Zebra ZD420 ZD620 Full PDF

ZD620 and ZD420
Desktop Printers with Link-OS®
User’s Guide
212485-002 Rev.B
Copyright
© 2017 ZIH Corp and/or its affiliates. All rights reserved. ZEBRA and the stylized Zebra
head are trademarks of ZIH Corp., registered in many jurisdictions worldwide. All other
trademarks are the property of their respective owners.
COPYRIGHTS AND TRADEMARKS: For complete copyright and trademark information, go to www.zebra.com/copyright
WARRANTY: For complete warranty information, go to www.zebra.com/warranty
END USER LICENSE AGREEMENT: For complete EULA information, go to www.zebra.com/eula
Terms of Use
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.
2
About
This guide is for integrators and operators of Zebra Link-OS ZD620 and ZD420 desktop
printers. Use this guide to install, change configuration, operate, and physically support
these printers.
Other Online resources are available to support this printer include:
• “How To” videos
• ZD620 or ZD420 Desktop Printer Product page links for printer specifications
• Printer accessory, supplies, parts, and software links
• Various setup and configuration guides
• Programmer’s manuals,
• Printer Drivers (Windows, Apple, OPOS, etc.)
• Printer Firmware
• Printer Fonts
• Utilities
• Knowledge base and support contacts
• Printer warranty and repair links
Use these links to get to your Online printer support resources:

• ZD620 Thermal Transfer Printer — www.zebra.com/zd620t-info
• ZD620 Direct Thermal Printer — www.zebra.com/zd620d-info
• ZD420 Thermal Transfer Ribbon Cartridge Printer — www.zebra.com/zd420c-info
3
About
Other Valuable Printer Resources

Zebra has a large suite of free and fee based software, Apps (applications), and other
technical resources for your Zebra Link-OS printer.
These are just some of the extensive software and resource areas available Online:
• Label Design software
• Printer Management tools
• Virtual Devices for legacy languages normally associated with other printer
brands
• Cloud based Enterprise printer management and printing
• XML and PDF format file printing
• Oracle and SAP support
• IoT data tools (Zatar)
• A suite of Link-OS Mobile Apps (applications for phones, tablets, etc.)
• Link-OS software development kit (SDK)
• Additional Operating Systems (OS) and Service platforms
See ZebraLink, Zebra Link-OS, and Zatar from this Online link: www.zebra.com/software
Zebra OneCare Printer Service and Support

For maximum productivity, we can help your business ensure its Zebra printers are Online
and ready for business. See the descriptions of the Zebra OneCare service and support
options available for your printers Online at this link: www.zebra.com/zebraonecare
Using This Document and Its Internally Attached Files

This document is best used with Adobe Reader or Adobe DC. This user’s guide includes
attached User Programming Example Files for sample printer operations.
Go to the Adobe Web site to load Adobe Reader (for free at the release time of this
publication): www.adobe.com
4
About
Document Conventions
The following graphic icons are used throughout the documentation set. These icons and
their associated meanings are described below.
Caution • If the precaution is not heeded, the user could receive minor or moderate injury.
Eye Injury Caution • If the precaution is not taken, the user’s eyes could be damaged. EXAMPLE:
Wear protective eyewear when installing or removing E-rings, C-clips, snap rings, springs, and
mounting buttons. These are under tension and could fly off.
Electrical Shock Caution • If the precaution is not taken, the user could receive an electrical shock.
EXAMPLE: Turn off (O) the printer and disconnect it from the power source before performing the
following procedure.
Hot Surface Caution • If the precaution is not taken, the user could be burned. EXAMPLE: The
printhead may be hot and could cause sever burns. Allow the printhead to cool.
Product Damage Caution • If the precaution is not taken, the product could be damaged.
EXAMPLE: Unplugging the computer without properly shutting it down may corrupt the data on your
hard drive.
ESD Caution • If the precaution is not taken, the product electronics could be damaged by an
electrostatic discharge. EXAMPLE: Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
Important • The text here indicates information that is important for the user to know. EXAMPLE:
Run the setup.exe file for the product BEFORE connecting the product to your printer.
Note • The text here indicates information that is supplemental for the user to know and that is not
required to complete a task. EXAMPLE: Refer to zebra.com for complete information on product
warranties.
5
Contents
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Terms of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
• About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Other Valuable Printer Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Zebra OneCare Printer Service and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Using This Document and Its Internally Attached Files . . . . . . . . . . . . . . . . . . . . . .4
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
• Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
• Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Link-OS 4 inch Desktop Thermal Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Common Desktop Link-OS Printer Features:. . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Link-OS 4 inch Desktop Printer Options: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Zebra Label Printing Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Modes of Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
What’s in the Box? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Open the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Closing the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
• Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Inside the ZD620 Dual Capacity Ribbon Roll Printer . . . . . . . . . . . . . . . . . . . . . . .29
Dual Capacity Ribbon Chassis - Ribbon Roll Holders . . . . . . . . . . . . . . . . . . . . . .30
Media Dancer - ZD620 Printer Models Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Inside the ZD620 and ZD420 Direct Thermal Printers . . . . . . . . . . . . . . . . . . . . . .31
Inside the ZD420 Ribbon Cartridge Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6
Contents
Accessing the Printhead of the Ribbon Cartridge Printer. . . . . . . . . . . . . . . . . . . .33

Label Dispenser Option (field installable) - All Models . . . . . . . . . . . . . . . . . . . . . .34
Cutter Option (field installable) - All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Linerless Media Tear-Off Option (Direct Thermal Models Only) . . . . . . . . . . . . . .35
Linerless Cutter Option (Direct Thermal Models Only). . . . . . . . . . . . . . . . . . . . . .35
Identifying Platen Drive Rollers Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Printer Power Supply Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Attached Power Supply Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Battery Power Base and Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
ZD620 and ZD420 Locking Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Zebra Print Touch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
• Install Hardware Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Field Installable printer Accessories and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Printer Connectivity Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Media Handling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Power Base Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Printer Connectivity Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Power Failure Recovery Mode Jumper (OFF by Default) . . . . . . . . . . . . . . . . . . .42
Accessing the Connectivity Module Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Installing the Serial Port Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Installing the Internal Ethernet (LAN) Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Removing Printer Connectivity Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Media Handling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Removing the Standard Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Installing the Label Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Installing the Standard Media Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Installing the Linerless Media Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Installing the Linerless Media ‘Tear-Off’ Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Media Roll Core Size Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Installing Media Roll Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Print Resolution Upgrade Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Installing the Printhead Resolution Upgrade Kits . . . . . . . . . . . . . . . . . . . . . . . . . .53
Installing the Attached Power Supply Base Options . . . . . . . . . . . . . . . . . . . . . . . . . .54
• Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Standard Interface Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
LCD User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Meaning of the Indicator Light Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Status - Typical Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Printer Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Media Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
7
Contents
Ribbon Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Ribbon Low (Ribbon Cartridge Printers Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Ribbon In (Ribbon Cartridge Printers Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Transferring Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Data Transfers Paused . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Out of Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Cover Open/Printhead (PH) Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Cut Error (Binding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Cartridge Authentication Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Status - Printhead Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Printhead Over Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Printhead Under Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Printhead Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Printhead Resolution Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Unauthorized Printhead Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Status - Bluetooth Low Energy (BTLE) Option. . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Bluetooth LE Paired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Bluetooth LE Failed to Pair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Status - Ethernet (LAN) Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Ethernet (LAN) No Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Ethernet (LAN) 100base Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Ethernet (LAN) 10base Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Ethernet (LAN) Link Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Status - Wi-Fi (WLAN) Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Wi-Fi Connecting to WLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Wi-Fi (WLAN) 100base Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Wi-Fi (WLAN) 10base Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Wi-Fi (WLAN) Link Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Display Controls and Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Navigating through Menu Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Idle Display (Default Start-up Screen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Home Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
• Printer Configuration Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Adjust Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
User Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
8
Contents
SETTINGS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

DARKNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
PRINT SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
MEDIA TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
PRINT METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
TEAR OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
PRINT WIDTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
PRINT MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
LABEL TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
LEFT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
REPRINT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
LABEL LENGTH MAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
TOOLS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
PRINT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
IDLE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
POWER UP ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
HEAD CLOSE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
LOAD DEFAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
MEDIA/RIBBON CAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
ZBI ENABLED? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
RUN ZBI PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
STOP ZBI PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
PRINT USB FILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
COPY USB FILE TO E: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
STORE E: FILE TO USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
PRINT STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
PASSWORD PROTECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
PRINT TEST FORMAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
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Contents
NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
ACTIVE PRINT SERVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
PRIMARY NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
WIRED IP ADDRESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
WIRED SUBNET MASK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
WIRED GATEWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
WIRED IP PROTOCOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
WIRED MAC ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
WLAN IP ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
WLAN SUBNET MASK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
WLAN GATEWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
WLAN IP PROTOCOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
WLAN MAC ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
ESSID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
CHANNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
IP PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
IP ALTERNATE PORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
RESET NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
VISIBILITY AGENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
BATTERY Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
BATTERY STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
LANGUAGE Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
COMMAND LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
COMMAND CHAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
CONTROL CHAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
DELIMITER CHAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
ZPL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
VIRTUAL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
SENSOR TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
LABEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
TAKE LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
BAUD RATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
DATA BITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
PARITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
HOST HANDSHAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
WML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
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Contents
BLUETOOTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
BLUETOOTH ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
DISCOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
CONNECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
BT SPEC VERSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
MIN SECURITY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
• Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Printer Setup Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Select a Location for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Install Printer Options and Connectivity Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Attaching Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Getting Ready to Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Preparing and Handling Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Media Storage Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Loading Roll Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Setting Media Sensing by Media type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Instructions for media loading: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Using the Movable Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Loading Roll Media (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Loading Thermal Transfer Roll Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Loading Zebra Transfer Roll Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Loading Non-Zebra 300 Meter Transfer Ribbon . . . . . . . . . . . . . . . . . . . . . . . . .161
Loading the ZD420 Ribbon Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Run a SmartCal Media Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
SmartCal Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Test Printing with the Configuration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Detecting a Media Out Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Detecting a Ribbon Out Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Connecting your Printer to a Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
Pre-install Windows® Printer Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
Interface Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
USB Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Ethernet (LAN, RJ-45) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Wi-Fi and Bluetooth Classic Wireless Connectivity Option . . . . . . . . . . . . . . . . . . . .178
Update Printer Firmware to Finish Option Installations . . . . . . . . . . . . . . . . . . . .178
• Setup for Windows® OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Windows to Printer Communication Setup (Overview). . . . . . . . . . . . . . . . . . . . . . . .179
Pre-install Windows® Printer Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Setting Up the Wi-Fi Print Server Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
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Configure Using the ZebraNet Bridge’s Connectivity Wizard . . . . . . . . . . . . . . . . . . .182

Using a Configuration Script. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Saving a Configuration Script. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Bluetooth Option Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Connecting to a Windows XP® SP2 Master Device. . . . . . . . . . . . . . . . . . . . . . .192
Connecting to a Windows Vista® SP2 or Windows 7® Master Device. . . . . . . . .193
Connecting the Printer to a Windows 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Connecting the Printer to a Windows 10 PC . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
After Your Printer is Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Testing Communications by Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
• Print Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Thermal Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Determining Your Printer’s Configuration Settings. . . . . . . . . . . . . . . . . . . . . . . .202
Select a Print Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Adjusting the Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Darkness Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Adjusting the Print Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
Replacing Supplies while Using the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
Printing on Fan-Fold Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Printing with Externally Mounted Roll Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
Externally Mounted Roll Media Considerations:. . . . . . . . . . . . . . . . . . . . . . . . . .209
Using the Label Dispenser Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
Using the Linerless Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Linerless Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Sending Files to the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
Ribbon Cartridge Programming Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
Printer Fonts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Identifying Fonts in Your Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
Localizing the Printer with Code Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
Asian fonts and Other Large Font Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
Getting Asian Fonts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
EPL Line Mode - Direct Thermal Printers only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Zebra® ZKDU — Printer Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
ZD620 and ZD420 Locking Printer Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
ZBI 2.0 ™ — Zebra Basic Interpreter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
Setting the Power Failure Recovery Mode Jumper . . . . . . . . . . . . . . . . . . . . . . . . . .223
• USB Host Port and Link-OS Demonstration Examples . . . . . . . . . . . . . . 225

USB Host . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Using USB Host for Firmware Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Flash Drive Preparation and Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . . .226
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Contents
USB Host and Printer Usage Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227

Items Required for the USB Host Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
Files for Completing the Exercises. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
File 1: ZEBRA.BMP . . . . . . . . . . . . . . . . . . . . . . . 227
File 2: SAMPLELABEL.TXT . . . . . . . . . . . . . . . . . . . . 227
File 3: LOGO.ZPL . . . . . . . . . . . . . . . . . . . . . . . 227
File 4: USBSTOREDFILE.ZPL . . . . . . . . . . . . . . . . . . . 228
File 5: VLS_BONKGRF.ZPL . . . . . . . . . . . . . . . . . . . . 228
File 6: VLS_EIFFEL.ZPL . . . . . . . . . . . . . . . . . . . . . 228
File 7: KEYBOARDINPUT.ZPL . . . . . . . . . . . . . . . . . . . 229
File 8: SMARTDEVINPUT.ZPL . . . . . . . . . . . . . . . . . . . 229
Exercise 1: Copy Files to a USB Flash Drive and Perform USB Mirror . . . . . . . .230
Exercise 2: Print a Label Format from a USB Flash Drive . . . . . . . . . . . . . . . . . .232
Exercise 3: Copy Files to/from a USB Flash Drive. . . . . . . . . . . . . . . . . . . . . . . .233
Exercise 4: Enter Data for a Stored File with a USB Keyboard and Print a Label235
Using the USB Hosts Port and the NFC Capabilities . . . . . . . . . . . . . . . . . . . . . . . . .236
Exercise 5: Enter Data for a Stored File with a Smart Device and Print a Label .237
• Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
Cleaning Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
Recommended Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Standard Platen (Drive) Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Linerless Platen (Drive) Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Media Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Label Dispenser Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
Cleaning the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
ZD620 / ZD420 Direct Thermal Printers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
ZD620 / ZD420 Thermal Transfer Printers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
ZD420 Ribbon Cartridge Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
Media Path Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Lower Half of ZD60/ZD420 Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Upper Half of ZD620/ZD420 Direct Thermal Printers. . . . . . . . . . . . . . . . . . . . . .247
Upper Half of ZD620/420 Thermal Transfer Printers . . . . . . . . . . . . . . . . . . . . . .247
Upper Half of ZD420 Thermal Transfer Ribbon Cartridge Printers . . . . . . . . . . .248
Cleaning the Cutter and Label Dispenser Options . . . . . . . . . . . . . . . . . . . . . . . .249
Cutter Option Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
Label Dispenser Option Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
Sensor Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
13
Contents
Lower Half of ZD60/ZD420 Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251

Upper Half of ZD620/ZD420 Direct Thermal Printers. . . . . . . . . . . . . . . . . . . . . .252
Upper Half of ZD620/ZD420 Thermal Transfer Printers. . . . . . . . . . . . . . . . . . . .252
Upper Half of ZD420 Ribbon Cartridge Printers. . . . . . . . . . . . . . . . . . . . . . . . . .253
Platen Cleaning and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
Removing the Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
ZD620 and ZD420 Direct Thermal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Removing the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
ZD620 and ZD420 Thermal Transfer Ribbon Roll . . . . . . . . . . . . . . . . . . . . . . . .265
Removing the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265
Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
ZD420 Thermal Transfer Ribbon Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
Printhead Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
Updating Printer Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
Other Printer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
RTC Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
• Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Resolving Alerts and Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Alert: Printhead Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Alert: Media Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Possible Cause - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Possible Cause - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
Possible Cause - 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
Alert: Ribbon In (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . . . . .279
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
Alert: Ribbon Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280
Possible Cause - 2 (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . .280
Possible Cause - 3 (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . .280
Possible Cause - 4 (Standard Roll - Thermal Transfer Printers) . . . . . . . . . . . . .280
Alert: Ribbon Low (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . . .281
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281
Alert: CUT ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282
14
Contents
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282

Alert: PRINTHEAD OVER TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
Alert: PRINTHEAD SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284
Alert: PRINTHEAD UNDER TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
Alert: OUT OF MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .286
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .286
Resolving Print Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Issue: General Print Quality Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Possible Cause - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Possible Cause - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Possible Cause - 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288
Issue: No Print on the Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288
Issue: Labels Are Distorted in Size or Print Area Start Position Varies . . . . . . . .289
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
Possible Cause - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
Communication Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
Issue: Label Job Sent, No Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
Possible Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
Issue: Label Job Sent, Skips Labels or Prints Bad Content . . . . . . . . . . . . . . . . .290
Possible Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
Issue: Label Job Sent, Data Transfers, But No Print . . . . . . . . . . . . . . . . . . . . . .291
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291
Miscellaneous Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
Issue: Settings are Lost or Ignored . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
Possible Cause - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
Issue: Non-continuous labels act as Continuous labels. . . . . . . . . . . . . . . . . . . .293
15
Contents
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293

Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293
Issue: Printer Locks-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
Issue: Erroneous Ribbon Cartridge Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
Possible Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
• Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
SmartCal Media Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
Configuration Report (CANCEL Self Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
Printer Network (and Bluetooth) Configuration Report. . . . . . . . . . . . . . . . . . . . .298
Print Quality Report (FEED self test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298
Reset Printer Factory Defaults (PAUSE + FEED Self Test). . . . . . . . . . . . . . . . .302
Reset Network Factory Defaults (PAUSE + CANCEL Self Test) . . . . . . . . . . . . .302
Reset Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
Communication Diagnostics Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304
Sensor Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
Advanced Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
Manual Media Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308
Manual Print Width Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309
Manual Print Darkness Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310
Factory Test Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311
• Interface Connector Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

Universal Serial Bus (USB) Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
Serial Port Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313
Connecting the Printer to a DTE Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313
Connecting the Printer to a DCE Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314
• Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
ZD620 / ZD420 Thermal Transfer Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316
ZD620 / ZD420 Ribbon Cartridge Thermal Transfer Models . . . . . . . . . . . . . . . . . . .323
ZD620 / ZD420 Direct Thermal Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330
• Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Types of Thermal Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336
Determining Thermal Media Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336
General Media and Print Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337
Label Dispenser (Peeler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338
Standard (Media) Cutter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
Linerless (Media) Cutter - Direct Thermal only. . . . . . . . . . . . . . . . . . . . . . . . . . .339
16
Contents
• ZPL Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Managing the ZPL Printer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
ZPL Printer Configuration Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343
Configuration Setting to Command Cross-reference . . . . . . . . . . . . . . . . . . . . . . . . .344
Printer Memory Management and Related Status Reports . . . . . . . . . . . . . . . . . . . .347
ZPL Programming for Memory Management . . . . . . . . . . . . . . . . . . . . . . . . . . . .347
17
Introduction
This section introduces the award winning Zebra® Link-OS 4-inch desktop thermal label
printers, the ZD620 and ZD420. It has an overview of the Link-OS printer’s features and
options, and what ships with your new printer.
This document covers the following ZD-series desktop printer models:
Link-OS 4 inch Desktop Thermal Printers
The Zebra® Link-OS 4 inch Desktop printers are compact label printers with a wide range
of features and options.
• Direct Thermal and Thermal Transfer printer models available.
• Includes ZD420 Healthcare printer models with plastics that withstand common
hospital cleaning chemicals and include a medical grade power supply.
• ZD620 printers can support printing speeds* up to 203.4 mm/s per second (8 ips -
inches per second) for 203 dpi (dots per inch print density) printers and
152.4 mm/s (6 ips) for 300 dpi version printers.
• ZD420 printers can support printing speeds* up to 152.4 mm/s per second (6 ips)
for 203 dpi printers and 101.6 mm/s (4 ips) for 300 dpi version printers.
• These printers support ZPL™ and EPL Zebra printer programming languages and
a wide variety of other printer control languages via Link-OS Virtual Devices.
* -Maximum print speeds vary by model, print resolution, and the type of media in use.
18
Introduction
Common Desktop Link-OS Printer Features:

• OpenAccess ™ design for simplified media loading.
• Color-coded “touch points” for operator controls and media guides.
• Enhanced user interface featuring three buttons and five status indicators.
• Easy, field installable media handling options.
• Media roll support:
• Outer Diameter (O.D.): Up to 127 mm (5 inch) and
• Inner Diameter (I.D.) roll cores:12.7 mm (0.5 inch), 25.4 mm (1 inch) and
additional core sizes with optional media core adapters.
• Movable Sensor provides compatibility with the widest range of media types:
• Compatible with full or partial width black mark media.
• Compatible with notched or slotted media.
• Multi-center position transmissivity sensor for use with label gap/web media.
• Universal Serial Bus (USB) Host Port that can be used for easy firmware
upgrades.
• Universal Serial Bus (USB) 2.0 interface
• Modular Connectivity Slot for field installable 10/100 Ethernet (802.3 RJ-45) or
Serial (RS-232 DB-9) interface options.
• On–the–fly OpenType and TrueType font scaling and import, Unicode, resident
scalable font (Swiss 721 Latin 1 font), and a selection of resident bitmap fonts.
• Backwards compatibility focused technology eases printer replacement:
• Drop in replacement of legacy Zebra desktop printers. The printer accepts
both EPL and ZPL programming languages.
• Supports Link-OS virtual devices to interpret non-Zebra printer programming
languages.
• XML-Enabled printing—allows XML communications for barcode label printing,
eliminating license fees and print server hardware and lowering customization and
programming costs.
• Zebra ™ Global Printing Solution – supports Microsoft Windows keyboard
encoding (and ANSI), Unicode UTF-8 and UTF 16 (Unicode Transformation
Formats), XML, ASCII (7 and 8 bit used by legacy programs and systems), basic
single and double byte font encoding, JIS and Shift-JIS (Japanese International
Standards), Hexadecimal encoding, and custom character mapping (DAT table
creation, font linking, and character remapping).
• Supports printer configuration via a setup utility running on mobile devices.
• Zebra’s Print Touch (Near Field Communication - NFC) ‘tap’ to pair devices,
access printer information, and access mobile applications.
• Zebra’s Link-OS - an open platform that connects operating systems for smart
Zebra devices with powerful software apps (applications), making the devices
easy to integrate, manage and maintain from any location.
19
Introduction
• Printhead maintenance reporting enabled and customizable by the user.

