item, 19
time setting on control panel, 33
print width
recycling printer parts, 113
how to adjust, 75
reflective media sensor, 103
user menu item, 21
reflective sensor
printer configuration label
selecting through user menu, 21
user menu item, 25
ways to select, 93
ways to print, 82
registration loss during printing, 116
printer diagnostics, 131
relative humidity
printer locks up, 130
operating and storage, 142
storing the print engine, 45
reload last saved settings, 84
remove shipping materials, 42
replacement parts, 113
report shipping damage, 42
P1051584-003 ZE500™ User Guide 3/27/14

Index 167
reprint mode S
how to set and use, 79 schedule for cleaning, 110
user menu item, 31 scratch test
requirements for installation, 46 media type, 39
reset network settings ribbon coated side, 40
user menu item, 35 self tests, 131
ways to reset, 90 CANCEL, 132
reset printer to default values, 84 communications diagnostics, 138
restore FEED, 134
factory default settings, 17 FEED and PAUSE, 137
network settings, 17 PAUSE, 133
printer or printer default values, 84 Power-On Self Test (POST), 131
RFID sensor profile
how to select RFID mode, 73 how to print, 82
“smart” labels, 37 user menu item, 26
troubleshooting, 120 sensor type
ribbon user menu item, 21
adhesive test, 40 ways to select, 93
broken or melted ribbon, 119 sensors
determining coated side, 39 adjustment, 102
removal, 101 interpreting sensor profile, 139
ribbon not detected correctly, 119 serial communications
ribbon slips or does not advance, 119 user menu item, 27
scratch test, 40 ways to set, 94
setting print method to Thermal Transfer mode, 74 serial port
when to use, 39 characteristics of serial connection, 54
wrinkled ribbon, 119 location, 53
ribbon length for early warning, 22 setup, 41
ribbon low mode remove shipping materials, 42
how to enable or disable, 79 unpack the print engine, 42
user menu item, 31 shipping
ribbon low output report damage, 42
how to enable or disable, 79 reshipping the printer, 45
user menu item, 31 SHORT CAL
ribbon sensor how to set as power-up action, 83
adjusting, 103 how to set for head-close action, 83
when to clean, 110 slew speed
ribbon sensor calibration how to select, 71
procedure, 97 user menu item, 19
user menu item, 26 “smart” labels, 37
ways to initiate, 85 smudge marks on labels, 117
ribbon tension specifications
how to set, 77 power cord, 58
user menu item, 29 print engine specifications, 141
right-hand print engine orientation, 12 start print signal
roll media, 37 how to change, 74
run a ZBI program user menu item, 20
START PROGRAM user menu item, 33 storing the print engine, 45
ways to run, 86 subnet mask
user menu item, 34
ways to view or set, 89
3/27/14 ZE500™ User Guide P1051584-003

168 Index
T types of media
tag stock, 37 black mark media, 38
Tear-Off mode continuous roll media, 38
how to select, 73 fanfold media, 38
select print mode through user menu, 20 how to specify, 74
tear-off bar cleaning, 110 non-continuous roll media, 38
tear-off position perforated media, 38
how to adjust, 72 RFID “smart” labels, 37
user menu item, 20 setting on control panel, 20
temperature tag stock, 37
operating and storage, 142 web media, 38
storing the print engine, 45
Thermal Transfer mode U
how to specify, 74 unpack the print engine, 42
media scratch test, 39 USB port
time setting, 33 characteristics of USB connection, 54
toggle positioning, 104 location, 53
transmissive (media) sensor
adjusting, 102
when to clean, 110 V
transmissive sensor vertical drift in top-of-form position, 117
selecting through user menu, 21
ways to select, 93 W
troubleshooting web media
communications problems, 128 described, 38
diagnostic tests, 131 wired print server
error messages, 123 characteristics, 55
print quality problems, 116 wireless print server
RFID problems, 120 characteristics, 56
ribbon problems, 119 wrinkled ribbon causes, 119
Z
Zebra Basic Interpreter (ZBI)
run a ZBI program
ways to run, 86
START PROGRAM user menu item, 33
Zebra protocol, 96
ZPL mode
user menu item, 29
ways to select, 92
P1051584-003 ZE500™ User Guide 3/27/14

Zebra Technologies Corporation
Zebra Technologies Corporation
475 Half Day Road, Suite 500
Lincolnshire, IL 60069 USA
T: +1 847 634 6700
Toll-free +1 866 230 9494
F: +1 847 913 8766
Zebra Technologies Europe Limited

Dukes Meadow
Millboard Road
Bourne End
Buckinghamshire, SL8 5XF, UK
T: +44 (0)1628 556000
F: +44 (0)1628 556001
Zebra Technologies Asia Pacific, LLC

120 Robinson Road
#06-01 Parakou Building
Singapore 068913
T: +65 6858 0722
F: +65 6885 0838
http://www.zebra.com
© 2014 ZIH Corp.
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Zebra® ZE500™ Series

Product Improvements Continuous improvement of products is a policy of Zebra Technologies. All

Part Number: P1051584-003 Rev. A

ZEBRA TECHNOLOGIES CORPORATION

Applicable Directives and Supporting Standards:

RLAN Enabled (if equipped)

Applicable Directives and Supporting Standards:

Manufactured for Zebra Technologies Corporation by:

Effective Date: 11 July 2012

3/27/14 ZE500™ User Guide P1051584-003

FCC Compliance Statement

1. This device may not cause harmful interference, and

FCC Radiation Exposure Statement

Canadian DOC Compliance Statement

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

P1051584-003 ZE500™ User Guide 3/27/14

About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 • Printer Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3/27/14 ZE500™ User Guide P1051584-003

Print Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3 • Printer Configuration and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4 • Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

P1051584-003 ZE500™ User Guide 3/27/14

Miscellaneous Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

A • Applicator Interface Board Reconfiguration . . . . . . . . . . . . . . . . . . . . . . . 145

3/27/14 ZE500™ User Guide P1051584-003

P1051584-003 ZE500™ User Guide 3/27/14

3/27/14 ZE500™ User Guide P1051584-003

Who Should Use This Document

How This Document Is Organized

P1051584-003 ZE500™ User Guide 3/27/14

3/27/14 ZE500™ User Guide P1051584-003

Print Engine Orientation

Figure 1 • Left-Hand (LH) Print Engine

Figure 2 • Right-Hand (RH) Print Engine

P1051584-003 ZE500™ User Guide 3/27/14

Print Engine Components

Figure 3 • Print Engine Components (RH model shown)

1 ribbon take-up spindle 7 peel roller assembly (hidden when

3/27/14 ZE500™ User Guide P1051584-003

Figure 4 • Control Panel

POWER PAUSE STATUS DATA

P1051584-003 ZE500™ User Guide 3/27/14

Control Panel Display

Figure 5 • Idle Display

1 The printer’s current status

Navigating in the Display

Enter Setup Mode

POWER PAUSE STATUS DATA POWER PAUSE STATUS DATA

Scroll through the Parameters

3/27/14 ZE500™ User Guide P1051584-003

Table 1 • Navigation (Continued)

Press PLUS (+) to perform the specified action.

Change Parameter Values

Press PLUS (+) or MINUS (-) to scroll through the