• Easy tool-less replacement of printhead and platen (driver) roller.
• A minimum of 64 MB of internal (E:\) printer memory for storing forms, fonts, and
graphics.
Link-OS 4 inch Desktop Printer Options:

• A Color LCD User Interface for easy setup, print configuration, printing, and a
range of Link-OS features.
• Healthcare printer models:
• Healthcare wipe-able plastics for disinfecting and cleaning.
• IEC 60601-1 certified power supply.
• Wi-Fi (802.11ac – includes a/b/g/n) and Bluetooth Classic 4.1 (3.X compatible)
wireless connectivity as a factory installed option.
• Thermal Transfer Printing - A choice of easy loading thermal transfer ribbon
cartridge or dual capacity ribbon roll (74 m and 300 m ribbons) models.
• ZD620 and select ZD420 printers have an factory installed, on-board Real Time
Clock (RTC) in printers that have Bluetooth Low Power (BTLE) or Wi-Fi with
Classic Bluetooth configurations.
• Field installable connectivity modules:
• Internal Ethernet Print Server (LAN, RJ-45 connector) — supports 10Base-T,
100Base-TX and fast Ethernet 10/100 auto-switching networks.
• Serial (RS-232 DB-9) Port
• Field installable media handling options:
• Label Dispenser (Peel-Off liner and present the label for the operator).
• General purpose media cutter.
• Linerless Label Tear-Off printing with a ‘Label Taken’ sensor.
• Linerless Label Cutter with a ‘Label Taken’ sensor.
20
Introduction
• Media Core Adapter kit include adapters for media rolls with Outer Diameters
(O.D.) up to 127 mm (5 inches):
• 38.1 mm (1.5 inch) I.D. media cores.
• 50.8 mm (2.0 inch) I.D. media cores.
• 76.2 (3.0 inch) I.D. media cores.
• Field upgrade kit to change printer resolution is available. Change your printer
from 203 dpi to 300 dpi - or - from 300 dpi to 203 dpi printing with these tool-less
upgrade kits.
• Asian Language support with printer configuration options for the large Simplified
and Traditional Chinese, Japanese, or Korean character sets.
• Printers sold in China have the Simplified Chinese SimSun font pre-installed.
• Zebra® ZBI 2.0 ™ (Zebra BASIC Interpreter) programming language. ZBI allows
you to create custom printer operations that can automate processes, use
peripherals (i.e. scanners, scales, keyboards, Zebra® ZKDU ™ , etc.) all without
being attached to a PC or network.
• Locking Media Cabinet for ZD620 Direct Thermal Healthcare printer models. This
special Healthcare model includes for additional security, Kensington ™ Slot for
Kensington locking devices to secure the printer.
21
Introduction
Zebra Label Printing Solution
The printer is just one of three (3) parts of a printing solution. To print; you need a printer
(ZD620 or ZD420), compatible media (thermal transfer ribbon cartridge or rolls, and
thermal transfer media; or just direct thermal media), and software (driver, applications or
programming) to tell the printer what to do and print. The printer can print without being
connected to other devices or systems.
The media may be labels, tags, tickets, receipt paper, fan-fold stacks, tamper proof labels,
etc.
Zebra assists you with label design and print with the free label and form design software:
ZebraDesigner ™ for Windows PC operating systems.
Zebra provides a complete suite of free Link-OS software applications and drivers to
configure printer settings, print labels and receipts, get printer status, import graphics and
fonts, send programming commands, update firmware, and download files.
The Zebra web site or your reseller will be able to help you identify media for your desired
use case.
22
Introduction
Modes of Printing
You can operate this printer in many different modes and media configurations:
• Direct thermal printing (which uses heat sensitive media to print).
• Thermal transfer printing with easy to use thermal transfer ribbon cartridge or rib-
bon rolls (heat and pressure transfers ink from the ribbon to media).
• Standard Tear-Off mode allows you to tear off each label/receipt or batch print a
strip of labels and tear them off after it is printed.
• Label Dispense Mode: If an optional dispenser is installed, the backing material
can be peeled away from the label as it is printed. After this label is removed, the
next one is printed.
• Media Cutting: If an optional media cutter is installed, the printer can cut the label
liner between labels, receipt paper or tag stock.
• Linerless media printing with Cut or Tear-Off label options for easy pick and place
label applications.
• Stand-alone: The printer can print without being directly connected to a computer.
• A printer with the color LCD display option can use menus to access and print
a label format/form.
• A Link-OS App connecting via Bluetooth (Wireless option).
• An auto running label format/form (programming based).
• A data input device connected to the printer’s USB Host port or serial port.
This mode accommodates data input devices, such as scanners, weigh
scales, a Zebra Keyboard Display Unit (ZKDU), etc.
• Shared network printing: Printers configured with Ethernet (LAN) and Wi-Fi
interface options include an internal print server.
23
Introduction
What’s in the Box?
After unpacking, make sure you have all parts shown below. Follow the procedures for
inspecting the printer to familiarize yourself with printer parts so you can follow the
instructions in this book.
Printer USB Cable Printer Documentation
Documentation
and Software
Power
Supply
Included with Thermal Transfer Printer (uses ribbon rolls)
Empty Starter Ribbon Cores Non-Zebra 300 Meter Ribbon

Adapters
24
Introduction
Unpack and Inspect the Printer

When you receive the printer, immediately unpack it and inspect for shipping damage.
• Save all packing materials.
• Check all exterior surfaces for damage.
• Open the printer and inspect the media compartment for damage to components.
If you discover shipping damage upon inspection:
• Immediately notify the shipping company and file a damage report. Zebra
Technologies Corporation is not responsible for any damage to the printer
incurred during shipment, and will not cover the repair of this damage under its
warranty policy.
• Keep all packaging material for shipping company inspection.
• Notify your authorized Zebra® reseller.
See the Zebra Web site for ‘How To’ videos on packing and unpacking your printer. See
About section for links to one of these 5 basic Link-OS printer variations.
25
Introduction
Open the Printer

To access the media compartment, pull the release latches towards you and lift the cover.
Check the media compartment for loose or damaged components.
ESD Caution • The discharge of electrostatic energy that accumulates on the surface of
the human body or other surfaces can damage or destroy the printhead and other
electronic components used in this device. You must observe static-safe procedures when
working with the printhead or the electronic components under the top cover.
Closing the printer
Lower the top cover. Press down in the middle of the cover in front until the cover snaps
closed.
26
Printer Features
This section will help you identify features of these Zebra® Link-OS 4-inch desktop thermal
label printers, the ZD620 and ZD420. ‘How to’ videos on the Zebra Web site include a
Printer Features video; as well as; other printer setup and task specific videos. Links to
these five (5) Link-OS 4- inch desktop printers are:
27
Printer Features
Printer Features
User Interface
Release
Latch
For more details on printer controls, see Controls and Indicators
Power Button
Fan-Fold Media
Entry Slot
Release
Latch
DC Power Interface and Connectivity

Receptacle Module Slot Access
28
Printer Features
Inside the ZD620 Dual Capacity Ribbon Roll Printer
Ribbon Carriage
Printhead
Upper Web (Gap)

Array Sensor
(other side)
Roll Holders
Media Guides
Media Guide Stop

Adjustment
Head-Up Sensor
(inside)
Platen (Drive) Roller

Movable Sensor
(Black Mark and Lower Web/Gap)
29
Printer Features
Dual Capacity Ribbon Chassis - Ribbon Roll Holders

Take Up Spindles
Supply Spindles (full ribbon rolls)
Media Dancer - ZD620 Printer Models Only

The printer’s window is removed to show the Media Dancer (plate). the Media Dancer is
re-colored to make it easier to see. It is the same color as the dark gray parts adjacent to it.
Media
Dancer
(ZD620 Only)
30
Printer Features
Inside the ZD620 and ZD420 Direct Thermal Printers
Printhead
Upper Web (Gap)

Array Sensor
Roll Holders
Media Guides
Media Guide Stop

Adjustment Media Dancer
(ZD620 Only)
Head-Up Sensor
(inside)

Movable Sensor
31
Printer Features
Inside the ZD420 Ribbon Cartridge Printer

Ribbon Drive
Transport
Ribbon Cartridge
Shown Installed
(sold separately)
Upper Web (Gap)

Array Sensor
Roll Holders
Media Guides
Media Guide Stop

Adjustment
Release
Arms (2)
Head-Up Sensor
(inside)
Movable Sensor
32
Printer Features
Accessing the Printhead of the Ribbon Cartridge Printer
PRINTHEAD ACCESS Printhead

Actuator Arm
1. Pull both release arms out
(green highlighted black parts).
Backside of
2. Ribbon drive transport drops Printhead
down.
3. Lift printhead actuator arm up

to access the printhead


 

Printhead
Ribbon Sensor
Ribbon Cartridge
Authentication and
Status Interface
Ribbon Sensor’s
Reflector
33
Printer Features
Label Dispenser Option (field installable) - All Models
Label Taken Label Liner

Sensor Exit Area
Label Peel Bar
Door Latch Dispenser Door

Peel Roll
Cutter Option (field installable) - All Models
Cutter Module
Media Exit Slot
34
Printer Features
Linerless Media Tear-Off Option (Direct Thermal Models Only)
Label Taken
Sensor
Linerless Cutter Option (Direct Thermal Models Only)
Label Taken
Sensor
Cut Label Landing

Area
35
Printer Features
Identifying Platen Drive Rollers Types

The platen (drive) rollers are colored differently to identify the platen type and print
resolution of your printer (and the platen). Do not exchange platen types unless instructed
to by an upgrade procedure or Zebra technical support. The printer will not operate
correctly and may cause a variety of problems requiring maintenance.
203 dpi Standard Platen (black)
300 dpi Standard Platen (gray)
203 dpi Linerless Platen (reddish-brown)
300 dpi Linerless Platen (brown)
36
Printer Features
Printer Power Supply Options

ZD-Series printers offer field installable attached power options: an attached power supply
base or a battery power base (available in Q2 2018). These options easily attach with
screws and replace the power supply that was included with your printer.
Attached Power Supply Base
Attached Power
Supply Base
Battery Power Base and Power Pack
Battery Power Base

Battery Power Base and Accessories
(artist rendering) available after Q2 2018
37
Printer Features
ZD620 and ZD420 Locking Printer Features

This option is only available in a Healthcare ZD620 printer model. It includes a lock and
key access to the printer’s media compartment and a Kensington Lock Slot on the back
panel of the printer to secure the printer. For more information on the Locking Printer
option, see ZD620 and ZD420 Locking Printer Option.
Cabinet Lock
Kensington Lock Slot
38
Printer Features
Zebra Print Touch
The Zebra Print Touch ™ feature allows you to touch an Android ™ -based, Near Field
Communication (NFC)-enabled device such as a smart phone or tablet to the printer’s
Print Touch logo to pair the device to the printer. This capability allows you to use your
device to provide information for which you are prompted and then print a label using that
information.
Important • Some mobile devices may not support NFC communication with the printer
until you configure the required NFC settings in your device. If you encounter difficulties,
consult your service provider or your smart device manufacturer for more information.
Print Touch Location

(Passive NFC)
Data encoded into the tag includes:

• A URL for a Zebra QuickHelp style support web page
• The printer’s unique Bluetooth Low Energy MAC address
• The printer’s Bluetooth Classic MAC address (if present)
• The printer’s Wi-Fi (WLAN) MAC address (if present)
• The printer’s Ethernet (LAN) MAC address (if present)
• The printer SKU – ex. ZD42022-D01W01EZ
• The printer’s unique serial number
The NFC tag can be used to:
• Facilitate Bluetooth pairing with a compatible mobile device
• Launch an application
• Launch a mobile browser to a web page
39
Install Hardware Options
This section assists you installing common printer connectivity modules and media
handling options.
Important • To simplify and speed up the setup process, install all connectivity modules
and media handling options before setting up and using your printer for the first time.
Important • It is strongly recommended that you update your printer’s firmware after the
printer has completed the setup process. Many of these options have internal firmware that
require an update to operate properly with the printer’s Main Logic Board’s installed
firmware version.
40
Field Installable printer Accessories and Options

Printer Connectivity Modules
The connectivity module’s access door must be removed prior to installing the following
options — Accessing the Connectivity Module Slot.
• ZD420 Serial Port — Installing the Serial Port Module
• RS-232 DB-9 connector with DTE/DTC auto-switching — Serial Port Interface
• ZD420 Internal Ethernet (LAN - wired) — Installing the Internal Ethernet (LAN)
Module
• RJ-45 connector
• Fast Ethernet 10/100 auto-switching, 10Base-T, and 100Base-TX networks.
Media Handling Options
The printer’s standard bezel must be removed prior to installing the following options —
Removing the Standard Bezel.
• Label Dispenser (Peel-Off Liner and Present Label for Operator) - Installing the
Label Dispenser
• General Purpose Media Cutter — Installing the Standard Media Cutter
• Linerless Media Cutter — Installing the Linerless Media ‘Tear-Off’ Bezel
• Linerless Media ‘Tear-Off’ Label Bezel —
• Printer Resolution Upgrade Kits (203 dpi and 300 dpi) - Print Resolution
Upgrade Kits
• Media Roll Adapters for 38.1 mm (1.5 inches), 50.8 mm (2.0 inches), or 76.2 mm
(3.0 inches) I.D. media cores - Media Roll Core Size Adapters
Power Base Options
The ZD-Series (ZD620 and ZD420) printers are supported with power base field upgrade
kits for each the direct thermal and thermal transfer versions of these printers.
• Attached Power Supply Base (power supply included)
• Battery Power Base and Battery Pack - Not Available until after Q2 2018.
The battery power base is designed to install like the AC Power Base
41
Printer Connectivity Modules
The connectivity modules can be easily installed without tools.

the human body or other surfaces can damage or destroy the printhead or electronic
components used in this device. You must observe static-safe procedures when working
with the printhead or the electronic components.
Power Failure Recovery Mode Jumper (OFF by Default)
All of the Printer Connectivity Modules have a Power Failure Recovery jumper. It is set to
the OFF position by default. With the jumper set to ON, the printer will automatically Power
ON when plugged into an active (ON) AC power source (and not power off). See Standard
Interface Controls - Power Button - Power Failure Recovery Mode for power ON/OFF
behaviors. See Setting the Power Failure Recovery Mode Jumper for instructions on
activating the mode.
Note • The Power Failure Recovery Mode is only available on printers with a Printer
Connectivity Module installed in your printer.
Accessing the Connectivity Module Slot

1. Disconnect the DC power plug from the rear of the printer.
2. Open the module access door by pushing down on the top of the door with your finger
tip. This releases the latch. Pull the door away and down to remove.
42
Installing the Serial Port Module
1. With the DC power plug and module’s access door removed, slide the serial port
module into the printer. Push the circuit card in slowly but firmly until the card is just
past the inside lip of the access door.
2. Align the bottom of the serial port’s door cover to the bottom lip of the module access
opening. Swing the door up and snap the cover closed.
Serial Port (RS-232)
Note • For best printer performance, update the printer’s firmware after installing options
or immediately after the printer’s initial setup. See Updating Printer Firmware.
43
Installing the Internal Ethernet (LAN) Module
1. With the DC power plug and module’s access door removed, slide the Ethernet
module into the printer. Push the circuit card in slowly but firmly until the card is just
past the inside lip of the access door.
2. Align the bottom of the Ethernet port’s door cover to the bottom lip of the module
access opening. Swing the door up and snap the cover closed.
Ethernet Port (RJ-45)
44
Removing Printer Connectivity Modules
Connectivity modules can easily be removed for the purpose of reconfiguring a printer or
repair. You should not remove and replace connectivity modules as a general practice.
1. Remove the interface cable (Ethernet or Serial).
2. Remove the module access door. Push down on the top of the door with your finger
tip. This releases the latch. Pull the door away and down to remove.
3. Re-attach the interface cable to the connectivity module and secure the cable.
4. Gently pull on the interface cable that is secured to the connectivity module. Slowly
pull the module out of the printer.
5. Install a different connectivity module or re-install the connectivity module’s access
door. Align it to the bottom lip of the access opening and swing it up to snap and lock
in place.
45
Media Handling Options

Removing the Standard Bezel

The standard bezel must be removed to mount your media handling option.
1. Disconnect the printer’s DC power input plug from the rear of the printer.
2. Turn the printer upside down. Remove the two (2) mounting screws with the supplied
Torx wrench. Save the screws.
3. Slide the bezel down the front about 12.5 mm (0.5 inch) and pull the loose bezel out.
46
Installing the Label Dispenser

The standard bezel must be removed and DC input power disconnected before the Label
Dispenser can be installed. See Removing the Standard Bezel.
1. Place the label dispenser module and printer right side up with the top of the module
12.5 mm (0.5 inch) below the bottom of the top cover. Center and push the module
into the front of the printer and slide it up until it stops.
2. Turn the printer upside down and attach the module to the printer with the two screws
using the Torx wrench.
47
Installing the Standard Media Cutter

The standard bezel must be removed and DC input power disconnected before the Label
Dispenser can be installed. See Removing the Standard Bezel.
Cut Warning • There are no operator serviceable parts in the cutter unit. Never remove
the cutter cover (bezel). Never attempt to insert objects or fingers in to the cutter
mechanism.
Important• Using un-approved tools, cotton swabs, solvents, etc. all may damage or
shorten the cutter’s usable life or cause the cutter to jam.
1. Place the Cutter module and printer right side up with the top of the module even with
the bottom of the top cover. Center and push the module into the front of the printer
and slide it up until it stops.
48
Installing the Linerless Media Cutter

The standard bezel must be removed and DC input power disconnected before the
Linerless Media Cutter Module can be installed. See Removing the Standard Bezel.
1. Open the printer and remove replace the standard platen roller with the Linerless
platen roller. See Platen Cleaning and Replacement for a replacement procedure.
See Installing the Printhead Resolution Upgrade Kits to help you identify platen
rollers.
2. Place the Cutter module and printer right side up with the top of the module even with
the bottom of the top cover. Center and push the module into the front of the printer
and slide it up until it stops.
49
Installing the Linerless Media ‘Tear-Off’ Bezel

The standard bezel must be removed and DC input power disconnected before the
Linerless Tear-Off Bezel module can be installed. See Removing the Standard Bezel.
1. Open the printer and remove replace the standard platen roller with the Linerless
platen roller. See Platen Cleaning and Replacement for a replacement procedure.
See Installing the Printhead Resolution Upgrade Kits to help you identify platen
rollers.
2. Place the Tear-Off bezel module and printer right side up with the top of the module
even with the bottom of the top cover. Center and push the module into the front of
the printer and slide it up until it stops.
50
Media Roll Core Size Adapters

The media roll adapters kit includes three (3) pairs of media roll adapters. The kits are for
the following inner diameter (I.D.) media cores:
• 38.1 mm (1.5 inches)
• 50.8 mm (2.0 inches)
• 76.2 (3.0 inches)
Adapter Usage
• The adapters are intended to be permanently installed in the printer.
• They may be changed to support other media roll sizes that require one of these
adapter sizes.
• The adapters may wear out if they are changed too much.
• Removing the media adapters to print on standard roll cores may leave plastic
pieces in the media roll holders side areas that rub against the roll. Push those
attached pieces back into the side of the media roll holder.
Installing Media Roll Adapters
1. Place one screw in the top adapter mounting hole of both of the roll holders. Start
turning the screws clockwise using the Torx wrench until the tip of the screw is just
protruding through the inside of the roll holder. The screws are self-tapping.
2. Place the adapter on the inside of the roll holder. The large side of the adapter is on
top. The smooth side (no ribs) faces the middle of the printer.
3. Align the adapter’s top screw hole to the protruding screw tip and pinch it tightly to the
roll holder body. Tighten the screw until there is no gap between the adapter and roll
holder. Do not tighten beyond this point. Over tightening will strip the thread.
51
4. Insert a screw in the bottom adapter mounting hole. Pinch the adapter tightly to the
roll holder while tightening the screw. Tighten the screw until there is no gap between
the adapter and roll holder. Do not tighten beyond this point. Over tightening will strip
the thread.
5. Repeat step 1-4 for the other adapter and roll holder.
Example of Label Roll

with 76.2 mm (3.0
inch) Inner Core
mounted on Media
Core Adapters
52
Print Resolution Upgrade Kits

There are four (4) print resolution upgrade kits. The same procedure is used to change all
the printhead resolution upgrade kits. Both the printhead and platen (drive) rollers must be
changed and are resolution dependent. The printer automatically detects the change in
printheads and the platen roller materials are identified by color.
• Standard Printing
• Change the printer from 203 dpi to 300 dpi printing.
• Linerless Printing (for Direct Thermal ZD620 printers only)
Printheads used in the upgrade kits include a 203 or 300 marking to help you keep the
unpackaged upgrade printhead separate from the original printhead. The original
printhead contains no marking identifying its print resolution.
The platen (drive) rollers are colored differently to help you keep from accidentally using
the old platen roller. See Identifying Platen Drive Rollers Types
Installing the Printhead Resolution Upgrade Kits
1. Turn the printer off and disconnect the power.

2. Use the platen roller replacement procedure. See Platen Cleaning and Replacement
3. Use the printhead replacement procedure. See Replacing the Printhead
4. Re-attach power and turn the printer on. The printer will automatically detect the
change in printhead (but not the platen) when the printer verifies the printer’s
configuration.
Important • For best results and the latest printer features and operation, download and
install the latest printer firmware. See Updating Printer Firmware.
53
Installing the Attached Power Supply Base Options
The power base is ready to attach to the printer. The base is installed using Torx T10
wrench (that you supply) and the mounting screws provided with the upgrade kit. The direct
thermal printer models attach to the printer with three (3) screws and thermal transfer
printer models use four (4) screws.
1. Remove any media rolls from the printer. Remove the original power supply cable
from the back of the printer.
2. Turn the printer over and align the power base to the bottom of the printer with the
printer power plug oriented toward the rear of the printer. The printer’s rubber feet
align with recesses in the top of the power base.
3. Use the screws provided to attach the power base to the printer. 3 screws for Direct
Thermal printers. 4 screws for thermal Transfer printers. Tighten the screws using the
Torx wrench supplied in the kit.
Thermal Transfer Printers Direct Thermal Printers
54
4. Insert the DC input power plug into the printer.
DC Input
Power Plug
DC Input
Power Plug
5. Re-connect the AC power cord to the printer power base.
55
Controls and Indicators
This section discusses the two user control panel variations and their functionality.
56
User Interface
The primary user controls are found on the front of the printer. The ZD-Series Desktop
printers support two user interface options.
• Standard User Interface — This interface provides basic control and status
needed by an operator. Printer operating status is reported by five (5) icon
indicator lights. The icons represent several functional areas of operation. The
indicator lights, as a group, provide a wide range of printer status notifications
when used in combination. They are visible from a greater distance than you can
read on a printer with a display. See the Meaning of the Indicator Light Patterns.
• This interface supports operator tasks of replacing printing supplies (labels,
receipt paper, transfer ribbon, etc.) when prompted by two indicators.
• Status indicator’s icons represent a functional area of printer operation.
• Status indicator lights typically use color to show the operator the functional
status of the printer. The status indicator lights may be off (not lit), red, green,
or amber (orange/yellow). Red is ‘needs attention’ or ‘not ready’. Green is for
‘ready’ or ‘functioning’. Amber (orange/yellow) is for busy or active process
(data downloading, over-temperature cooling cycle, etc.). An off or un-lit status
indicator does not require the operators attention.
• A status indicator can flash (blink), fade (bright to off), alternate between
colors, or remain on in a variety of patterns that denote various printer
activities, and operational status as a group.
• Control buttons are used in various combinations to access internal utilities
that calibrate the printer to your media and make limited print settings.
• LCD User Interface — This color LCD interface provides easy printer setup,
configuration, and is customizable for all user types. The interface includes all the
Standard User Interface controls and indicators to provide you with common
functionality and behaviors for these Link-OS printer models.
• The display option provides written printer status and messages. The display
supports 19 languages, selectable by the operator or with programming.
• It has a menu system. Users can make changes to print settings (darkness,
speed, etc.), run utilities, and set wired and wireless communication interfaces
(Serial, Ethernet, Wi-Fi, etc.) that are installed on your printer.
57
Standard Interface Controls
1 2 3 4 5 6
9 8 7
1 • Power Button — Turns power ON and OFF in the printer. It is also used to initiate
low-power sleep and wake states.
• Initial Power ON — Press the Power button until the printer’s indicator
lights flash on. The indicator lights will flash on and off in various
combinations while the printer does self diagnostics, configuration checks,
and integrate optional components which will take several seconds to
complete.
The Status indicator will turn solid GREEN indicating the printer is ready for
normal print operations.
• Sleep Mode — Pressing and releasing the button once will cause the
printer to enter Sleep Mode. The printer will turn off after storing various
configuration and status information in memory. All the indicators will be off
except the Status Indicator will slowly change between On and Off to indicate
Sleep Mode.
• Power OFF with Sleep Mode Delayed — Press and Hold the button for 4-
9 seconds. The operator can start a batch print job and put the printer into the
low power consumption state of Sleep mode — after the job has finished.
• Power OFF / Shutdown — Press and Hold the button for 4-9 seconds.
The printer will turn OFF.
• Power Failure Recovery Mode — This printer feature is activated by a
hardware jumper setting on one of the optional Printer Connectivity Modules
installed in the printer. See Setting the Power Failure Recovery Mode Jumper.
• The printer will automatically Power ON when plugged into an active (ON)
AC power source.
• Supports Sleep Mode and Power OFF with Sleep mode Delayed.
58
• A Power OFF/Shutdown will reset the printer and then runs the Initial
Power ON sequence.
Connectivity Module installed in the printer.
2 • Status Indicator — Primary status indicator for overall printer health and
operational status. This indicator is also known as the Power indicator.
• Green: Ready for print and data activity.

• Green, Slowly Changing between ON and OFF: Printer is in Sleep Mode.
• Red: Media out, media detection error, head (cover/printhead) open, cut error,
printhead authentication failure.
• Amber: Printhead Over Temp (temperature), printhead element failure, out of
memory while storing content (formats, graphics, fonts, etc.), and interface
power fault for USB Host or Serial ports.
• Blinking Amber: Printhead Under Temp (temperature)
• Blinking Red: Printhead Over Temp (temperature) — this status is coupled
with blinking red Pause indicator. Requires cooling and printer restart.
3 • Pause Indicator — The printer is in Pause mode when the Pause indicator light is
on. A label (print form) or all labels (print forms) in the print buffer’s queue can be
canceled when the Pause indicator is on using the Cancel button.
• Amber: The printer is paused. Print, label FEED (advance), and other label
routines are suspended until the pause state is removed by pressing the
Pause button.
• Blinking Red: Printhead Over Temp (temperature) — this status is coupled
with blinking red Status indicator. Requires cooling and printer restart.
59
4 • Data Indicator — Indicates the status of data transfer activity.
• Off: Data is not being transferred.

• Green: A data communication operation has not finished, but is not actively
being transferred.
• Blinking Green: Data communications are in process.
• Blinking Amber: Out of memory while storing content (formats, graphics,
fonts, etc.).
5 • Supplies Indicator — Indicates media (label, receipt, tags, transfer ribbon, ribbon
cartridge, etc.) status.
• Red: There is a media out condition.

• Blinking Red: Ribbon Out.
• Blinking Red and Amber: Ribbon Cartridge Low (ZD420 Cartridge printers
only).
• Blinking Amber: Ribbon In (ZD420 Cartridge printers only) detected while the
printer is attempting to print in direct thermal mode.
6 • Network Indicator — Indicates network activity and status.
• Amber: 10 base Ethernet (LAN) connection detected.

• Green: 10/100 Ethernet (LAN) connection detected or when Wi-Fi (WLAN)
has a strong signal and is connected.
• Red: when an Ethernet (LAN) or Wi-Fi (WLAN) fault occurs.
• Blinking Red: during Wi-Fi (WLAN) association.
• Blinking Amber: during Wi-Fi (WLAN) authentication.
• Blinking Green: when Wi-Fi (WLAN) has completed, but has a weak signal.
60
7 • Pause Button — Pauses print and media movement actions.
• Pressing the Pause button will stop print activities and place the printer into a
‘Pause’ state. The printer will complete printing a label that is printing before it
pauses.
• The Pause indicator will display Amber (orange/yellow) to indicate the Pause
state.
• Pressing the Pause button while in Pause state will return the printer to normal
operation. If printing a multi label (form/format) job or another print job is
waiting to print in the print queue, then the printer will resume printing.
8 • FEED (Advance) Button — Advance a label (print form/format).
• Feed One Label - Pressing (and releasing) the FEED button when the printer
is not printing, causes the printer to advance media one (1) blank form/format
length (label, receipt, tag, ticket, etc.).
• Advance Multiple Labels - Pressing and Holding the FEED button when the
printer is not printing, causes the printer to advance labels until released. It
finishes advancing to the beginning position of the next label.
• Reprint Last Label (activated via a SGD command: ezpl.reprint_mode) -
The intended purpose of this feature is to allow reprint of a failed media print. If
the printer runs out of media (paper, labels, transfer ribbon, etc.), then the
printer can re-print the last label (print form/format). The print buffer that stores
the print image available for reprint is cleared when the printer gets turned off
or is reset.
9 • Cancel Button — Cancels print jobs.
• Only functional when the printer is in the Pause state.

• Pressing the Cancel button once causes the printer to cancel printing the
next format in the print buffer.
• Pressing and holding the button for two seconds cancels printing of ALL
pending formats.
61
LCD User Interface
Printers with the display provide the operator and integrator with readable printer status
and a menu system.
1 1 2
ZEBRA ZD620
PRINTER READY
3
V84.20.05ZP37288
168.192.0.1
4 4 1
1 • Standard Interface Controls — Provides visual and operational continuity for users
that use both styles of Zebra Link-OS printers.
2 • LCD Navigation Controller and Selector — Navigate through printer menus and
parameter settings on the LCD using the direction ARROW buttons to choose
printer settings and utility actions. Use the SELECT (Check-mark) button to items
that are highlighted (icons) or displayed as named menu items.
3 • Display — Displays printer status information and the printer configuration menu
system. The printer’s default screen information is shown. The top line has printer
model information and can be customized. The center area is for printer status
information and pop-up messages.
4 • Action Selectors — The action selector buttons, LEFT SELECT and

RIGHT SELECT, activates item highlighted white, like the Home icon (used to
activate the menu system). Pressing the LEFT SELECT button immediately below
the HOME icon will change the display to the Menu’s Home screen.
62
Meaning of the Indicator Light Patterns
All of the Link-OS 4 inch printers have status indicators. The indicators may be off or on in
a variety of lighting patterns of red, green, or amber (orange/yellow). The status indicators
can flash (blink), fade (bright to off), alternate between colors, or just remain on. The status
information that these lighting patterns represent is detailed in this section.
Indicator States
Steady-On Flashing Fade Off
Status - Typical Operating Conditions

Printer Ready
The printer is powered on and ready to print.
Pause
The printer is paused. The operator must press
the Pause button to resume print operations.
Media Out
The media (labels, receipts, tags, tickets, etc.)
supply is out. The printer needs attention and
cannot continue without user intervention.
Ribbon Out
Detected end of ribbon roll (reflective end on ribbon
rolls), a missing ribbon cartridge, or the ribbon
cartridge needs replaced to continue printing when
the printer is in thermal transfer mode.
Ribbon Low (Ribbon Cartridge Printers Only)

Default value is 10% of ribbon remaining. The
Media indicator flashes red and yellow while the
Status indicator is solid yellow.
63
Ribbon In (Ribbon Cartridge Printers Only)

thermal transfer printer is in Direct Thermal Mode
and has a ribbon cartridge installed. Remove the
ribbon cartridge to continue printing in direct
thermal mode.
Transferring Data
Data communications are in process.
Data Transfers Paused

A data communication operation has not finished,
but is not actively being transferred.
Out of Memory
Out of memory while storing content (formats,
graphics, fonts, etc.).
Cover Open/Printhead (PH) Open

The cover (printhead) is open. The printer needs
attention and cannot continue without user
intervention.
Cut Error (Binding)

The cutter blade is bound and is not moving
properly.
Cartridge Authentication Failed

The ribbon cartridge can not be authenticated or
has been altered. The printer only supports
Genuine Zebra Ribbon Cartridges and does not
support refurbished or non-Zebra cartridges.
64
Status - Printhead Operation

Hot Surface Caution • The printhead may be hot and could cause sever burns. Allow the printhead
to cool.
Printhead Over Temp

The printhead is over temperature and paused to
allow the printhead to cool. The print operation will
resume after the printhead has cooled.
Printhead Under Temp

The printhead is under temperature. Typically, the
operating environment is below the printer’s
minimum operational temperature.
Printhead Shutdown
The printhead is over temperature. Turn the
printer OFF. After several minutes to allow the
printer to completely cool, turn the printer ON.
Printhead Resolution Error

The printer is unable to read the printhead
resolution type (dpi). The printhead has been
replaced incorrectly or with non-Zebra printhead.
Unauthorized Printhead Error

The printhead was replaced with one that is not a
genuine Zebra printhead. Install a genuine Zebra
printhead to continue.
65
Status - Bluetooth Low Energy (BTLE) Option

Bluetooth LE Paired
Bluetooth Low Energy has paired.
Bluetooth LE Failed to Pair

Bluetooth Low Energy has failed to pair.
Status - Ethernet (LAN) Option

Ethernet (LAN) No Link
No Ethernet link is available. NETWORK status is
light off
Ethernet (LAN) 100base Link

A 100 Base link was found.
Ethernet (LAN) 10base Link

A 10 Base link was found.
Ethernet (LAN) Link Error

An error condition exists. The printer is not
connected to your network.
66
Status - Wi-Fi (WLAN) Option

Wi-Fi Connecting to WLAN
The light flashes red while the printer associates
with the network.
The light then flashes yellow while the printer is

authenticating with the network.f
Wi-Fi (WLAN) 100base Link

The printer is connected to your network and the
Wi-Fi signal is strong.
Wi-Fi (WLAN) 10base Link

The printer is connected to your network and the
Wi-Fi signal is weak.
Wi-Fi (WLAN) Link Error

An error condition exists. The printer is not
connected to your network.
67
Display Controls and Menus
ZD620 printer’s with the LCD User Interface provides the user printer status and a menu
system to configure the printer and run internal utilities. The printer is capable of displaying
messages in multiple languages.
ZEBRA ZD620
PRINTER READY
V84.20.05ZP37288
168.192.0.1
The printer’s default screen information is shown.

• The top line displays printer model information.
• The center area shows printer status information (customizable) and pop-up
messages.
• The two (2) bottom lines show the printer’s Firmware version and the printer’s IP
Address by default. This area can be customized to show different, user
selectable information. See IDLE DISPLAY for a more information.
• The bottom area below the white line are for Action items.
68
Navigating through Menu Display Screens

This section shows the following:
• The options available for navigating through the screens of the LCD User Inter-
face.
• How to select or modify things shown on the display.
Idle Display (Default Start-up Screen)
ZEBRA ZD620
PRINTER READY
V84.20.05ZP37288
168.192.0.1
• At the Idle Display, press LEFT SELECT or center SELECT (check-mark) to go to

the printer’s HOME menu.
Home Menu
ZEBRA ZD620
PRINTER READY
V84.20.05ZP37288
168.192.0.1
• To move from icon to icon in the Home menu, press any of the ARROW buttons.
• When an icon is selected, its colors are reversed to highlight it.
SETTING Menu Icon highlighted SETTING Menu Icon
• To select the highlighted menu icon and enter the menu, press the center Select
button.
69
BACK Button
• Press LEFT SELECT to exit the Home menu and return to the Idle Display. The
printer automatically returns to the Idle Display after 15 seconds of inactivity in the
Home menu.
• To scroll through the items in a user menu, press the LEFT ARROW or RIGHT
ARROW.
• Menu items with ▲ and ▼ on the far left and right sides of the display indicate that
a value can be changed. The value displayed is the setting.
• Press the UP ARROW or DOWN ARROW to scroll through accepted values. Any
changes that you make are saved immediately when you exit the menu item.
70
• MENU Shortcuts - When you reach the end of one menu, the next menu will be
displayed (an adjacent menu). To go to the next user menu from a menu shortcut,
press the SELECT (Checkmark) or press RIGHT SELECT to select the GO (go to
menu) action. The display will then display the first menu item of the newly
selected menu.
• A word in the bottom-right corner of the display indicates an available action.

• Press the SELECT (Checkmark) or press the RIGHT SELECT to perform the
action shown.
71
Printer Configuration Menus
This section presents the printer settings that you can change and identifies the tools for
changing them.
72
Adjust Printer Settings
These menu item settings and utilities descriptions include the following:
• The printer’s user menus
See the information that follows in this section.
• ZPL and Set/Get/Do (SGD) commands
See the Zebra® Programming Guide for more information.
• The printer’s web pages when the printer has an active wired or wireless print
server connection
See the Wired and Wireless Print Servers User Guide for more information.
Note • See About section for this manual, other information and support links for your
specific printer model.
User Menus
The user menus break the printer configuration into several task based menus. Click any
menu item to go to its description in the table. For navigation instructions, see Navigating
through Menu Display Screens.
73
SETTINGS TOOLS NETWORK BATTERY
— DARKNESS — PRINT — ACTIVE PRINT — BATTERY STAT

— PRINT SPEED INFORMATION** SERVER — LANGUAGE ME
— IDLE DISPLAY — PRIMARY NETWORK
— MEDIA TYPE
— POWER UP ACTION — WIRED IP ADDRESS
— PRINT METHOD
— HEAD CLOSE ACTION — WIRED SUBNET
— TEAR OFF
— LOAD DEFAULTS MASK
— PRINT WIDTH
— MEDIA/RIBBON CAL** — WIRED GATEWAY
— PRINT MODE
— DIAGNOSTIC MODE — WIRED IP PROTOCOL
— LABEL TOP
— ENERGY STAR — WIRED MAC
— LEFT POSITION
ADDRESS
— CONFIG INFO TO USB
— REPRINT MODE — WLAN IP ADDRESS
— ZBI ENABLED?
— LABEL LENGTH MAX — WLAN SUBNET MASK
— RUN ZBI PROGRAM
— LANGUAGE** — WLAN GATEWAY
— STOP ZBI PROGRAM
— TOOLS MENU* — WLAN IP PROTOCOL
— PRINT USB FILE
— WLAN MAC ADDRESS
— COPY USB FILE TO E:
— ESSID
— STORE E: FILE TO
USB — CHANNEL
— PRINT STATION — SIGNAL
— PASSWORD — IP PORT
PROTECT — IP ALTERNATE PORT
— APPLCTR ERR: — PRINT
PAUSE INFORMATION**
— PRINT TEST FORMAT — RESET NETWORK
— VISIBILITY AGENT
LANGUAGE SENSORS PORTS BLUETOOTH
— LANGUAGE** — SENSOR TYPE — BAUD RATE — BLUETOOTH

— COMMAND — MEDIA/RIBBON CAL** — DATA BITS ADDRESS
LANGUAGE — MODE
— PRINT — PARITY
— COMMAND CHAR INFORMATION** — DISCOVERY
— HOST HANDSHAKE
— CONTROL CHAR — LABEL SENSOR — CONNECTED
— WML
— DELIMITER CHAR — TAKE LABEL — BT SPEC VERS
— BLUETOOTH MENU*
— ZPL MODE — PORTS MENU* — MIN SECURITY
— VIRTUAL DEVICE — SETTINGS MEN
— SENSORS MENU*
* Denotes a shortcut to the next user menu.

**Appears in multiple user menus for your convenience.
74
SETTINGS Menu
DARKNESS
SETTINGS
— DARKNESS
— PRINT SPEED
— MEDIA TYPE
— PRINT METHOD
— TEAR OFF
— PRINT WIDTH
— PRINT MODE
— LABEL TOP
— LEFT POSITION
— REPRINT MODE
— LABEL LENGTH MAX
— LANGUAGE
Description: Set the print darkness to the lowest setting that provides good print quality.
If you set the darkness too high, the label image may not print clearly, barcodes may not
scan correctly, the ribbon may burn through, or the printhead may wear prematurely.
If desired, use the Print Quality Report (FEED self test) to determine the best darkness
setting.
Accepted values: 0.0 to 30.0
Related ZPL command(s): ^MD, ~SD
SGD command used: print.tone
Print Server web page: View and Modify Printer Settings > General Setup >
Darkness
75
PRINT SPEED
SETTINGS
— DARKNESS
— PRINT SPEED
— MEDIA TYPE
— PRINT METHOD
— TEAR OFF
— PRINT WIDTH
— PRINT MODE
— LABEL TOP
— LEFT POSITION
— REPRINT MODE
— LANGUAGE
Description: Select the speed, in inches per second (ips), for printing a label. Slower print
speeds typically yield better print quality.
Accepted values:
ZD620 203 dpi = 2 to 8 ips
ZD620 300 dpi = 2 to 6 ips
ZT420 203 dpi = 2 to 6 ips
ZT420 300 dpi = 2 to 4ips
Related ZPL command(s): ^PR
SGD command used: media.speed
Print Speed
76
MEDIA TYPE
SETTINGS
— DARKNESS
— PRINT SPEED
— MEDIA TYPE
— PRINT METHOD
— TEAR OFF
— PRINT WIDTH
— PRINT MODE
— LABEL TOP
— LEFT POSITION
— REPRINT MODE
— LANGUAGE
Description: Select the type of media that you are using.

Accepted values: CONTINUOUS, GAP/WEB, MARK/NOTCH
If you select CONTINUOUS, you must include a label length in your label format (^LL if you
are using ZPL). If you select GAP/WEB or MARK/NOTCH for various noncontinuous media,
the printer FEEDs media to calculate the label length.
Related ZPL command(s): ^MN
SGD command used: ezpl.media_type
Print Server web page: View and Modify Printer Settings > Media Setup >
Media Type
77
PRINT METHOD
SETTINGS
— DARKNESS
— PRINT SPEED
— MEDIA TYPE
— PRINT METHOD
— TEAR OFF
— PRINT WIDTH
— PRINT MODE
— LABEL TOP
— LEFT POSITION
— REPRINT MODE
— LANGUAGE
Description: Specify if the printer needs to use ribbon for printing.

Accepted values:
THERMAL TRANS—Uses ribbon and thermal transfer media.
DIRECT THERMAL—Uses direct thermal media and no ribbon.
Related ZPL command(s): ^MT
SGD command used: ezpl.print_method
Print Method
78
TEAR OFF
SETTINGS
— DARKNESS
— PRINT SPEED
— MEDIA TYPE
— PRINT METHOD
— TEAR OFF
— PRINT WIDTH
— PRINT MODE
— LABEL TOP
— LEFT POSITION
— REPRINT MODE
— LANGUAGE
Description: Adjusts the rest position of the media after a label is printed. The rest or stop
position sets where the tear-off point is on or between labels.
If necessary, shift the position of the media over the tear-off bar after printing.
• Lower numbers move the media into the printer by the specified number of dots
(the tear line moves closer to the edge of the label just printed).
• Higher numbers move the media out of the printer (the tear line moves closer to
the leading edge of the next label).
Accepted values: –120 to 120

Related ZPL command(s): ~TA
SGD command used: ezpl.tear_off
Tear Off
79
PRINT WIDTH
SETTINGS
— DARKNESS
— PRINT SPEED
— MEDIA TYPE
— PRINT METHOD
— TEAR OFF
— PRINT WIDTH
— PRINT MODE
— LABEL TOP
— LEFT POSITION
— REPRINT MODE
— LANGUAGE
Description: Specifies the width of the labels being used, in dots. The default value is the
maximum width for the printer, based on the printhead’s DPI value.
Accepted values:
ZD620 203 dpi = 0002 to 832 dots
ZD620 300 dpi = 0002 to 1280* dots
ZT420 203 dpi = 0002 to 832 dots
ZT420 300 dpi = 0002 to 1280* dots
*- EPL mode has a maximum default width of 1248 dots.
Related ZPL command(s): ^PW

SGD command used: ezpl.print_width
Print Width
Important • Setting the print width too wide wastes formatting memory. Printing off the sides of the
label and onto the platen roller may damage the platen.
Note • Setting the width too narrow can result in portions of a label format not being printed on the
media.
Note• This setting can affect the horizontal position of the label format if the image was inverted
using the ^POI ZPL II command.
80
PRINT MODE
SETTINGS
— DARKNESS
— PRINT SPEED
— MEDIA TYPE
— PRINT METHOD
— TEAR OFF
— PRINT WIDTH
— PRINT MODE
— LABEL TOP
— LEFT POSITION
— REPRINT MODE
— LANGUAGE
Description: Select a print mode that is compatible with your printer options. For
information about how the print mode selections work with different printer options, see
PRINT MODE.
Accepted values: TEAR-OFF, PEEL-OFF, CUTTER
Related ZPL command(s): ^MM
SGD command used: media.printmode
Print Mode
81
LABEL TOP
SETTINGS
— DARKNESS
— PRINT SPEED
— MEDIA TYPE
— PRINT METHOD
— TEAR OFF
— PRINT WIDTH
— PRINT MODE
— LABEL TOP
— LEFT POSITION
— REPRINT MODE
— LANGUAGE
Description: Shifts the position of the image vertically on the label if necessary.
• Negative numbers move the image higher on the label (toward the printhead).
• Positive numbers move the image farther down on the label (away from the
printhead) by the specified number of dots.

Related ZPL command(s): ^LT
SGD command used: media.printmode
Print Mode
82
LEFT POSITION
SETTINGS
— DARKNESS
— PRINT SPEED
— MEDIA TYPE
— PRINT METHOD
— TEAR OFF
— PRINT WIDTH
— PRINT MODE
— LABEL TOP
— LEFT POSITION
— REPRINT MODE
— LANGUAGE
Description: Shifts the position of the image horizontally on the label, if necessary.
• Negative numbers move the left edge of the image toward the left edge of the
label by the number of dots selected.
• Positive numbers move the edge of the image toward the right edge of the label.

Related ZPL command(s): ^LS
SGD command used: zpl.left_position
Left Position
83
REPRINT MODE
SETTINGS
— DARKNESS
— PRINT SPEED
— MEDIA TYPE
— PRINT METHOD
— TEAR OFF
— PRINT WIDTH
— PRINT MODE
— LABEL TOP
— LEFT POSITION
— REPRINT MODE
— LANGUAGE
Description: When reprint mode is enabled, you can reprint the last label printed by
pressing FEED button.
Accepted values: ON or OFF (default)
Related ZPL command(s): ^JZ
SGD command used: zpl.left_position
Print Server web page: Not supported at this time
84
LABEL LENGTH MAX

SETTINGS
— DARKNESS
— PRINT SPEED
— MEDIA TYPE
— PRINT METHOD
— TEAR OFF
— PRINT WIDTH
— PRINT MODE
— LABEL TOP
— LEFT POSITION
— REPRINT MODE
— LANGUAGE
Description: This setting controls the distance the printer utilities, like SmartCal, use to
automatically detect labels (black mark, notch or gap/web). If the printer does not detect
and calibrate the label, the printer assumes that continuous media is loaded.
1
3
1 — Label length (including inter-label gap)

2 — Inter-label gap
3 — Label length (1) plus an inch (25.4mm)
Set the value to the longest label used with the printer plus 1.0 inch (25.4 mm) greater than
the maximum length label. Ideally, use a value 2 times the max. label length plus an inch.
Accepted values: 1-39 (inches), 39 default
Related ZPL command(s): ^ML (^LL, ^PW)
SGD command used: ezpl.label_length_max
Print Server web page: View and Modify Printer Settings > Media Setup >
Maximum Length
85
TOOLS Menu
PRINT INFORMATION
TOOLS
— PRINT INFORMATION
— IDLE DISPLAY
— POWER UP ACTION
— HEAD CLOSE ACTION
— LOAD DEFAULTS
— MEDIA/RIBBON CAL
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— STORE E: FILE TO USB
— PRINT STATION
— PASSWORD PROTECT
— PRINT TEST FORMAT
Description: Print the selected information (1 of 7 choices) on one or more labels. This
menu item is available through three user menus with different default values for each.
Accepted values:
• SETTINGS—Prints a printer configuration label. A sample label is shown in Test
Printing with the Configuration Report.
• NETWORK—Prints the settings for any print server or Bluetooth device that is
installed.
• FORMATS—Prints the available formats stored in the printer’s RAM and Flash
memory.
• IMAGES—Prints the available images stored in the printer’s RAM and Flash
memory.
• FONTS—Prints the available fonts in the printer, including standard printer fonts
plus any optional fonts. Fonts may be stored in RAM and Flash memory.
• BARCODES—Prints the available barcodes in the printer. Barcodes may be stored
in RAM or Flash memory.
• ALL—Prints the previous six labels.
• SENSOR PROFILE—Shows the sensor settings compared to actual sensor
readings. To interpret the results, see Manual Media Calibration.
86
Related ZPL command(s):

• SETTINGS: ~WC
• NETWORK: ~WL
• SENSOR PROFILE: ~JG
• Others: ^WD
SGD command used: Not applicable
Print Server web page: View and Modify Printer Settings >
Print Listings on Label
Figure 1 • Sample Printer Figure 2 • Sample Network

Configuration Label Configuration Label
87
IDLE DISPLAY
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Select one of six information formats to display when the printer is idle.
Accepted values: FW VERSION, IP ADDRESS, MM/DD/YY 24 HR, MM/DD/YY 12 HR,
DD/MM/YY 24 HR, DD/MM/YY 12 HR
Related ZPL command(s): Not Applicable
SGD command used:
• device.idle_display_format
• device.idle_display_value
Print Server web page: Not Applicable
88
POWER UP ACTION
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Set the action for the printer to take during the power-up sequence.
Accepted values:
• CALIBRATE—Adjusts sensor levels and thresholds, determines the label length,
and FEEDs the media to the next web/gap.
• 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/gap.
• 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/gap.
• SHORT CAL—Sets the media and web thresholds without adjusting sensor gain,
determines the label length, and FEEDs the media to the next web/gap.
Related ZPL command(s): ^MF
SGD command used: ezpl.power_up_action
Print Server web page: View and Modify Printer Settings > Calibration
89
HEAD CLOSE ACTION
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Set the action for the printer to take when you close the printhead.
Accepted values:
• CALIBRATE—Adjusts sensor levels and thresholds, determines the label length,
and FEEDs the media to the next web.
• FEED—FEEDs the labels to the first registration point.
• LENGTH—Determines the label length using current sensor values, and FEEDs
the media to the next web.
• NO MOTION—Tells the printer not to move the media. 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/gap.
Related ZPL command(s): ^MF
SGD command used: ezpl.head_close_action
90
LOAD DEFAULTS
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Restore specific printer, print server, and network settings back to the factory
defaults. Use care when loading defaults because you will need to reload all settings that
you changed manually. This menu item is available through two user menus with different
default values for each.
Accepted values:
• 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 also reassociates with your wireless network.
• LAST SAVED—Loads settings from the last permanent save.
Related ZPL command(s):
• FACTORY: ^JUF
• NETWORK: ^JUN
• LAST SAVED: ^JUR
SGD command used: Not Applicable
• FACTORY: View and Modify Printer Settings > Restore Default Con-
figuration
• NETWORK: Print Server Settings > Reset Print Server
• LAST SAVED: View and Modify Printer Settings > Restore Saved Con-
figuration
91
MEDIA/RIBBON CAL
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Calibrate the printer to adjust the sensitivity of the media sensors.
Related ZPL command(s): ~JC
SGD command used: ezpl.manual_calibration
Print Server web page: The calibration procedure cannot be initiated through the web
pages.
92
DIAGNOSTIC MODE
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Use this diagnostics tool to cause the printer to output the hexadecimal
values for all data received by the printer. For more information, see Communication
Diagnostics Test.
Accepted values: DISABLED or ENABLED
Related ZPL command(s): ~JD to enable, ~JE to disable
SGD command used: device.diagnostic_print
Print Server web page: The calibration procedure cannot be initiated through the web
pages.
93
ZBI ENABLED?
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Zebra Basic Interpreter (ZBI 2.0™) is a programming option that may be
purchased for your printer. If you would like to purchase this option, contact your Zebra
reseller for more information.
Accepted values: NO or YES
SGD command used: zbi.key (identifies if the ZBI 2.0 option is enabled or disabled on
the printer)
94
RUN ZBI PROGRAM
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: This menu item appears only if ZBI is enabled on your printer. If ZBI
programs have been downloaded to your printer, you may select one to run using this
menu item. If no program exists on your printer, NONE is listed.
To run a ZBI program that you have downloaded to your printer:
1. Use the UP ARROW or DOWN ARROW to select a file from this menu.
2. Press RIGHT SELECT to select RUN. If no program exists, the RUN option does not
perform an action.
Accepted values: NONE or PROGRAM FILE NAMES

Related ZPL command(s): ^JI, ~JI
SGD command used: zbi.control.run
Print Server web page: Printer Home Page > Directory Listing
95
STOP ZBI PROGRAM
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: This menu item appears only if ZBI is enabled on your printer. Use this menu
item to stop a ZBI program. The printer lists only programs that are running.
To stop a ZBI program:
1. If necessary, use the UP ARROW or DOWN ARROW to select the file from this
menu.
2. Press RIGHT SELECT to select STOP.
Accepted values: NONE or PROGRAM FILE NAMES

Related ZPL command(s): ~JQ
SGD command used: zbi.control.terminate
Print Server web page: Printer Home Page > Directory Listing
96
PRINT USB FILE
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Select files to print from a USB Flash drive. See the exercises in Using the
USB Hosts Port and the NFC Capabilities for an exercise using this capability.
To print files from a USB Flash drive:
1. Insert a USB Flash drive into the printer’s USB host port.
2. The printer lists available files. SELECT ALL is available to print all available files on
the USB Flash drive.
4. Press RIGHT SELECT to select PRINT.
Accepted values: NONE, SELECT ALL or PROGRAM FILE NAMES

Related ZPL command(s): Not Applicable
SGD command used: usb.host.read_list
97
COPY USB FILE TO E:
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Select files to copy to the printer from a USB Flash drive. See the exercises
in Using the USB Hosts Port and the NFC Capabilities on page 261 for an exercise using this
capability.
To copy files to the printer from a USB Flash drive:
1. Insert a USB flash drive into the printer’s USB host port.
2. The printer lists available files. SELECT ALL is available to copy all available files from
the USB Flash drive.
4. Press RIGHT SELECT to select STORE.

SGD command used: usb.host.read_list
98
STORE E: FILE TO USB
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Select files from the printer to store on a USB Flash drive. See the exercises
in Using the USB Hosts Port and the NFC Capabilities on page 261 for an exercise using this
capability.
To copy files from the printer to a USB Flash drive:
1. Verify that a USB flash drive into the printer’s USB host port.
2. The printer lists available files. SELECT ALL is available to store all files available files
from the printer on the USB Flash drive.
4. Press RIGHT SELECT to select STORE.

SGD command used: usb.host.write_list
99
PRINT STATION
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Use this menu item to fill in variable fields in a label format and print the label
using a Human Input Device (HID), such as a USB keyboard, scale, or barcode scanner.
A suitable label format must be stored on the E: drive of the printer to use this option. See
the exercises in USB Host Port and Link-OS Demonstration Examples for an exercise
using this capability.
When you plug an HID into one of the printer’s USB host ports, use this user menu to select
a form on the printer’s E: drive. After you have been prompted to fill in each variable ^FN
field on the form, you can specify the desired quantity of labels to print.
For more information about using the ^FN command or the SGD commands related to this
feature, refer to the Zebra Programming Guide. You can download a copy of the manual from:
www.zebra.com/manuals/.
Accepted values: NO INPUT DEVICE FOUND, NONE, or PROGRAM FILE NAMES
SGD command used:
• usb.host.keyboard_input (must be set to ON)
• usb.host.template_list
• usb.host.fn_field_list
• usb.host.fn_field_data
• usb.host.fn_last_field
• usb.host.template_print_amount
100
PASSWORD PROTECT
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ENERGY STAR
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Select the level of password protection for user menu items. The default
printer password is 1234.
Accepted values: NONE, SELECTED, ALL
Related ZPL command(s): ^KP (to change the printer password)
101
PRINT TEST FORMAT
TOOLS
— IDLE DISPLAY
— POWER UP ACTION
— LOAD DEFAULTS
— DIAGNOSTIC MODE
— ZBI ENABLED?
— RUN ZBI PROGRAM
— PRINT USB FILE
— PRINT STATION
Description: Use this menu item to initiate test sequences that print specific types of
labels to help you troubleshoot printing issues.
Accepted values:
• DARKNESS—Runs a repeated image in incrementing darkness levels.
• FIRST DOT LOCATION—Identifies the first dot location and label top to assist you
with adjusting the position of the label.
• PRINT LINE—Initiates a test sequence.
• IMAGE COMPRESSION—Prints an image with lines and circles to assist with issues
regarding compression or stretching of an image.
• ELEMENT OUT—Prints a horizontal image designed to show if a printhead element
is not functioning.
SGD command used:
print.troubleshooting_label_choices (specifies the type of label)
print.troubleshooting_label_print (prints the label)
102
NETWORK
ACTIVE PRINT SERVER
NETWORK
— ACTIVE PRINT SERVER
— PRIMARY NETWORK
— WIRED IP ADDRESS
— WIRED SUBNET MASK
— WIRED GATEWAY
— WIRED IP PROTOCOL
— WIRED MAC ADDRESS
— WLAN IP ADDRESS
— WLAN SUBNET MASK
— WLAN GATEWAY
— WLAN IP PROTOCOL
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— IP ALTERNATE PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: View whether the WIRED or WIRELESS print server is currently active.
103
PRIMARY NETWORK
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: View or modify whether the WIRED or WIRELESS print server is considered
primary. You may select which one is primary.
Accepted values: WIRED or WIRELESS
SGD command used: ip.primary_network
104
WIRED IP ADDRESS
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: View and, if necessary, change the printer’s Wired IP Address.

To save changes to this setting, set WIRED IP PROTOCOL to PERMANENT, and then
reset the print server (see RESET NETWORK).
Accepted values: 000 to 255 for each field
Related ZPL command(s): ^ND
SGD command used: internal_wired.ip.addr
Printer Web page: View and Modify Printer Settings > Network Communications
Setup > TCP/IP Settings
105
WIRED SUBNET MASK
NETWORK

— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: View and, if necessary, change the wired subnet mask.

SGD command used: internal_wired.ip.netmask

106
WIRED GATEWAY
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: View and, if necessary, change the default wired gateway.

SGD command used: internal_wired.ip.gateway
Printer Web page: View and Modify Printer Settings > Network Communications Setup >
TCP/IP Settings
107
WIRED IP PROTOCOL
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: This parameter indicates if the Net Administrator/User (permanent) or the

server (dynamic) selects the Wired print server’s IP address. When a dynamic option is
chosen, this parameter tells the method(s) by which this print server receives the IP
address from the server.
Important • The print server must be reset to allow changes to the network settings to take effect.
Accepted values:
• ALL
• GLEANING ONLY
• RARP
• BOOTP
• DHCP
• DHCP & BOOTP
• PERMANENT
SGD command used: internal_wired.ip.protocol
108
WIRED MAC ADDRESS
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: View the Media Access Control (MAC) address of the wired print server.
SGD command used: internal_wired.mac_addr
TCP/IP Settings
109
WLAN IP ADDRESS
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: View and, if necessary, change the printer’s Wireless IP address.

To save changes to this setting, set WLAN IP PROTOCOL to PERMANENT, and then
SGD command used: ip.addr, wlan.ip.addr
Wireless Setup
110
WLAN SUBNET MASK
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: View and, if necessary, change the Wireless subnet mask.

To save changes to this setting, set WLAN IP PROTOCOL to PERMANENT, and then reset
the print server (see RESET NETWORK).
SGD command used: wlan.ip.netmask
Wireless Settings
111
WLAN GATEWAY
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: View and, if necessary, change the default wireless gateway.

To save changes to this setting, set WLAN IP PROTOCOL to PERMANENT, and then
SGD command used: wlan.ip.gateway

Wireless Setup
112
WLAN IP PROTOCOL
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: This parameter indicates if the Net Administrator/User (permanent) or the

server (dynamic) selects the Wireless print server’s IP address. When a dynamic option is
chosen, this parameter tells the method(s) by which this print server receives the IP
address from the server.
Accepted values: ALL, GLEANING ONLY, RARP, BOOTP, DHCP, DHCP & BOOTP,
PERMANENT
SGD command used: wlan.ip.protocol
Wireless Setup
113
WLAN MAC ADDRESS
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: View the Media Access Control (MAC) address of the wireless print server.
SGD command used: wlan.mac_addr
Wireless Setup
114
ESSID
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: The Extended Service Set Identification (ESSID) is an identifier for your
wireless network. This setting, which cannot be modified from the user interface, gives the
ESSID for the current wireless configuration.
Accepted values: 32-character alphanumeric string (default 125)
SGD command used: wlan.mac_addr
Wireless Setup
115
CHANNEL
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: View the wireless channel being used when the wireless network is active
and authenticated.
SGD command used: wlan.channel
Wireless Setup
116
SIGNAL
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: View the wireless signal strength when the wireless network is active and
authenticated.
SGD command used: wlan.signal_strength
Wireless Setup
117
IP PORT
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: This printer setting refers to the internal wired print servers port number that
the TCP print service is listening on. Normal TCP communications from the host should be
directed to this port.
SGD command used: internal_wired.ip.port
TCP/IP Settings
118
IP ALTERNATE PORT
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: This command sets the port number of the alternate TCP port.
SGD command used: internal_wired.ip.port_alternate
TCP/IP Settings
Note • Print servers supporting this command will monitor both the primary port and the
alternate port for connections at the same time.
119
RESET NETWORK
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: This option resets the wired or wireless print server and saves any changes
that you made to any network settings.
Related ZPL command(s): ~WR

SGD command used: device.reset
Print Server web page: Print Server Settings > Reset Print Server
120
VISIBILITY AGENT
NETWORK
— PRIMARY NETWORK
— WIRED GATEWAY
— WLAN IP ADDRESS
— WLAN GATEWAY
— ESSID
— CHANNEL
— SIGNAL
— IP PORT
— RESET NETWORK
— LOAD DEFAULTS
Description: When the printer is connected to a wired or wireless network, it will attempt
to connect to Zebra’s Asset Visibility Service via the Cloud-based Zebra Printer Connector
using an encrypted, certificate-authenticated web socket connection. The printer sends
Discovery Data and Settings and Alerts Data. Data printed via any label formats is NOT
transmitted.
To opt out of this feature, disable this setting. For more information, see the “Opting Out of
the Asset Visibility Agent” application note at http://www.zebra.com.
Accepted values: ON or OFF
SGD command used: weblink.zebra_connector.enable
Printer Web page: View and Modify Printer Settings > Network Configuration >
Cloud Connect Settings
121
BATTERY Menu
BATTERY STATUS
BATTERY
— BATTERY STATUS
Description: Display the status of the Battery subsystem of the printer. The battery is not
available at the time of publication.
Accepted values: BATTERY NOT PRESENT
122
LANGUAGE Menu
LANGUAGE
LANGUAGE
— LANGUAGE
— COMMAND LANGUAGE
— COMMAND CHAR
— CONTROL CHAR
— DELIMITER CHAR
— ZPL MODE
— VIRTUAL DEVICE
Description: Change the language that the printer displays as necessary. This change
affects the text shown on the following:
• the Home menu
• the user menus
• error messages
• the printer configuration label, the network configuration label, and other labels
that you can select to print through the user menus
Accepted values: ENGLISH, SPANISH, FRENCH, GERMAN, ITALIAN, NORWEGIAN,

PORTUGUESE, SWEDISH, DANISH, SPANISH 2, DUTCH, FINNISH, CZECH, JAPANESE, KOREAN,
ROMANIAN, RUSSIAN, POLISH, SIMPLIFIED CHINESE, TRADITIONAL CHINESE
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.
Related ZPL command(s): ^KL
SGD command used: display.language
Language
123
COMMAND LANGUAGE
LANGUAGE
— LANGUAGE
— COMMAND CHAR
— CONTROL CHAR
— DELIMITER CHAR
— ZPL MODE
— VIRTUAL DEVICE
Description: The setting allows you to control the primary programming language
variations available, such as, EPL_ZPL, EPL (legacy language), and Hybrid_XML_ZPL
(used for format/form variable fill-in with XML structured elements).
Acceptable values:
• EPL_ZPL (EZPL)
• Hybrid_XML_ZPL
• EPL
124
COMMAND CHAR
LANGUAGE
— LANGUAGE
— COMMAND CHAR
— CONTROL CHAR
— DELIMITER CHAR
— ZPL MODE
— VIRTUAL DEVICE
Description: This menu item is used to change the format command prefix. The format
command prefix is an ASCII (two-digit hexadecimal value shown in parenthesis) used as
a parameter place marker in ZPL/ZPL II format instructions. The printer looks for this
command character to indicate the start of a ZPL/ZPL II format instruction.
Set the format command character to match what is used in your label formats.
Important • You cannot use the same hexadecimal value for the format command prefix, control
character, or delimiter characters. The printer must see different characters to work properly. If you
are setting the value through the interface, the printer will skip any value that is already in use.
Acceptable values: 00 to FF hexadecimal

Related ZPL command(s): ^CC or ~CC
SGD command used: zpl.caret
Print Server web page: View and Modify Printer Settings > ZPL Control
125
CONTROL CHAR
LANGUAGE
— LANGUAGE
— COMMAND CHAR
— CONTROL CHAR
— DELIMITER CHAR
— ZPL MODE
— VIRTUAL DEVICE
Description: This menu item is used to change the control command prefix. The default
prefix is the tilde (~). The printer looks for this character to indicate the start of a ZPL/ZPL
II command. Set the format prefix character to match what is used in your label formats.
The control command prefix is an ASCII (two-digit hexadecimal value shown in
parenthesis) used as a parameter place marker in ZPL/ZPL II control instructions.
Important • You cannot use the same hex value for the format command prefix, control character,
and delimiter characters. The printer must see different characters to work properly. If you are
setting the value through the interface, the printer will skip any value that is already in use.

Related ZPL command(s): ^CT or ~CT
SGD command used: zpl.control_character
126
DELIMITER CHAR
LANGUAGE
— LANGUAGE
— COMMAND CHAR
— CONTROL CHAR
— DELIMITER CHAR
— ZPL MODE
— VIRTUAL DEVICE
Description: This menu item is used to separate command parameters (command

delimiter). The default prefix is the comma (,). The printer looks for this character to
separate parts of ZPL/ZPL II commands. Set the delimiter character to match what is used
in your label formats.
The delimiter command prefix is an ASCII (two-digit hexadecimal value shown in
parenthesis) used as a parameter place marker in ZPL/ZPL II control instructions.
Important • You cannot use the same hex value for the format command prefix, control character,
and delimiter characters. The printer must see different characters to work properly. If you are
setting the value through the interface, the printer will skip any value that is already in use.

Related ZPL command(s): ^CD or ~CD
SGD command used: zpl.delimiter
127
ZPL MODE
LANGUAGE
— LANGUAGE
— COMMAND CHAR
— CONTROL CHAR
— DELIMITER CHAR
— ZPL MODE
— VIRTUAL DEVICE
Description: Select the mode that matches what is used in your label formats. This printer
accepts label formats written in either ZPL or ZPL II, eliminating the need to rewrite any
ZPL formats that already exist. The printer remains in the selected mode until it is changed
in one of the ways listed here.
Acceptable values: ZPL II or ZPLl
Related ZPL command(s): ^SZ
SGD command used: zpl.zpl_mode
128
VIRTUAL DEVICE
LANGUAGE
— LANGUAGE
— COMMAND CHAR
— CONTROL CHAR
— DELIMITER CHAR
— ZPL MODE
— VIRTUAL DEVICE
Description: If any Link-OS Virtual Device apps are installed on your printer, you may
view or enable/disable them from this user menu. For more information about Virtual
Devices, go to the User Guide for the appropriate Virtual Device, or contact your local
reseller.
129
SENSORS
SENSOR TYPE
SENSORS
— SENSOR TYPE
— LABEL SENSOR
— TAKE LABEL
Description: Select the media sensor that is appropriate for the media that you are using.
The reflective sensor typically is used only for black mark media. The transmissive sensor
typically is used for other media types.
Acceptable values: TRANSMISSIVE or REFLECTIVE
Related ZPL command(s): ^JS
SGD command used: device.sensor_select
Print Server web page: View and Modify Printer Settings > Media Setup
130
LABEL SENSOR
SENSORS
— SENSOR TYPE
— LABEL SENSOR
— TAKE LABEL
Description: Set the sensitivity of the label sensor.

Important • This value is set during sensor calibration. Do not change this setting unless you
are told to do so by Zebra Technical Support or by an authorized service technician.
Acceptable values: 0 to 255
SGD command used: ezpl.label_sensor
131
TAKE LABEL
SENSORS
— SENSOR TYPE
— LABEL SENSOR
— TAKE LABEL
Description: Set the intensity of the label taken sensor circuit.

Important • This value is set during sensor calibration. Do not change this setting unless you
are told to do so by Zebra Technical Support or by an authorized service technician.
Acceptable values: 0 to 255
SGD command used: ezpl.take_label
132
PORTS
BAUD RATE
PORTS
— BAUD RATE
— DATA BITS
— PARITY
— HOST HANDSHAKE
— WML
Description: Select the baud value that matches the one being used by the host
computer.
Acceptable values: 115200, 57600, 38400, 28800, 19200, 14400, 9600, 4800
Related ZPL command(s): ^SC
SGD command used: comm.baud
Serial Communications Setup
133
DATA BITS
PORTS
— BAUD RATE
— DATA BITS
— PARITY
— HOST HANDSHAKE
— WML
Description: Select the data bits value that matches the one being used by the host
computer.
Acceptable values: 7 or 8
SGD command used: comm.data_bits
134
PARITY
PORTS
— BAUD RATE
— DATA BITS
— PARITY
— HOST HANDSHAKE
— WML
Description: Select the parity value that matches the one being used by the host
computer.
Acceptable values: NONE, EVEN, ODD
SGD command used: comm.parity
135
HOST HANDSHAKE
PORTS
— BAUD RATE
— DATA BITS
— PARITY
— HOST HANDSHAKE
— WML
Description: Select the handshake protocol that matches the one being used by the host
computer.
Acceptable values: XON/XOFF, RTS/CTS, DSR/DTR
SGD command used: comm.handshake
136
WML
PORTS
— BAUD RATE
— DATA BITS
— PARITY
— HOST HANDSHAKE
— WML
Description: View the Wireless Markup Language (WML) version. This value cannot be
changed.
137
BLUETOOTH
BLUETOOTH ADDRESS
BLUETOOTH
— BLUETOOTH
ADDRESS
— MODE
— DISCOVERY
— CONNECTED
— BT SPEC VERSION
— MIN SECURITY MODE
Description: View the printer’s Bluetooth MAC Address

SGD command used: bluetooth.address
138
MODE
BLUETOOTH
— BLUETOOTH ADDRESS
— MODE
— DISCOVERY
— CONNECTED
— BT SPEC VERSION
Description: View the Bluetooth connection pair printer’s device type—Slave (typical) or
Master.
139
DISCOVERY
BLUETOOTH
— MODE
— DISCOVERY
— CONNECTED
— BT SPEC VERSION
Description: Select if the printer is “Discoverable” for Bluetooth device pairing.

Acceptable values:
• ON—Enables Bluetooth discoverable mode.
• OFF—Disables Bluetooth discoverable mode.
SGD command used: bluetooth.discoverable
140
CONNECTED
BLUETOOTH
— MODE
— DISCOVERY
— CONNECTED
— BT SPEC VERSION
Description: View the Bluetooth connection status to its paired device (Yes or No).
141
BT SPEC VERSION
BLUETOOTH
— MODE
— DISCOVERY
— CONNECTED
— BT SPEC VERSION
Description: View the Bluetooth operational specification level.

SGD command used: bluetooth.radio_version
142
MIN SECURITY MODE
BLUETOOTH
— MODE
— DISCOVERY
— CONNECTED
— BT SPEC VERSION
Description: View the printer’s Bluetooth minimum level of applied security.
143
Setup
This section assists you in setting up and operating your printer. The setup process to can
be broken down into two (2) phases: hardware setup and host system (software/driver)
setup. This section covers the physical hardware setup needed to print your first label.
Printer Setup Overview

• Install any printer hardware options first. See Install Hardware Options.
• Place the printer in a safe location with access to power and where you can con-
nect interface cables or wirelessly to the system.
• Attach the printer and power supply to a grounded AC power source.
• Select and prepare media for your printer.
• Load the media.
• Turn the printer ON. Calibrate the media with a SmartCal Media calibration.
• Print a ‘Configuration Report’ to verify basic printer operation.
• Turn the printer OFF.
• Choose method to communicate via a wired or wireless connection to your printer.
Available wired local connections are:
• USB port
• Optional Serial port
• Optional Ethernet (LAN)
• Attach the printer cable to the network or host system (printer OFF).
• Begin second phase of printer setup: typically Setup for Windows® OS.
144
Setup
Select a Location for the Printer
The printer and media need a clean safe area with moderate temperatures to have optimal
print operations.
Select a location for the printer that meets these conditions:
• Surface: The surface where the printer will be located must be solid, level, and of
sufficient size and strength to hold the printer with media.
• Space: The area where the printer will be located must include enough space for
opening the printer (media access and cleaning), and for printer access to con-
nectivity and power cords. To allow for proper ventilation and cooling, leave open
space on all sides of the printer.
Important • Do not place any padding or cushioning material under or around the base of
the printer because this restricts air flow and could cause the printer to overheat.
• Power: Put the printer close to an easily accessible power outlet.
• Data Communication Interfaces: Please ensure that cabling and Wi-Fi or Blue-
tooth radios do not exceed the maximum distance specified by the communication
protocol standard or product data sheet for this printer. Radio signal strength can
be reduced by physical barriers (objects, walls, etc.).
• Data Cables: Cables should not be routed with or near power cords or conduits,
fluorescent lighting, transformers, microwave ovens, motors or other sources of
electrical noise and interference. These interference sources may cause problems
with communications, host system operation, and printer functionality.
• Operating Conditions: Your printer is designed to function in a wide range of
environments.
• Operational Temperature: 32° to 104°F (0° to 40°C)
• Operational Humidity: 20 to 85% non-condensing
• Non-Operational Temperature: -40° to 140°F (-40° to 60°C)
• Non-Operational Humidity: 5 to 85% non-condensing
145
Setup
Install Printer Options and Connectivity Modules
Install the following printer options before proceeding with the printer’s setup.
• Serial (RS-232 DB-9) Port Module - Installing the Serial Port Module
• Internal Ethernet (LAN) Module - Installing the Internal Ethernet (LAN) Module
• Label Dispenser (Peel-Off Liner and Present Label for Operator) - Installing the
Label Dispenser
• Linerless media cutter - Installing the Standard Media Cutter
• Linerless Media Tear-Off bezel- Installing the Label Dispenser
• General purpose media cutter - Installing the Standard Media Cutter
• Media Roll Core Size Adapters for 38.1 mm (1.5 inch), 50.8 mm (2.0 inch), or 76.2
(3.0 inch) I.D. media cores.
• Print Resolution Upgrade Kits (200 and 300 dpi for standard and Linerless media)
146
Setup
Attaching Power
Caution • Never operate the printer and power supply in an area where they can get wet.
Serious personal injury could result!
Note • Set up your printer so that you can handle the power cord easily if needed. Some
processes for setup or troubleshooting issues may ask you to remove power. Separate the
power cord from the power supply receptacle or AC electrical outlet to make certain the
printer cannot carry electrical current.
1. Plug the power supply into the printer’s DC power receptacle.
2. Insert the AC power cord into the power supply.
3. Plug the other end of the AC power cord into an appropriate AC electrical outlet. Note
that AC outlet end of the power cord’s plug type can vary by region.
4. The active power light will turn on green if power is on at the AC outlet.
Important • Ensure the appropriate power cord with a three (3) prong plug and an
IEC 60320-C13 connector are used at all times. These power cords must bear the relevant
certification mark of the country in which the product is being used.
147
Setup
Getting Ready to Print
The printer setup cannot be completed without media. The media may be labels, tags,
tickets, receipt paper, fan-fold stacks, tamper proof labels, etc. Ideally choose the same
media used for normal operation. This will help you identify any setup and real application
issues while using this guide. The printer does not come with media.
The Zebra Web site or your reseller may be able to help you select the right media for your
intended printing application. Find media at: www.zebra.com/supplies
Preparing and Handling Media

Careful handing and storage of your media is important in order to maximize print quality.
If the media becomes contaminated or dirty, it can damage the printer and cause defects
in the printed image (voids, streaks, discoloration, compromise the adhesive, etc.).
Important • During manufacturing, packaging, handling and storage, the outside length of
media may become dirty or contaminated. We recommend removing the outside layer of
the media roll or stack. This will remove any contaminants which might be transferred onto
the printhead during normal operation.
Media Storage Tips

• Store media in a clean, dry, cool, dark area. Direct thermal media is chemically
treated to be heat sensitive. Direct sunlight or heat sources may ‘expose’ the
media.
• Do not store media with chemicals or cleaning products.
• Leave media in its protective packaging until it is going to be put in the printer.
• Many media types and label adhesives have a ‘shelf life’ or expiration date.
Always use the oldest, viable (non-expired) media first.
Loading Roll Media
All of the ZD620 and ZD420 4 inch Link-OS printers load print media rolls the same. The
printers support the three basic types of media:
• Continuous (receipt, etc.) with no marks to define print length,
• Marked media (black lines, black marks, notches, or holes) to define print length
• Label media that uses the sensor to look through the media backing (liner) to see
the beginning and end of labels on the roll.
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Setup
The printer utilizes two (2) sensing methods to accommodate a wide range of media
• Center area transmissive sensing for continuous media and gap/web label media.
• Full-width reflective sensing for print format (length) using black marks, black
lines, notches or holes.
Setting Media Sensing by Media type

• For web/gap media, the printer senses the differences between the label and the
liner to determine the print format length.
• For continuous roll media, the printer only senses the media’s characteristics.
The print format’s length is set by programming (driver or software) or the last
stored form’s length.
• For black mark media, the printer senses the beginning of the mark and the dis-
tance to the start of the next black mark to measure the print format length.
• For other common media and setting variations, see one of the following:
• Using the Label Dispenser Option after you have loaded media using this
procedure.
• See Printing on Fan-Fold Media
149
Setup
Instructions for media loading:

This procedure works for Tear-Off (standard bezel), Label Dispense and Media Cutting
printer options.
1. Open the printer. Pull the release latch levers toward the front of the printer.
2. Open the media roll holders. Orient the media roll so that its printing surface will face
up as it passes over the platen (drive) roller. Pull the media guides open with your free
hand and place the media roll on the roll holders and release the guides. Verify the
roll turns freely. The roll must not sit in the bottom of the media compartment.
150
Setup
3. Pull the media so that it extends out of the front of the printer.
4. Push the media under both of the media guides.
151
Setup
5. Flip the media up and align the movable media sensor for your media type.
• For continuous roll receipt type media or label media without black marks
or notches, align the media to the default center position.
• For black mark (black line, notches or holes) backed media, adjust the
sensor position so the sensor aligns to the center of the black mark. Avoid the
center area of the media to only use black mark sensing for operation with
black marks.
Default - Web (Gap) Sensing

Standard Operating Position
Off Center
Black Mark Sensing Only
152
Setup
Using the Movable Sensor

The movable sensor is a dual function sensor. It provides transmissive (sees through
media) and reflective media sensing. The printer can use either sensing method, but not
both at the same time.
The movable sensor has a center array of sensors. This provides adjustable transmissive
web (gap) sensing to positions that match legacy Zebra® desktop printer sensor locations
and positions in between. This also provides for use of some atypical media variations or
irregularly shaped media.
The movable sensor allows the printer to use media with black marks or notches (holes
through the media) on the back side of the media (or media liner). The sensor aligns to the
middle of black marks or notches not in the center of the media roll to avoid Web/Gap
sensing array.
Adjusting the Movable Sensor for Black Marks or Notches
The black mark sensing looks for non-reflective surfaces such as black marks, black lines,
notches or holes on the back of the media which do not reflect the sensor’s near infrared
light beam back to the sensor’s detector. The sensor light and its black mark detector are
next to each other under the sensor cover.
Position the movable sensor’s alignment arrow to the middle of the black mark or notch in
the underside of the media. Sensor alignment should be set as far as possible from the
edge of media but where 100% of the sensor window is covered by the mark. When
printing, the media can move from side to side ±1mm (due to media variations and edge
damage due to handling). Notches cut into the side of the media can also become
damaged.
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Setup
Adjusting the Movable Sensor for Web (Gap) Sensing
The movable sensor for web/gap sensing supports multiple positions.

• The movable sensor’s ‘Default’ position is ideal for most label types.
• The adjustment range is ‘from center’ to ‘off-center’ positions which are ideal for
printing two (2) labels side by side on a roll.
• The movable sensor adjustment range covers sensor positions use by legacy
Zebra printers.
• Web (Gap) sensing with the movable sensor only functions when the movable
sensor’s alignment arrow points to any position on the alignment key.
Alignment Key
Alignment Arrow
(Default Position)
Center Line - CL Default Gap
Sensing Position
Adjustment Range - Left to Right
Center Aligned Default Maximum Right
CL CL CL
Zebra Printer Models Fixed Sensor Position Relative to a ZD-Series Printer
• Default — Zebra Models: G-Series ™ fixed position sensors, LP/TLP 2842 ™ ,

LP/TLP 2844 ™ , LP/TLP 2042 ™
• Center Aligned — Zebra Model: LP/TLP 2742 ™
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Setup
Loading Roll Media (continued)

1. Cutter Models - For printers with the optional cutter module installed, thread the
media through cutter’s media slot and pull it out the front of the printer.
2. Close the printer. Press down until the cover snaps closed.
You may need a calibrate your printer for the media. The printer’s sensors need to adjust
to sense the label, the liner, and the distance between labels to operate properly. When
reloading the same media (size, vendor, and batch), you can just press the FEED
(Advance) button once to prepare the media for printing.
155
Setup
Loading Thermal Transfer Roll Ribbon
The ZD620 and ZD420 thermal transfer printers have a flexible ribbon system. It supports
300 meter and 74 meter genuine Zebra® ribbons. The printer includes 300 meter ribbon
adapters for non-Zebra ribbon rolls. 74 meter ribbon from non-Zebra printers does not
need the Non-Zebra ribbon adapters to operate properly.
Transfer ribbons come in several varieties and in some cases colors to match your
application needs. Genuine Zebra® transfer ribbons are specifically designed for your
printer and Zebra brand media. Using non-Zebra media or ribbons not approved for use in
your Zebra® printer may damage your printer or printhead.
• The media and ribbon types should be matched to provide you with optimal print
results.
• Always use ribbon that is wider than the media to protect the printhead from wear.
• For direct thermal printing, do not load ribbon in the printer.
• Always use an empty ribbon core that matches your transfer ribbon roll’s inner
diameter (I.D.). Ribbon wrinkling and other print problems can occur.
Your printer needs to use genuine Zebra® ribbons that have a ribbon out trailer (reflector)
to stop printing when roll of transfer ribbon has been used up. Genuine Zebra® ribbons and
ribbon cores also include notches used to maintain positive ribbon roll engagement and
drive without slipping while printing.
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Setup
Genuine Zebra® ribbons for this printer include:

• Performance Wax
• Premium Wax/Resin
• Performance Resin for synthetics (6 ips max. speed) and coated paper (4 ips
max. speed)
• Premium Resin for synthetics (4 ips max. speed)
For transfer ribbon rolls and other printing supplies, see
Important • 74 Meter Ribbons - DO NOT USE early model desktop printer ribbon cores!
The older style ribbon cores (and some Non-Zebra ribbons) can be identified by notches
on only one side of the ribbon core. These older cores are too large.
Important • DO NOT USE ribbon cores with damaged notches - rounded, frayed,
smashed, etc. The core notches should be square to lock the core on the spindle or the
core may slip causing ribbon wrinkle, poor end of ribbon sensing or other intermittent
failures.
Loading Zebra Transfer Roll Ribbon

Before following these steps, prepare the ribbon by removing its wrapping and pulling its
adhesive strip free.
Notch
(Required on left
side of ribbon)
Right Side
Adhesive Strip (printer and roll)
Notches are also

on right side of the
74m ribbon
Verify that the ribbon and empty ribbon core have notches on the left side of the ribbon
cores as shown above. If they do not, see Loading Non-Zebra 300 Meter Transfer Ribbon.
3. With the printer open, place an empty ribbon core on printer’s take-up spindles. Push
the right side of the empty core onto the spring loaded spindle (right side). Align the
core with the center of the left side spindle’s hub and rotate the core until the notches
align and lock.
Note • You can find your first ribbon take-up core in the packing box. Subsequently, use
the empty supply core from the supply spindle for the next roll of ribbon.
157
Setup
1. Place a new ribbon roll on printer’s lower ribbon supply spindle. Push it onto the right
spindle and lock the left side the same as the take-up mounting the take-up core.
74m
300m
158
Setup
2. Attach the ribbon to the take up core. Use the adhesive strip on new rolls; otherwise,
use a thin strip of tape. Align the ribbon so that it will be taken straight onto the core.
3. Turn the ribbon take-up hub with the top moving toward rear to remove slack from the
ribbon. Rotating the hub helps to finish aligning the take up ribbon position to the
supply ribbon roll. The ribbon leader should be completely covered by the ribbon.
4. Verify that the media is loaded and ready to print and then close the printer cover.
159
Setup
5. If printer power is on, press the FEED button to have the printer advance a minimum
of 20 cm (8 inches) of media to remove slack and ribbon wrinkle (straightens the
ribbon), and to align the ribbon on the spindles. Otherwise, wait to turn on the printer
and complete the printer instructions in this chapter.
6. Change the print mode setting from direct thermal printing to thermal transfer to set
the printer’s temperature profiles for thermal transfer media. This can be done with
the printer driver, application software, or printer programming commands.
• When controlling printer operations with ZPL programming, refer to the Media
Type (^MT) ZPL II command (follow the instructions in the ZPL Programming
Guide).
• When controlling printer operations with EPL Page Mode, refer to the Options
(O) EPL command (follow the instructions in the EPL Page Mode
Programmer’s Guide).
To verify the mode change from direct thermal printing to thermal transfer printing, use the
Test Printing with the Configuration Report to print a configuration label. The ‘PRINT
METHOD’ should read ‘THERMAL-TRANS’ on the printer configuration status label.
160
Setup
Loading Non-Zebra 300 Meter Transfer Ribbon

Loading non-Zebra 300 meter transfer ribbon in your printer requires the use of Zebra
ribbon core adapters.
Minimum requirements to use non-Zebra 300 meter ribbons with your printer:
• Inside core diameter (I.D.) of 25.4mm (1.0 inch, range 1.004 to 1.016 inches).
Material: Fiberboard; hard materials such as plastic cores may not function cor-
rectly.
• Ribbon width range of 110 to 33mm (4.3 to 1.3 inches).
• The maximum outer diameter of the ribbon is 66mm (2.6 inches).
Caution • Using non-Zebra media or ribbons not approved for use in your Zebra® printer
may damage your printer or printhead. Image quality may also be affected by poor or
marginal ribbon performance (maximum print speed, ink formulation, etc.), core material
(too soft or hard), and fit (loose or tight ribbon core or exceeds maximum outer diameter -
66mm).
The adapters help you align the ribbon and core to the media (and printer’s) center. The
adapters include a ‘core lock’ spring to engage the soft fiberboard inside of the ribbon core
and scale measured from the printer’s center-line when mounted in the printer.
= Center-line
‘Core Lock’ Spring
1. Load an empty ribbon core onto a ribbon core adapter. The empty ribbon core should
be the same width (or larger) than the ribbon roll. Roughly center the core over the
adapters center line. An empty Zebra ribbon core may be used instead of the adapter
and empty non-Zebra ribbon core. One 300m empty ribbon core is supplied with the
printer.
2. Load the non-Zebra ribbon roll onto the ribbon core adapter. Orient the adapter flange
on the left side and verify that the ribbon unwraps on the backside of the roll as shown
in the illustration. Roughly center the core over the adapters center line.
161
Setup
Ribbon Exiting the

Roll in the Back
Flange - Place on Left
Note • The maximum roll width of 110 mm (4.3 inches) does not require centering. For
media less than maximum width down to the minimum width of 33mm (1.3 inches), use the
graduated scale on the adapter core to align the ribbon rolls to the media and printer.
162
Setup
3. Place the adapter with an empty core on the take-up spindles and the adapter with
the ribbon roll on the lower supply spindles. The right side of the core adapter fits on
the cone tip on each of the spring loaded right side spindles. Continue pushing the
adapter onto right side spindle and swing the adapter onto the left side spindle hubs.
Rotate the adapters and hubs until the until notches on the adapters flange align and
lock ton the left spindles hub spokes.
163
Setup
4. While the ribbon and empty cores were being installed during the previous steps, they
may have been bumped off center.
• Verify that the ribbon roll and empty core are aligned to the center of the
media (labels, paper, tags, etc.). Remember that you can use the center line
scales on the ribbon core adapter to place their positions.
• If you have forgotten to check if the ribbon is wide enough the for the media in
use, now is the time to check. The ribbon must be wider than the media
(including the label liner or backing) to protect the printhead.
164
Setup
5. Attach the ribbon to the take up core. Use thin strip of tape to secure the ribbon to the
take-up core, if your media does not have an adhesive strip on the ribbon leader like
genuine Zebra@ ribbon. Align the ribbon so that it will be taken straight onto the core.
6. Turn the ribbon take-up hub with the top moving toward rear to remove slack from the
ribbon. Rotating the hub helps to finish aligning the take up ribbon position with the
supply ribbon roll. The ribbon should be wound, at minimum, one and a half times
around the take-up ribbon core.
7. Verify that the media is loaded and ready to print and then close the printer cover.
165
Setup
8. If printer power is on, press the FEED button to have the printer advance a minimum
of 20 cm (8 inches) of media to remove slack and ribbon wrinkle (straightens the
ribbon), and to align the ribbon on the spindles. Otherwise, wait to turn on the printer
and complete the printer ‘Getting Started’ instructions in this chapter.
9. Change the print mode setting from direct thermal printing to thermal transfer to set
the printer’s temperature profiles for thermal transfer media. This can be done with
the printer driver, application software, or printer programming commands.
• When controlling printer operations with ZPL programming, refer to the Media
Type (^MT) ZPL II command (follow the instructions in the ZPL Programming
Guide).
• When controlling printer operations with EPL Page Mode, refer to the
Options (O) EPL command (follow the instructions in the EPL Page Mode
Programmer’s Guide).
10. To verify the mode change from direct thermal printing to thermal transfer printing,
use the Test Printing with the Configuration Report to print a configuration label. The
‘PRINT METHOD’ should read ‘THERMAL-TRANS’ on the printer configuration status
label.
Your printer is now ready to print.
166
Setup
Loading the ZD420 Ribbon Cartridge
The printer uses a transfer ribbon cartridge for thermal transfer printing. Just slide the
cartridge into the ribbon transport and close the printer. The printer reads cartridge
information stored on the cartridge.
Insert th Cartridge Guide Rails

is En d
Hold the Ribbon Ins

Cartridge Here er t
thi
s En
d
Cartridge Information Smart Chip
1. Insert the ribbon cartridge into the ribbon cartridge slot on the ribbon transport in your
open printer. Push until the cartridge is nearly flush to the front of the ribbon transport.
You will hear and feel the cartridge lock into place. Only Genuine Zebra Ribbon
Cartridges are supported.
Front of
Ribbon
Transport
Smart Chip
Reader
Cartridge
Guides
167
Setup
Run a SmartCal Media Calibration
The printer needs to set the media parameters for prior to printing optimal operation. The
printer will automatically determine media type (web/gap, black mark/notch, or continuous)
and measure media characteristics.
Important • After the initial calibration to a specific media is completed, it is not required
to perform additional calibrations each time the media is replaced. The printer
automatically measures the media to adjust for small changes in the media characteristics
while printing.
Pressing the FEED (Advance) once or twice after a new roll of media (same batch) has been
installed will synchronize the labels. It is then ready to continue printing.
SmartCal Procedure
1. Make sure the media and ribbon cartridge (if you are thermal transfer printing) are
loaded properly in the printer and the top cover of the printer is closed.
2. Press the POWER button to turn the printer on.
3. Once the printer is in the ready state (Status indicator is solid green), press and hold
the PAUSE and CANCEL button for two (2) seconds and release.
4. The printer will measure a few labels and adjust media sensing levels.
5. When the printer stops, the Status indicator will turn solid green.
168
Setup
Test Printing with the Configuration Report
Before you connect the printer to a computer, make sure that the printer is in proper
working order. You can do this by printing a configuration report. The information on the
Configuration reports printout that may be helpful with printer installation and with
troubleshooting your printer.
1. Make sure the media and ribbon cartridge (if you are thermal transfer printing) are
loaded properly in the printer and the top cover of the printer is closed.
2. Turn the printer ON.
3. Once the printer is in the ready state (Status indicator is solid green), press and hold
the FEED and CANCEL buttons for two (2) seconds and release.
4. .The Printer and Network Configuration Reports (shown below) will be printed.
5. When the printer stops, the Status indicator will turn solid green.
If you cannot get these reports to print, then see Troubleshooting.
169
Setup
Detecting a Media Out Condition
When you run out of media, your printer will report a ‘Media Out’ condition with the Status
and Media indicators both light solid red. This is part of the normal media usage cycle.
Recovering from a Media Out condition
1. Open the printer.

2. Observe that the media is at the end or nearly at the end of the roll with a label
missing from the liner.
3. Remove the remaining media and roll core.
4. Insert a new roll of media. See Loading Roll Media.
• If you are installing more of the same media, just load the new media and
press the FEED (Advance) button once to resume printing.
• If you are loading different media (size, vendor, or even batch is different),
then reloading media followed by a SmartCal is needed to ensure optimal
operation.
• Note that changing media size (length or width) usually requires to you to
change the programmed media dimensions or the active label format in the
printer.
Important • Sometimes a label may be missing some where in the middle of your roll of
labels (not at the end of media). This will also cause a ‘Media Out” condition.
To recover, just pull the media past the missing label until the next label is over the platen
roller. Close the printer. Press the FEED (Advance) button once. The printer will
resynchronize the label position and will be ready to resume printing.
170
Setup
Detecting a Ribbon Out Condition
When you run out of printable ribbon, your printer will report a ‘Ribbon Out’ condition with
the Status and Media indicators. This is part of the normal media usage cycle.
When the printer detects that the ribbon is out, the Status indicator will turn solid red and
the Media indicator will be flashing red.
Recovering from a Ribbon Out condition
1. Open the printer.

2. Observe a reflective ribbon (used to detect end of ribbon) is exposed on the
underside of the ribbon cartridge or ribbon roll.The front ribbon roll is also full.
3. Remove the used ribbon cartridge and dispose of it properly.
4. Load new ribbon rolls or Insert a new ribbon cartridge. See Loading Thermal Transfer
Roll Ribbon or Loading the ZD420 Ribbon Cartridge.
5. Press the FEED (Advance) button once to resume printing.
171
Setup
Connecting your Printer to a Computer
The printer supports a variety of interface options and configurations. These include:
• Universal Serial Bus (USB 2.0) interface - Standard.
• RS232 Serial - ZD620 standard. Field Upgrade Option for ZD420 printers.
• Ethernet (LAN) - ZD620 standard. Field Upgrade Option for ZD420 printers.
• Internal Wi-Fi (802.11ac) and Bluetooth Classic 4.1 (3.0 Compatible) - Factory
Installed Option.
• WiFi models include Bluetooth Low Energy (low speed connection) for printer
configuration using software running on an Android or iOS device.
Pre-install Windows® Printer Drivers
Install the Zebra Setup Utilities (ZSU) before applying power to the printer connected
to the PC. The utility installs the Zebra Windows drivers first. The ZSU installation wizard
will then prompt you turn on the printer. Follow the instructions to complete your printer
installation.
The Zebra Setup Utility is designed to assist you with installing your printer. The
cabling and unique parameters for each of these physical printer communication interfaces
is discussed in the following pages to assist you with making configuration setup choices
prior to and immediately following applying power. The Zebra Setup Utilities configuration
wizards will instruct you to turn the printer’s power on at the appropriate time to complete
the installation of your printer.
For more details on configuring network (Ethernet or Wi-Fi) and Bluetooth communication,
see the following guides:
• Wired and Wireless Print Server User Guide
• Bluetooth Wireless Guide
172
Setup
Interface Cable Requirements

Data cables must be of fully shielded construction and fitted with metal or metalized
connector shells. Shielded cables and connectors are required to prevent radiation and
reception of electrical noise.
To minimize electrical noise pickup in the cable:
• Keep data cables as short as possible (1.83 m [6 foot] recommended).
• Do not tightly bundle the data cables with power cords.
• Do not tie the data cables to power wire conduits.
Important • This printer complies with FCC “Rules and Regulations,” Part 15, for Class B
Equipment, using fully shielded data cables. Use of un-shielded cables may increase
radiated emissions above the Class B limits.
173
Setup
USB Interface
Universal Serial Bus (version 2.0 compliant) provides a fast interface that is compatible
with your existing PC hardware. USB’s “plug and play” design makes installation easy.
Multiple printers can share a single USB port/hub.
When using a USB cable, verify that the cable or cable packaging bears the “Certified
USB ™ ” mark (see below) to guarantee USB 2.0 compliance.
.
USB
174
Setup
Serial Interface
The printer uses a Null Modem (cross-over) cable for DTE communications. The required
cable must have a nine-pin “D” type (DB-9P) male connector on one end which plugs into
the mating (DB-9S) serial port located on the back of the printer. The other end of this
signal interface cable connects to a serial port on the host computer. For pin-out
information, refer to Appendix A.
The serial port communication settings between the printer and host (typically a PC) must
match for reliable communication. The Bits per second (or Baud rate) and Flow control are
the most common settings that get changed.
Serial communications between the printer and the host computer can be set by:
• ZPL programming ^SC command
• Resetting the printer to its default printer configuration.
Factory defaults for serial communication settings are: 9600 baud, 8 bit word length,
NO parity, 1 stop bit, and XON/XOFF (‘Software’ data flow control in the Windows based
host system).
Important • Do not use RS-232 cable adapter dongles (DTE<=>DCE) with this printer.
Some dongles can interfere with the operation of USB Host port devices at printer power
up.
175
Setup
Ethernet (LAN, RJ-45)

The printer requires UTP RJ45 Ethernet cable rated CAT-5 or better.
The printer has a built-in network print server. For more information on configuring your
printer to run on a compatible Ethernet based network, see the Wired and Wireless Print
Server users guide. The printer must be configured to run on your network. The print server
on board your printer can be accessed through the printer’s print server Web pages.
Ethernet Cable
(RJ45 Connector)
Ethernet Status/Activity Indicators
The Ethernet connector on the printer has two (2) status/activity indicators that are partially
visible to provide interface status at the connector. The printer also has the user interface
indicator lights for printer network operation status, see the Meaning of the Indicator Light
Patterns for more details.
LED Status Description

Both OFF No Ethernet link detected
Green 100 Mbps link detected
Green with the Amber flashing 100 Mbps link and Ethernet activity detected
Amber 10 Mbps link detected
Amber with the Green flashing 10 Mbps link and Ethernet activity detected
176
Setup
Assigning an IP Address for Network Access
All devices on an Ethernet network (LAN and WLAN) require a network IP (Internet
Protocol) address. The printer’s IP address is needed to access the printer for printing and
printer configuration. The five different ways to assign an IP address are:
• DHCP (Dynamic Host Connection Protocol) - Default setting
• Zebra Setup Utilities (includes the ZebraDesigner Windows printer driver)
• Telnet
• Mobile Apps
• ZebraNet Bridge
DHCP for Personal Networks
The printer by default is set to operate on a Ethernet LAN or Wi-Fi network with DHCP.
This setting is intended primarily for personal networks. The network automatically
provides a new network IP address each time the printer is turned on. The Windows printer
driver uses a Static IP address to connect to the printer. The IP address set in the printer
driver will need to be changed to access the printer if its assigned IP address has changed
after the printer’s initial installation.
Managed Networks
Using the printer in a structured network (LAN or Wi-Fi) requires a network administrator
to assign the printer a Static IP address and other settings needed to operate on the
network properly.
Print Server - Default User ID and Password
There are some features that require the default User ID and/or default password to
access the printer’s print server or if you have the Wi-Fi option in the printer. The Factory
Default Values are shown below:
• User ID: admin
• Password: 1234
177
Setup
Wi-Fi and Bluetooth Classic Wireless Connectivity Option
This guide covers basic configuration of your Internal Wi-Fi Print Server and Bluetooth
Classic 4.X wireless connectivity option.This manual only covers installing the Wi-Fi as
part of the Wi-Fi and Bluetooth Classic wireless connectivity option in the Setting Up the
Wi-Fi Print Server Option. See the Zebra Web site for Wired and Wireless Print Server
User Guide for more information on the printer’s Ethernet operation.
This manual only covers installing the Bluetooth as part of the Wi-Fi and Bluetooth Classic
wireless connectivity option in the Bluetooth Option Configuration. See the Zebra Web site
for Bluetooth Wireless Guide for more information on the printer’s Bluetooth operation.
Update Printer Firmware to Finish Option Installations
It is recommended that you always update the printer’s firmware with the latest version for
optimal printer performance. For instructions on how to update printer firmware, see
Updating Printer Firmware. See the About section of this guide to find direct links to printer
support pages for your specific Link-OS printer model and Firmware updates.
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Setup for Windows® OS
The section helps you setup communications between your printer and the Windows
operating system environment.
Windows to Printer Communication Setup (Overview)
For supported Windows Operating systems (most common) with a Local (wired)
connection:
1 • Download the Zebra Setup Utilities form the Zebra Web site.
ZD620 Thermal Transfer Printer — www.zebra.com/zd620t-info
ZD620 Direct Thermal Printer — www.zebra.com/zd620d-info
ZD420 Thermal Transfer Ribbon Cartridge Printer — www.zebra.com/zd420c-info
ZD420 Thermal Transfer Printer — www.zebra.com/zd420t-info
ZD420 Direct Thermal Printer — www.zebra.com/zd420d-info
2 • ‘Run’ the Zebra Setup Utilities from your Download directory.
3 • Click on ‘Install New Printer’ and run the install wizard.
4 • Select ‘Install Printer’.and select your printer’s model number from the list of
ZDesigner printers.
5 • Select the port (USB or Serial) that you connected to the PC. Use these interfaces to
assist Wizard guided installation of networked or Bluetooth Classic (4.0).
6 • Turn the printer ON and configure printer communications for your interface type.
7 • Use the Windows driver to print a ‘Test Print’ to verify operation with Windows.
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Pre-install Windows® Printer Drivers
Install the Zebra Setup Utilities (ZSU) before applying power to the printer connected
to the PC (running a Zebra driver supported Windows operating system). The utility installs
the Zebra Windows drivers first. The ZSU installation wizard will then prompt you to apply
the printer power. Continue to follow the instructions to complete your printer installation.
The Zebra Setup Utility is designed to assist you setting up printer communication
on a PC running the Windows operating system. The cabling and unique parameters
for each of these physical printer communication interfaces is discussed in the following
pages to assist you with making configuration setup choices prior to and immediately
following applying power. The Zebra Setup Utilities configuration wizards will instruct you
to turn the printer’s power on at the appropriate time to complete the installation of your
printer.
For more details on installing Ethernet (network) and Bluetooth interfaces:
• Wired and Wireless Print Servers User Guide
• Bluetooth Wireless Guide
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Setting Up the Wi-Fi Print Server Option
This section covers basic configuration of your internal Wi-Fi Print Server option. For more
detailed information, refer to the Wired and Wireless Print Servers User Guide.
Note • The wireless radio option, which includes Wi-Fi, Bluetooth classic and Bluetooth low
energy, is only available as a factory installed configuration.
You may configure your printer for wireless operation in the following ways. This basic
guide covers only the first option, the Connectivity Wizard.
• Through the Connectivity Wizard, which writes a ZPL script for you. On the last
screen of the utility, you may choose to send the command directly to your printer,
or you may choose to save the ZPL script to a file. The saved ZPL file has several
purposes:
• The file can be sent to the printer through any available connection (serial,
parallel, USB, or wired print server).
• The file can be resent to the printer after the network settings have been
restored to factory defaults.
• The file can be sent to multiple printers that will use the same network
settings.
• Through ZPL script that you write yourself. Use the ^WX command to set the
basic parameters for security type. You can send the command through any avail-
able connection (serial, parallel, USB, or wired print server). Refer to the ZPL Pro-
gramming Guide for more information on this option.
• Through Set/Get/Do (SGD) commands that you send to the printer. Begin with
wlan.security to set the wireless security type. Depending on which security type
that you select, other SGD commands will be necessary to specify other parame-
ters. You can send the commands through any available connection (serial, paral-
lel, USB, or wired print server). Refer to the ZPL Programming Guide for more
information on this option.
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Configure Using the ZebraNet Bridge’s Connectivity Wizard

Note • The preferred tool for connecting and configuring Link-OS printers to cloud, WLAN,
and LAN; is now Link-OS Profile Manager. You can get Profile Manager and ZebraNet
Bridge Enterprise (local and LAN configurations) utility is available through
http://www.zebra.com/software. ZebraNet Bridge Enterprise version 1.2.5 or later is
required to configure the printer correctly for use.
The Connectivity Wizard, which is part of this software, allows you to configure your printer
easily for wireless operation by writing the appropriate ZPL script for you. Use this utility
when you are first installing the wireless print server or after you set the network options
back to factory defaults.
Note • You can only set up one print server at a time with the Connectivity Wizard. To configure
multiple print servers (wired and wireless), run the program once for each print server.
To use the Connectivity Wizard, complete these steps:
1. If it is not already installed, install ZebraNet Bridge Enterprise on your computer.

You can get the program from the Zebra Web site at http://www.zebra.com/software.
2. Launch the ZebraNet Bridge Enterprise program.
If you are prompted for a serial number, you may click Cancel. You will still be able to
use the Connectivity Wizard.
3. From the Menu bar, select Tools > Connectivity Wizard. The Connectivity Wizard
opens.
4. From the Choose Port list, select the port to which your printer is connected.
• If you will save the file without sending it to the printer, you may select any avail-
able port.
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• If you select File:, you will be asked to browse to the location of the file you want to
save.
• If you select a serial port, the serial configuration information appears below the
‘Choose Port’ list. If necessary, change the serial communication settings to
match your printer’s settings.
Note • If a port is in use by another device, it will not be included in the drop-down list.
5. Click Next.
The wizard prompts for the print server device to configure.
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6. Select Wireless and then click Next.

The wizard prompts you for the type of printer you are using.
7. Select the type of printer you are using and then click Next.
The wizard prompts for the wireless IP information.
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8. Enable the DHCP (dynamic) or static IP option.
If you will be using... Complete the following steps...

DHCP a. Select DHCP and click Next.
b. Continue with step 9.
Static a. Select Static.
b. The IP settings fields are activated.
c. Enter the IP Address, Default Gateway, and Subnet
Mask for the wireless print server. Contact your network
administrator for the correct values.
d. Continue with step 9.
9. Click Next.
The Wireless Settings window opens.
10. Enter the ESSID.

Note • The ESSID and pass phrase, if used, must be set at your access point before
completing these steps.
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11. From the drop-down, select your Security Mode.
If you select… Then…

None Continue with step 12.
WEP 40-Bit a. In the WEP Options section of the window, enter the
WEP 128-Bit following values:
• Authentication type
• WEP Index
• Encryption Key Storage
• WEP Keys
b. Click Next and continue with step 12.
EAP-TLS In the EAP section of the window, if necessary:
EAP-TTLS a. Enter the Optional Private Key.
EAP-FAST b. Click Next and continue with step 12.
WPA-EAP-TLS
PEAP In the General Security section of the window:
LEAP a. Enter the Security Username and Password.
WPA-EAP-TTLS b. Click Next and continue with step 12.
WPA-PEAP
WPA-LEAP
WPA-PSK In the WPA section of the window:
a. Select the PSK Type.
b. Enter the PSK Name.
c. Click Next and continue with step 12.
WPA-EAP-FAST a. In the General Security section of the window, enter
the Security Username and Password.
b. In the EAP section of the window, if necessary, enter
the Optional Private Key.
c. Click Next and continue with step 12.
KERBEROS a. In the Kerberos Settings section of the window, enter
the following values:
• Kerberos User
• Kerberos Password
• Kerberos Realm
• Kerberos KDC
b. Click Next and continue with step 12.
Note • KERBEROS is not supported on Internal Wireless Plus print servers or radio cards.
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12. Click Advanced Options in the Wireless Settings window. step 12

The Advanced Wireless Settings window opens.
13. Review the settings in the Advanced Wireless Settings window. Change the settings
as necessary, and then click OK.
The Wireless Settings window returns.
14. Click Next. Based on your selections in the Wireless Setup Wizard, the program
writes the appropriate ZPL commands and displays them for your review. If you
selected Tabletop/Desktop then the a dialog box similar to this displays.
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15. Determine if you will send the script immediately, or save it for use at a later time.
Using a Configuration Script

Complete setup by sending the ZPL script to the printer through the port selected at the
beginning of this procedure
1. Verify that the printer is connected to the computer through the wired cable
connection to port you selected, USB or Serial.
2. If you have not already done so, turn ON the printer.
3. On the Review and Send ZPL for Wireless window, click Finish.
4. The printer sends the ZPL script to the printer through the selected port. The Wireless
Setup Wizard screen closes.
5. Turn the printer OFF and then back ON.
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Saving a Configuration Script

Save the ZPL script to a file for use later or for use with other printers
Note • You can send the ZPL script file to multiple printers that use the same configuration, or you
can send the file to a printer that had the network settings restored to the factory defaults. This
saves you from having to go through the Wireless Setup Wizard more than once.
1. On the ‘Review and Send ZPL for Wireless’ window, highlight the script, right-click,
and select Copy.
2. Open a text editor, such as Notepad, and paste the script into the application.
3. Save the script.
4. In the Connectivity Wizard, click Cancel to exit without sending the script at this time.
5. If you have not already done so, turn ON the printer.
6. Send the ZPL file to the printer through the connection of your choice.
7. Observe the wireless status on the printer’s indicator lights, and confirm that you have
set up your printer for wireless connectivity.
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Bluetooth Option Configuration
The Zebra Setup Utilities provides a quick and easy way to configure a Bluetooth wireless
connection with your printer.
1. Double-click the Zebra Setup Utilities icon on your desktop.
2. Connect a USB cable from your printer to your computer.
3. On the first ZSU screen, highlight the printer displayed in the window and click on the
Configure Printer Connectivity where shown.
4. Select ‘Bluetooth’ on the Connectivity Type screen and click on the Next button.
5. On the Bluetooth Settings screen, check “Enabled” to enable Bluetooth functionality.

6. In the Friendly Name text field, set the Bluetooth name of the device. This name
appears during device discovery and the master device will label the printer with this
name.
7. Set Discoverable to “On” or “Off” to set whether the device will appear when master
devices are looking for new devices to pair with.
8. Set Authentication to “On.” (Note: This setting does not exist in Link-OS, but you need
to turn on if you want to enter a PIN in ZSU. Actual authentication setting on the
printer is set in the Security Mode on the Advanced Settings menu.)
9. The values set in the Authentication PIN field will vary depending on the Bluetooth
version of the master device. If the master uses BT v2.0 or older, enter a numeric
value in this field. You will be prompted to enter this same value on the master device
to verify pairing. Security Mode 2 or 3 in Advanced Settings should also be selected
for PIN paring.
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10. If the master device uses BT v2.1 or newer, this setting has no effect. BT v2.1 and
newer uses Secure Simple Paring (SSP) which does not require the use of a PIN.
11. Clicking on the Advanced Settings button will display the Advanced Bluetooth
Settings window. For more information on Advanced Settings, refer to the Wired and
Wireless Print Server Guide.
12. Click Next to continue configuring your printer.
13. The SGD commands to properly configure your printer will be displayed. Click Next to
continue to the Send Data screen.
14. On the Send Data screen, click on the Printer that you want to send the commands to
or click on the File button to save the commands to a file for reuse later.
15. To send the commands to the printer, click on the Finish button. The printer will
update and then reboot. You may disconnect the USB interface from your printer now.
16. To complete the Bluetooth pairing process, enable Bluetooth device discovery on
your master device and follow the directions provided with the master device.
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Connecting to a Windows XP® SP2 Master Device

This process covers the printer installation for Windows XP SP2 (or above)
1. From the Windows ‘Start’ menu, open the ‘Printers and Faxes’ window. Click on
‘Add Printer’ and a wizard will start. Click ‘Next’ when the “Welcome” window displays
to continue.
2. Leave the ‘Local’ radio button with the ‘Automatic detect ...’ checkbox (checked)
selected and click ‘Next’.
3. No printer should be found. If there is one or more new printers detected, then do not
select any of those printers and click ‘Next’.
4. Select the ‘Create a new port’ radio button and select ‘Bluetooth Printer Port’ from the
associated pull down menu.
5. From the new ‘Bluetooth Printer Port’ window, select your printer from the Bluetooth
devices in the list. This may take several minutes. Click on the ‘Connect’ button.
6. The ‘Install Printer Software’ window will open. Select ‘ZDesigner’ as ‘Manufacture’ to
select supported Zebra printer models, and then select your printer model in the
‘Printers’ selection. Click ‘Next’ to continue.
7. Select ‘Keep the existing drivers’ and click ‘Next’.
8. Name your printer and choose your default printer setting as desired. Click ‘Next’.
9. Answer ‘Yes’, you want to print a test page. Click ‘Next’ to continue.
10. Click ‘Finish’ on the ‘Completing the Add Printer Wizard’ window and the Bluetooth
printer will complete installation and print a Windows test print page (a Windows logo
at minimum).
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Connecting to a Windows Vista® SP2 or Windows 7® Master Device

The Windows Vista (SP2 or higher) and Windows 7 Bluetooth install differs from the XP
install.
• Windows Vista: Open the ‘Add Printer’ wizard by clicking the ‘Start’ button, click-
ing ‘Control Panel’, clicking ‘Hardware and Sound’, clicking ‘Printers’, and then
clicking ‘Add a printer’.
• Windows 7: Open Devices and Printers by clicking the ‘Start’ button, and then, on
the ‘Start’ menu, clicking ‘Devices and Printers’
• Some non-Microsoft Bluetooth dongles and built-in Bluetooth devices in the host
PC’s have marginal driver support for Secure Simple Paring (SSP) printing and
may not complete the ‘Add printer’ wizard normally. You may need to go to the
‘Bluetooth Devices’ in the ‘Control Panel’ or from the system tray on the Windows
‘Start’ bar and activate SPP for the ‘device’, your Bluetooth printer you are install-
ing. Install the printer to a local printer (USB or Serial Port for your Link-OS 4 inch
Desktop printer) and then change the ‘Port’ after the install has completed to the
SPP (virtual serial port) COM port.
1. Access the ‘Devices and Printers’ from the Windows Start menu.
2. Check for Bluetooth devices in the ‘Devices and Printers’ window. Note the generic
Windows Bluetooth icon below.
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3. Hover over the Bluetooth icon with the mouse pointer and the icon will highlight.
Right-Click on the high-lighted Bluetooth icon. Select ‘Bluetooth Settings’ from the
pop-up menu. Verify that both of the Connections check boxes are checked. Verify
that the ‘Turn off the Bluetooth adapter’ is not checked. Click the ‘Apply’ button. Click
the ‘OK’ button to close the window.
4. Click on the ‘Add a device’ in the top bar of the “Devices and Printers’ window. The
“Add a device’ windows will populate with Bluetooth devices near you.
5. Turn the Bluetooth 4.0 (3.0 compatible) enabled Zebra printer on. After a few
moments the “Add a device’ windows will add your new printer. Click on the printer
icon. Right-Click and select ‘Add device’.
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6. The printer will print a pairing code. Verify that the pairing numbers match with those
on your display screen. If the numbers match, then press the ‘Next button’ in the ‘Add
a device’ window.
7. When the pairing process successfully completes, the following message will be
displayed.
Note • The COM port number displayed in the task bar pop-up. It will only remain for a few seconds.
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Connecting the Printer to a Windows 8

Before adding (also called pairing) a Bluetooth enabled device, make sure it is turned on
and discoverable. As stated in the previous section under Connecting to a Windows Vista®
SP2 or Windows 7® Master Device
, your Windows device may need a Bluetooth adapter to
connect to Bluetooth device. Check with your device manufacturer’s User Manual for
further information.
1. Swipe in from the right edge of the screen or move your mouse towards the right edge
of the screen, select Settings, and then select Change PC Settings.
.
2. Select PC and devices, and then select Bluetooth. Once Windows displays the
Bluetooth-enabled devices, select the device and click Pair.
Note • Windows will display the pairing code for only 10 seconds, so complete this step
quickly!
3. Follow the instructions on your screen to finish pairing your device.
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Connecting the Printer to a Windows 10 PC

Before adding (also called pairing) a Bluetooth enabled device, make sure it is turned on
and discoverable. As stated in the previous section under “Installing the Printer on a
Windows 7 PC,” your Windows device may need a Bluetooth adapter to connect to
Bluetooth device. Check with your device manufacturer’s User Manual for further
information.
1. Open the Windows Start Menu by clicking on the Windows Start ( )button and
select Settings.
.
2. Click on the Devices category in the Settings window.
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3. Click on Bluetooth. If your PC doesn’t have Bluetooth installed, the Bluetooth

category will not be displayed in the list of device categories. The printer is identified
by the serial number.
Printer Serial Number
4. Click on the printer and then click on the ‘pairing’ button for the printer.
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5. The printer will print a passcode. Compare that with the passcode showing on screen.
Click ‘Yes’ if they match.
6. The printer status changes to connected when pairing has completed.
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After Your Printer is Connected
Now that you have basic communication to your printer, you may want to test printer
communications and then install other printer related applications, drivers or utilities.
Testing Communications by Printing
Verifying the print system’s operation is a relatively simple process. For Windows
operating systems, use the Zebra Setup Utility or the Windows ‘Printers and Faxes’
Control Panel to access and print a test label. For non-Windows operation systems, copy
a basic ASCII text file with a single command (~WC) to print a configuration status label.
Test Printing with Zebra Setup Utility:
1. Open the Zebra Setup Utility.

2. Click on the newly installed printer’s icon to select the printer and activate the printer
configuration buttons below it in the window.
3. Click the ‘Open Printer Tools’ button.
4. In the ‘Print’ tab window, click on the ‘Print configuration label’ line and click on the
‘Send’ button. The printer should print a configuration report.
Test Printing with Windows ‘Printer and Faxes’ menu:
1. Click on the Windows ‘Start’ menu button, to access the ‘Printers and Faxes’ menu or
‘Control Panel’ to access the ‘Printers and Faxes’ menu. Open the menu.
2. Select the newly installed printer’s icon to select the printer and right-click the mouse
to access the printer ‘Properties’ menu.
3. From the printer’s ‘General’ tab window, click on the ‘Print Test Page’ button. The
printer should print a Windows test print page.
Test Print with an Ethernet printer connected to a network
Test Print on an Ethernet printer connected to a network (LAN or WLAN) with a (MS-DOS)
‘Command Prompt’ (or ‘Run’ from the Windows XP Start menu):
1. Create a text file with the following ASCII three characters: ~WC
2. Save the file as: TEST.ZPL (an arbitrary file name and extension name).
3. Read the IP address off the printer’s Configuration Report’s Network Status printout.
On a system that is connected to the same LAN or WAN as the printer, type the
following in the Web browser window’s address bar and enter:
ftp (IP address)
(for IP address 123.45.67.01 it would be: ftp 123.45.67.01)
4. Type the word ‘put’ followed by the file name and enter. For this ‘test print’ file, it
would be: put TEST.ZPL
The printer should print a new Print Configuration Report.
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Test Print with a Copied ZPL Command File for Non-Windows Operating Systems:
1. Create a text file with the following ASCII three characters: ~WC
2. Save the file as: TEST.ZPL (an arbitrary file name and extension name).
3. Copy the file to the printer. For DOS, a file sent to a printer connected to the system’s
serial port would be as simple as:
COPY TEST.ZPL COM1
Other interface connection types and operating systems will have different command
strings. See your operating system documentation for detailed instructions to copy to
the appropriate printer interface for this test.
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Print Operations
This section provides general information on media and print handling, font and language
support, and the setup of less common printer configurations.
Thermal Printing
The ZD-Series printers use heat to expose direct thermal media or heat and pressure to
melt and transfer ‘ink’ to the media. Extra care should be taken to avoid touching the
printhead which gets hot and is sensitive to electrostatic discharges.
Hot Surface Caution • The printhead becomes hot while printing. To protect from
damaging the printhead and risk of personal injury, avoid touching the printhead. Only use
the cleaning pen to perform printhead maintenance.
Determining Your Printer’s Configuration Settings

ZD-series printer provide a configuration report of the printer’s settings and hardware.
Operational status (darkness, speed, media type, etc.), installed printer options (network,
interface settings, cutter, etc.) and printer description information (serial number, model
name, firmware version, etc.) are all included on the configuration report.
See Test Printing with the Configuration Report to print this label.
See Managing the ZPL Printer Configuration to help interpret the configuration report and
the associated programming command and command states it is identifying in the report.
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Print Operations
Select a Print Mode
Use a print mode that matches the media being used and the printer options available. The
media path is the same for roll and fanfold media.
To set the printer to use an available print mode:
• See PRINT MODE.
• See the ZPL Programmer’s manual, ^MM command. See About section for infor-
mation and support links for your specific printer model.
Print Modes
• TEAR OFF -— This mode (default) can be used with any printer options and most
media types. The printer prints label formats as it receives them. The printer oper-
ator can tear off the printed labels any time after they print.
• PEEL — Label Dispenser Option only. The printer peels the label from the liner
during printing and then pauses until the label is removed.
• CUTTER — Cutter Option only. The printer cuts between labels after each one is
printed.
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Print Operations
Adjusting the Print Quality
Print quality is affected by the heat (density) setting of the printhead, the print speed, and
the media in use. Experiment with these settings to find the optimal mix for your
application. Print quality can be configured with the Zebra Setup Utility’s ‘Configure Print
Quality’ routine.
Note • Media manufacturers may have specific recommendations for speed settings for
your printer and the media. The recommended speed may be lower than your printer’s
maximum speed setting!
The darkness (or density) setting can be controlled by:
• The Set Darkness (~SD) ZPL command (consult your ZPL Programming Guide).
• See the Manual Print Darkness Adjustment.
• See the Darkness Control.
If you find that the print speed needs to be adjusted, use:
• The Windows printer driver or application software such as ZebraDesigner ™ .
• The Print Rate (^PR) command (consult your ZPL Programming Guide).
Use the printer’s ‘Print Quality Report’ (also known as the FEED Self Test) to print a range
of labels that help you identify print DARKNESS and SPEED settings for optimizing
general print and barcode quality. See the Print Quality Report (FEED self test) for details.
The printer’s media settings can be verified by printing a Printer Configuration label. See
the Test Printing with the Configuration Report for more details.
The maximum distance the automatic media type detection and sensing checks can be
reduced using the ZPL Maximum Label Length command (^ML). The minimum distance
should be no less than two times the longest label being printed. If the largest label being
printed was a 2 by 6 inch label, then the maximum label (media) length detection distance
can be reduced from the default distance of 39 inches down to 12 inches.
Note • See About section for information and support links for your specific printer model.
204
Print Operations
Darkness Control
The Darkness Control switch allows the operator to modify the darkness setting for minor
variations in media and printers avoiding the need to change the program or driver settings
sent to the printer.
Darkness Control
The control switch has three (3) settings:

• Left (Low - Default): no effect .
• Middle (Medium): increases ZPL darkness 3 levels.
• Right (High): increases ZPL darkness 6 levels.
The Low (default) setting makes no change to the actual Darkness setting as set by
programming or driver setting. The Medium setting increases the Darkness level by 3, i.e.
if the printer is set to the default darkness level of 20, then the actual darkness applied
while printing will be 23. The High setting will add six (6) darkness levels to the set
darkness level.
Important • Setting the Darkness too high or too low may reduce barcode readability.
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Print Operations
Adjusting the Print Width
Print width must be set:

• Before you use the printer for the first time.
• Any time you change the width of the media in use.
Print width may be set by:
• The Windows printer driver or application software such as ZebraDesigner ™ .
• Controlling printer operations with ZPL programming; refer to the Print Width (^PW)
command (consult your ZPL Programming Guide).
• See Manual Print Width Adjustment.
Replacing Supplies while Using the Printer

If media (ribbon, labels, receipts, tags, tickets, etc.) run out while printing, leave the printer
power on while reloading (data loss results if you turn off the printer). After you load a new
roll of media, press the FEED button to restart.
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Print Operations
Printing on Fan-Fold Media
Printing on fan-fold media requires you to adjust the media guides stop position.
1. Open the top cover.
Fan-Fold
Media Path
2. Adjust the media guide stop position with the gold thumb wheel. Use a piece of the
fan-fold media to set the stop position. Rotate the wheel away from you to make the
guides wider. Rotate the wheel toward you to make the media guides narrower.
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Print Operations
3. Insert the media through the slot at the rear of the printer and place the media
between the media guide and roll holders.
4. Close the top cover.
After printing or using the FEED button to advance several labels: If the media does
not track down the center (moves from side to side) or the sides of the media (liner, tag,
paper, etc.) are frayed or damaged when exiting the printer, then the media guide stop
position may need further adjustment.
If this does not correct the problem, then the media can be routed over the two roll holding
pins on the media guide. An empty roll core of the same width as the stack of the fan-fold
media can be placed between the roll holders to provide additional support for thin media.
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Print Operations
Printing with Externally Mounted Roll Media
The printer accommodates externally mounted roll media similar to the printer’s support of
fan-fold media. The printer requires the media roll and stand combination to have a low
initial inertia to pull the media off the roll.
Externally Mounted Roll Media Considerations:

• The media ideally should enter the printer directly behind the printer through the
fan-fold media slot in the rear of the printer. See Printing on Fan-Fold Media for
media loading.
• Lower the print speed to decrease the chance of motor stalls. The roll typically has
the highest inertia when trying to start the roll moving. Larger media roll diameters
require the printer to have more torque applied to get the roll moving.
• The media should move smoothly and freely. The media should not slip, skip, jerk,
bind and then move, etc. when mounted on your media stand.
• The printer should not touch the media roll.
• The printer should not slip or lift up off the operating surface.
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Print Operations
Using the Label Dispenser Option
The label dispenser option allows you to print a label and have the backing material
(liner/web) automatically removed. When printing multiple labels, removing the dispensed
(peeled) label triggers the printer to print and dispense the next label.
To use dispense-mode, set ‘Media Handling’ to ‘Peel-Off’ in the printer driver or with the
Zebra Setup Utility using the ‘Configure Printer Settings’ wizard. Otherwise, you must send
the ZPL programming commands to the printer.
When programming in ZPL, you can use the command sequences shown below to
configure the printer to use the dispenser option:
^XA ^MMP ^XZ
^XA ^JUS ^XZ
1. Load your labels into the printer. Close the printer and press the FEED button until a
minimum of 100 millimeters or 4 inches of exposed labels exit the printer. You can
leave the labels on the liner.
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Print Operations
2. Lift the liner over the top of the printer. Pull the gold latch in the center of dispenser
door away from the printer and the door will open.
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Print Operations
3. Insert the label liner between the dispenser door and the printer body.
4. Close the dispenser door while pulling the end of the label liner tight.
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Print Operations
5. Press and release the FEED (Advance) button one or more times until a label gets
presented for removal.
6. During the print job, the printer will peel off the backing and present a single label.
Take the label from the printer to allow the printer to print the next label.
Note • If you did not activate the label taken sensor to detect the removal of the dispensed
(peeled) label with software commands, the printed labels will stack and may bind the
mechanism.
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Print Operations
Using the Linerless Options
The Linerless Media Tear-Off and Cutter options operate like the standard media printers.
These options include an additional sensor to detect when a printed and presented label
is taken from the printer.
Linerless printers require special cleaning processes to maximize the platen (drive) roller
and special non-stick surfaces in the printer and media path areas.
the Linerless printing option allows you to print a multi-label format/form that stops
between each label. Removing the dispensed (peeled) label triggers the printer to print and
dispense the next label until all labels have been printed.
To use dispense-mode, set ‘Media Handling’ to ‘Peel-Off’ in the printer driver or with the
Zebra Setup Utility using the ‘Configure Printer Settings’ wizard. Otherwise, you must send
the ZPL programming commands to the printer.
When programming in ZPL, you can use the command sequences shown below to
configure the printer to use the dispenser option:
^XA ^MMP ^XZ
^XA ^JUS ^XZ
Linerless Printing
• Linerless media loads the same as models with the standard ‘tear-off’’ bezel or the
general cutter factory options. See Loading Roll Media.
• Media Reloading - Clean the printhead and inspect the media path and platen
roller for build up of adhesive and debris. Remove particles with the adhesive side
of your linerless media. Lightly touch the media path and platen roller with the
label to lift particles off the exposed area of the platen roller and the media path
areas. See Linerless Platen (Drive) Roller cleaning procedure.
• Don’t remove new media from it’s protective wrapping until you are ready to
place it in the printer. Setting the roll on its side will pick up contaminants and may
stick to surfaces.
• Important • The platen roller can accumulate adhesive on the outer edges of the
roller. After using many rolls of media, these ‘rings’ of adhesive can get dislodged
when using printer. These particle clumps can then get transferred to other areas.
214
Print Operations
Sending Files to the Printer
Graphics, fonts and programming files can be sent to the printer from the Microsoft
Windows operating systems by using the Link-OS Profile Manager, Zebra Setup Utilities
(and driver), ZebraNet ™ Bridge or Zebra® ZDownloader found on the Zebra Web site:
www.zebra.com/software.
Ribbon Cartridge Programming Commands

The ZD420 Ribbon Cartridge printer offers several Set Get Do (SGD) programming
commands to support the use of the ribbon cartridge. See the ZPL Programmer’s Guide
for more details on SGD commands and SGD “ribbon” commands in particular. The
following are examples of SGD ribbon cartridge commands.
! U1 getvar "device.feature.ribbon_cartridge"
! U1 getvar "ribbon.cartridge.part_number"
! U1 getvar "ribbon.cartridge.authenticated"
! U1 getvar "ribbon.cartridge.length_remaining"
! U1 getvar "ribbon.cartridge.serial_number"
! U1 getvar "ribbon.cartridge.width"
! U1 getvar "ribbon.cartridge.type"
! U1 getvar "ribbon.cartridge.length"
! U1 getvar "ribbon.cartridge.inserted"
ribbon.ribbon_low.warning : 50 , Choices: off,5,10,15,25,50,75,100
! U1 getvar "ribbon"
! U1 getvar "ribbon.ribbon_low.warning"
! U1 setvar "ribbon.ribbon_low.warning" "75"
! U1 setvar "ribbon.ribbon_low.warning" "off"
The Zebra Setup Utilities may be used to send commands and receive status back from
the printer using the ‘Open Communication With Printer’ feature.
215
Print Operations
Printer Fonts
The ZD-Series printer supports your language and font requirements. The ZPL ™
programming language provides advanced font mapping and scaling technology to
support outline fonts (TrueType ™ or OpenType ™ ) and Unicode character mapping as
well as basic bitmapped fonts and character code pages.
The printer’s font capabilities are programming language dependent. The ZPL and the
legacy EPL programming guides describe and document the fonts, code pages, character
access, listing fonts, and limitations for their respective printer programming languages.
See the printer programming guides for information on Text, Fonts and Character support.
Zebra has variety of utilities and application software that support font download to the
printer for ZPL and EPL printer programming languages.
Important • Some factory installed ZPL fonts in your printer cannot be copied, cloned or
restored to your printer by reloading or updating firmware. If these license restricted ZPL
fonts are removed by an explicit ZPL object delete command, they must be repurchased
and reinstalled via a font activation and installation utility. EPL fonts do not have this
restriction.
216
Print Operations
Identifying Fonts in Your Printer

Fonts and memory are shared by the programming languages in the printer. Fonts can be
loaded into various storage locations in the printer. ZPL programming can recognize EPL
and ZPL fonts. EPL programming can only recognize EPL fonts. See the respective
programmer guides for more information on fonts and printer memory.
ZPL Fonts
• To manage and download fonts for ZPL print operation, use the Zebra Setup Util-
ity or ZebraNet ™ Bridge.
• To display all of the fonts loaded in your printer, send the printer the ZPL com-
mand ^WD. See the ZPL Programmers Guide for details.
• Bitmap fonts in the various printer memory areas are identified by the .FNT file
extension in ZPL.
• Scalable fonts are identified with the .TTF, .TTE or .OTF file extensions in
ZPL. EPL does not support these fonts.
Localizing the Printer with Code Pages

The Link-OS 4 inch Desktop printer supports two sets of language, region and character
sets for permanent fonts loaded into the printer for each printer programming language,
ZPL and EPL. The printer supports localization with common international character map
code pages.
• For ZPL code page support, including Unicode, see the ^CI command in the ZPL
programmer’s guide.
217
Print Operations
Asian fonts and Other Large Font Sets

Asian language ideographic and pictographic fonts have large character sets with
thousands of characters that support single language code page. In order to support the
large Asian character sets, the industry adopted a double-byte (67840 maximum)
character system instead of the single-byte characters (256 maximum) used by Latin
based language characters to address large font sets. In order to address multiple
languages with a single font set, Unicode was invented. A Unicode font supports one or
more code points (relate these to code page character maps) and is accessed in a
standard method that resolves character mapping conflicts. The ZPL programming
language supports Unicode. Both of the printer’s programming languages support the
large pictographic double-byte character Asian font sets.
The number of fonts that can be downloaded is dependent upon the amount of available
flash memory not already in use and the size of the font to be downloaded.
Some Unicode fonts are large such as MS (Microsoft) Arial Unicode font (23 MB) available
from Microsoft or the Andale font (22 MB) offered by Zebra. These large font sets typically
support a large number of languages as well.
Getting Asian Fonts
Asian bitmap font sets are downloaded into the printer by the user or integrator. The ZPL
fonts are purchased separately from the printer. EPL Asian Fonts are available for free to
download from the Zebra Web site.
• Simplified and Traditional Chinese
(The SimSun scalable font is pre-loaded onto printers sold with a Chinese
power cord.)
• Japanese — JIS and Shift-JIS mappings
• Korean including Johab
• Thai
218
Print Operations
EPL Line Mode - Direct Thermal Printers only
Your direct thermal printer supports Line Mode printing. EPL Line Mode printing is
designed to be command compatible with EPL1 programming language used in early
model LP2022 and LP2042 printers. The Zebra 2800 series direct thermal printers also
included Line Mode printer language support. The Link-OS 4 inch Desktop continues
Zebra’s support of Line Mode.
Line mode printing is ideal for basic retail (point of sale - POS), shipping, inventory, work
flow control, and general labeling. EPL printers with Line Mode, are versatile and are
capable of printing a wide range media and bar codes.
Line Mode printing only prints single lines the height of the largest element present in the
line of text and data - bar code, text, a logo or simple vertical lines. Line mode has many
limitations due to the single line of print: no fine element placement, no overlapping
elements, and no horizontal (ladder) bar codes.
• Line Mode printer operation is entered by sending the printer the EPL OEPL1 com-
mand. See the EPL Programmers Guide (Page Mode) or the EPL Line Mode Pro-
grammers Guide.
• Line Mode printer operation is exited by sending the printer the escOEPL2 Line
Mode command. See the EPL Line Mode Programmers Guide.
• With Line Mode active, ZPL and EPL (EPL2) Page Mode programming will be pro-
cessed as Line Mode programming and data.
• With the default ZPL and EPL (EPL2) Page Mode active, Line Mode programming
will be processed as ZPL and/or EPL programming and data.
• Verify printer programming modes by printing out a printer configuration.
219
Print Operations
Zebra® ZKDU — Printer Accessory
The Zebra® ZKDU (keyboard display unit) is a small terminal unit that interfaces with the
printer for accessing EPL or ZPL label forms stored in the printer.
The ZKDU is strictly a terminal and does not have the capability to store data or set up
parameters.
The ZKDU is used for the following functions:
• List label forms stored in printer
• Retrieve label forms stored in printer
• Input variable data
• Printing labels
• Switching between EPL and ZPL to dual support both printer language
format/form types that can be stored and printed in many later model Zebra
label printers.
220
Print Operations
ZD620 and ZD420 Locking Printer Option
The Locking Printer option is available as a Healthcare printer only. The Locking Printer’s
features are:
• Lock and key access to the printer’s media compartment.
• Metal locking mechanism built into the printer.
• Precision fabricated metal parts for repeatable movement.
• Locking mechanism comes with two-keys.
• Supports industry recognized Kensington lock slot that allows you to lock printer
to any immovable object such as a desk.
• Permanently sealed media window for added security (not serviceable).
• The FEED button is disabled to prevent user from manually advancing media
while the media compartment is locked. The FEED key will always boot up in
FEED disabled mode.
• Supports all media that is contained within the printer. Not recommend for fan-fold
media.
For an illustration of the Locking Printer’s features, see ZD620 and ZD420 Locking Printer
Features.
221
Print Operations
ZBI 2.0 ™ — Zebra Basic Interpreter
Customize and enhance your printer using the ZBI 2.0 ™ programming language. ZBI 2.0
allows Zebra printers to run applications and take input from scales, scanners and other
peripherals without a PC or network connection. ZBI 2.0 works with the ZPL printer
command language so that printers can understand non-ZPL data streams and convert
them into labels. That means the Zebra printer can create barcodes and text from input
received, non-ZPL label formats, sensors, keyboards and peripherals. Printers can also be
programmed to interact with PC based database applications to retrieve information to be
used on printed labels.
• ZBI 2.0 can be activated by ordering a ZBI 2.0 Key Kit, or activated by purchasing
a key from Zebra.
• Use the ZBI Key Manager (also know as ZDownloader utility) to apply the key.
• An intuitive ZBI-Developer ™ is used to create, test and distribute ZBI 2.0 applica-
tions. The built-in "Virtual Printer" allows you to quickly create, test and prepare
programs for use. ZBI-Developer is available at the Zebra Web site:
Go to the Zebra Web site and search for Zebra Basic Interpreter 2.0.
www.zebra.com
222
Print Operations
Setting the Power Failure Recovery Mode Jumper
The printer can be configured to re-start itself after a power failure, unattended, with Power
Failure Recovery Mode.
Connectivity Module installed in your printer.
The Printer Connectivity Modules have a Power Failure Recovery jumper set to OFF. With
the jumper set to ON, the printer will automatically Power ON when plugged into an active
(ON) AC power source (and not power off).
Setting the Jumper
1. Disconnect the DC power plug and any interface connectors from the rear of the
printer.
2. Remove the module access door and connectivity module. See Removing Printer
Connectivity Modules for instructions for ZD420 printer models. The connectivity
module on a ZD620 printer model is removed like a ZD420 printer’s module.
3. Move the AUTO (Power Failure Recovery Mode) jumper from the OFF position to the
ON.
223
Print Operations
4. Reinstall the connectivity module and module access door. See Installing the Internal
Ethernet (LAN) Module or Installing the Serial Port Module for ZD420 printer models.
The connectivity module on a ZD620 printer model is installed like a ZD420 printer’s
module.
5. Reconnect the printer DC power plug and interface cables to the printer.
224
USB Host Port and Link-OS
Demonstration Examples
This section has information on using the printer’s USB Host port along with Link-OS
features and Apps (applications).
USB Host
The USB host port allows you to connect USB devices — such as a keyboard, scanner, or
USB Flash (memory) drive — to the printer.
USB Host Port Uses
• Firmware updates,
• File transfers and management
• A port for low power USB data entry devices (keyboards, scales, scanners, and
other wedge devices).
USB Host Port
Important • The USB Flash drive must be formatted with the FAT file system. Filenames
may be 1 to 16 alphanumeric characters (A, a, B, b, C, c, ..., 0, 1, 2, 3, ...) only. Only use
ASCII characters. Do not use Asian characters, Cyrillic characters, or accented characters
in file names. Some functions may not work properly if there are underscores in a file
name. Use periods instead.
225
USB Host Port and Link-OS Demonstration Examples
Using USB Host for Firmware Updates

The USB host port allows you to connect an USB Flash drive to the printer to perform
firmware updates.
This is an example of using the powerful printer management, Zebra Mirror functions. See
the printer ZPL programming manual — Mirror and Set-Get-Do (SGD) usb.mirror
commands operation.
Important • Supports USB Flash drives (or “thumb drive” or “memory stick”) up to
1 Terabyte (TB). The printer will not recognize drives larger than 1 TB.
Flash Drive Preparation and Firmware Update

1. On your USB Flash Drive, create the following:
• a folder called Zebra
• in that folder, create three sub-directories:
• appl
• commands
• files
2. In the /appl folder, place a copy of the latest firmware for your printer.
3. Load the printer with media. See Loading Roll Media.
4. Insert the USB Flash drive into the USB host port on your printer.
5. Observe the user interface and wait.
If the firmware version on the USB Flash drive is different than the version installed on
the printer, the firmware will download to the printer. The data indicator will flash
green while the firmware is downloading. The printer will restart with all indicators
flashing. When the firmware update has completed, the STATUS indicator will display
solid Green as the firmware is validated and installed. The ZD620 printer will display
firmware download status messages on the LCD (and with the default IDLE DISPLAY
mode set, the LCD shows the firmware version). A printer Configuration Report is
automatically printed and the firmware update has been completed.
6. Remove the USB Flash drive from the printer.
226
USB Host and Printer Usage Examples
The exercises in this section will teach you how to perform USB mirror (using an alternate
firmware update procedure), how to transfer files to and from the printer, and how to
provide information for which you are prompted and then print a label using that
information.
Items Required for the USB Host Exercises

To perform the exercises in this document, you will need the following:
• USB Flash drive up to 1 Terabyte (TB). The printer will not recognize drives larger
than 1 TB.
• USB keyboar.d
• Various files referenced below (from files attached inside this PDF file)
• Free Zebra Utilities app for your smart phone (search for Zebra Tech in the
Google Play store).
Files for Completing the Exercises

Most of the actual files that you need to complete the exercises in these section are
attached here in the PDF file. Copy these files to your computer before you begin the
exercises. Where possible, the contents of the files are shown. The contents of files that
contain coded content, which cannot be viewed as text or as an image, are not included.
File 1: ZEBRA.BMP
File 2: SAMPLELABEL.TXT
^XA
^FO100,75^XGE:zebra.bmp^FS
^FO100,475Â0N,50,50^FDMirror from USB Completed^FS
^XZ
This simple label format prints the Zebra logo and a line of text at the end of the mirroring
exercise.
File 3: LOGO.ZPL
Uses the Zebra logo bitmap file.
227
File 4: USBSTOREDFILE.ZPL
CT~~CD,~CC^~CT~
^XA~TA012~JSN^LT0^LH0,0^JMA^PR4,4~SD15^LRN^CI0^XZ
~DG000.GRF,07680,024,,[image data]
^XA
^LS0
^SL0
^BY3,3,91^FT35,250^BCN,,Y,N^FC%,{,#^FD%d/%m/%Y^FS
^FT608,325^XG000.GRF,1,1^FS
^FT26,75Â0N,28,28^FH\^FDThis label was printed from a format stored^FS
^FT26,125Â0N,28,28^FH\^FDon a USB Flash Memory drive. ^FS
^BY3,3,90^FT33,425^BCN,,Y,N
^FD>:Zebra Technologies^FS
^PQ1,0,1,Y^XZ
^XAÎD000.GRF^FS^XZ
This label format prints an image and text. This file will be stored on the USB memory
device at the root level so that it can be printed.
File 5: VLS_BONKGRF.ZPL
File 6: VLS_EIFFEL.ZPL
228
File 7: KEYBOARDINPUT.ZPL
^XA
^CI28
^FT40,70Â0N,28,28^FH\^FDThis label was printed using a keyboard input.
^FS
^FT35,260Â0N,28,28^FH\^FDThis label was printed by:^FS
^FT33,319Â0N,28,28^FN1"Enter Name"^FS
^XZ
This label format, used for the USB keyboard input exercise, does the following:
• Creates a barcode with the current date, based on your Real-Time Clock (RTC)
setting. (RTC may not be present in the printer version you purchased)
• Prints the Zebra logo graphic
• Prints fixed text
• Prints text entered with the keyboard by a operator
File 8: SMARTDEVINPUT.ZPL
^XA
^CI28
^FT40,70Â0N,28,28^FH\^FDThis label was printed using a smart device
input. ^FS
^FT35,260Â0N,28,28^FH\^FDThis label was printed by:^FS
^FT33,319Â0N,28,28^FN1"Enter Name"^FS^XZ
The same label format as the previous label, only with different text printing. This format is
used for the smart device input exercise.
229
Exercise 1: Copy Files to a USB Flash Drive and Perform USB Mirror
7. On your USB Flash Drive, create the following:
• a folder called Zebra
• in that folder, three subfolders:
• appl
• commands
• files
1. In the /appl folder, place a copy of the latest firmware for your printer.
Note • Some functions may not work properly if there are underscores in a file name. Use
periods instead.
2. In the /files folder, place the following file:
• File 1: ZEBRA.BMP
3. In the /commands folder, place the following files:
• File 2: SAMPLELABEL.TXT
• File 3: LOGO.ZPL
4. Insert the USB Flash drive into a USB host port on the front of your printer.
5. Observe the user interface and wait. The following should happen:
• If the firmware on the USB Flash drive is different than what is on the printer,
the firmware downloads to the printer. The printer then restarts and prints a
printer configuration label. (If there is no firmware on the USB Flash drive or if
the firmware version is the same, the printer skips this action.)
• The printer downloads the files in the /files folder and briefly shows the
names of the files that are downloading on the display.
• The printer executes any files in the /commands folder.
• The printer restarts and then displays the message
MIRROR PROCESSING FINISHED.
6. Remove the USB Flash drive from the printer.
230
Exercise 1: Advanced User Information
See the ZPL Programming Guide for more information about these commands.
Enable/disable mirroring:
! U1 setvar "usb.mirror.enable" "value" — Values: "on" or "off"
Enable/disable automatic mirroring that occurs when a USB Flash drive is inserted
into the USB host port:
! U1 setvar "usb.mirror.auto" "value" — Values: "on" or "off"
Mirror Operation Retry Number — Specify the number of times that the mirror
operation will be repeated if it fails:
! U1 setvar "usb.mirror.error_retry" "value" — Values: 0 to 65535
Change File Path FROM USB — Reprogram the file location the printer searches to
retrieve files from the USB memory during Mirror operations.
! U1 setvar "usb.mirror.appl_path" "new_path" — Default: "zebra/appl"
Change File Path TO USB — Reprogram the file location the printer places files into
USB memory during Mirror operations.
! U1 setvar "usb.mirror.path" "path" — Default: "zebra"
Enable/disable the USB Host port
! U1 setvar "usb.host.lock_out" "value" — Values: "on" or "off"
231
Exercise 2: Print a Label Format from a USB Flash Drive

The Print USB File option allows you to print files from a USB mass storage device, such
as a USB Flash drive. Only printable files (.ZPL and .XML) may be printed from the USB
mass storage device, and the files must be located at the root level, not in a directory.
1. Copy the following files to your USB Flash drive:
• File 4: USBSTOREDFILE.ZPL
• File 5: VLS_BONKGRF.ZPL
• File 6: VLS_EIFFEL.ZPL
3. On the printer’s LCD users interface, press the LEFT SELECT button (below the
home icon) to access the printer’s Home Menu.
4. Use the ARROW buttons to scroll to the Tools menu and SELECT (checkmark icon)
5. Use the ARROW buttons to scroll to PRINT USB FILE.
The printer loads any executable files and processes them. The available files are listed.
SELECT ALL is available to print all files on the USB Flash drive.
6. If necessary, use the up and down arrow to select USBSTOREDFILE.zpl.
7. Press the RIGHT SELECT button to select PRINT. The label prints.
232
Exercise 3: Copy Files to/from a USB Flash Drive

The Copy USB File option allows you to copy files from a USB mass storage device to the
printer’s Flash memory E: drive.
1. Copy the following files to the root directory of your USB Flash drive. Do not put these
files into a subfolder.
• File 7: KEYBOARDINPUT.ZPL
• File 8: SMARTDEVINPUT.ZPL
3. On the printer’s LCD users interface, press the LEFT SELECT button to access the
printer’s Home Menu.
4. Use the ARROW buttons to scroll to the Tools menu and press SELECT (checkmark
icon).
5. Use the ARROW buttons to scroll to COPY USB FILE TO E:.
SELECT ALL is available to copy all of the available files from the USB Flash drive.
6. If necessary, use the UP or DOWN ARROW to select the file STOREFMT.ZPL.
7. Press the RIGHT SELECT button to select STORE.
The printer stores the file in E: memory. All file names are converted to uppercase.
8. Repeat this process to select the file STOREFMTM1.ZPL.
9. Press the RIGHT SELECT button to select STORE.
The printer stores the file in E: memory.
10. Remove the USB Flash drive from the USB host port.
233
NOTE: You can now copy these files from the printer to a USB Flash drive using the user
menu item STORE E: FILE TO USB.
The option SELECT ALL is available to store all of the available files from the printer to
the USB Flash drive. Any .ZPL file that is copied will be post-processed such that the
contents of the file will be suitable to be sent to a printer for normal execution.
234
Exercise 4: Enter Data for a Stored File with a USB Keyboard

and Print a Label
The Print Station feature allows you to use a USB Human Interface Device (HID), such as
a keyboard or a barcode scanner, to enter ^FN field data into a *.ZPL template file.
1. After performing the previous exercise, plug a USB keyboard into a USB host port.
2. Use the ARROW buttons to scroll to the Tools menu.
3. Press OK.
4. Use the ARROW buttons to scroll to PRINT STATION.
5. If necessary, use the UP or DOWN ARROW to select the file KEYBOARDINPUT.ZPL.
6. Press the RIGHT SELECT button to choose SELECT.
The printer accesses the file and prompts you for the information in the ^FN fields in the
file. In this case, it prompts you for your name.
7. Type your name, and then press <ENTER>. The printer prompts for the number of
labels to print.
8. Specify the desired quantity of labels, and then press <ENTER> again.
The specified number of labels is printed, with your name in the appropriate fields.
235
Using the USB Hosts Port and the NFC Capabilities
The Zebra Print Touch ™ feature allows you to touch an Android ™ -based, Near Field
Communication (NFC)-enabled device such as a smart phone or tablet to the printer’s
Print Touch logo to pair the device to the printer. This capability allows you to use your
device to provide information for which you are prompted and then print a label using that
information.
Important • Some mobile devices may not support NFC communication with the printer
until you configure the required NFC settings in your device. If you encounter difficulties,
consult your service provider or your smart device manufacturer for more information.
Print Touch Location

(Passive NFC)
236
Exercise 5: Enter Data for a Stored File with a Smart Device

and Print a Label
Note • The steps in this exercise may vary somewhat based on your smart device, on your
service provider, or on whether you already have the free Zebra Utilities app installed on
your smart device.
Refer to the Zebra Bluetooth User Guide for specific instructions for configuring your
printer to use a Bluetooth interface. A copy of this manual is available at:
http://www.zebra.com/manuals.
1. If you do not have the Zebra Utilities app installed on your device, go to the app store
for your device, search for the Zebra Utilities app, and install it.
2. Pair your smart device with the printer by holding the smart device next to the
Zebra Print Touch icon on the printer.
a. If necessary, access the Bluetooth information about your printer using your
smart device. For instructions, refer to the manufacturer’s documentation for
your device.
b. If necessary, select the Zebra printer’s serial number to pair it with the device.
c. After your smart device has been detected by the printer, the printer may
prompt you to accept or reject the pairing. If necessary, press the LEFT
SELECT button on the printer to select ACCEPT. Some smart devices will pair
with the printer without this prompt.
The printer and your device are paired.

3. Start the Zebra Utilities app on your device.
The Zebra Utilities main menu displays.
237
4. Perform these steps if you have an Apple device:

a. Tap the Settings icon in the lower-right corner.
b. Change the setting for Get Labels From Printer to ON.
c. Tap Done.
5. Tap Files.
The smart device gets data from the printer and displays it.
Note • This retrieval process may take a minute or more to complete.
6. Scroll through the formats shown and select E:SMARTDEVINPUT.ZPL.

Based on the ^FN field in the label format, the smart device prompts you for your name.
7. Enter your name at the prompt.
8. Change the quantity of labels to print, if desired.
9. Tap PRINT to print the label.
238
Maintenance
This section provides routine cleaning and maintenance procedures.
Cleaning
Your Zebra printer may require periodic maintenance to keep your printer functional and
printing high quality labels, receipts, tags, etc.
Cleaning Supplies
The following printer cleaning supplies are recommended for use with your printer:
• Printhead Cleaning Pens for simple operator printhead cleaning
• 99% pure Isopropyl Alcohol (Use a labeled dispenser. Never re-moisten clean-
ing materials used to clean the printer).
• Fiber-free Cleaning Swabs for media path, guides, and sensors and Cleaning
Wipes for media path and interior (for example Kimberly-Clark Kimwipes ).
• Can of Compressed Air.
Important • The cutter mechanism does not require maintenance cleaning. DO NOT clean
the blade or mechanism. The blade has a special coating to resist adhesives and wear.
Important • Using too much alcohol can result in contamination of the electronic
components requiring a much longer drying time before the printer will function properly.
Important • Do Not Use an air compressor in place of the can of compressed air. Air
compressors have micro contaminants and particles the get into the air system and
damage your printer.
Eye Injury Caution • Use eye protection to protect your eyes from flying particles and
objects when using compressed air.
Get Zebra Supplies and Accessories for Cleaning Your Printer
Go to the Zebra Web site: www.zebra.com/accessories
239
Maintenance
Recommended Cleaning Schedule

Printhead
Interval: Clean the printhead after every 5 rolls printed.
Procedure: Cleaning the Printhead
Standard Platen (Drive) Roller
Interval: As needed to improve print quality. Platen rollers can slip causing print image
distortion and in worst case scenarios not move the media (labels, receipts, tags, etc.).
Procedure: See Platen Cleaning and Replacement.
Note • Standard platen rollers come in two colors, black (203 dpi) and gray (300 dpi).
Linerless Platen (Drive) Roller

Interval: If there is observed build-up of particles on the platen roller, use this procedure.
The linerless platen normally does not require cleaning. The adhesive side of the media
picks up particles as you print.
If the linerless media is sticking and binding in the printer, the linerless platen normally
needs to be replaced. The silicon non-stick coating has been used up.
Important • Linerless platen rollers come in two colors, reddish-brown (203 dpi) and brown
(300 dpi).
Important • Cleaning the roller with solutions or rubbing the delicate surface of this type of
roller will permanently damage or shorten the usable life of the linerless platen.
Important • The platen roller can accumulate adhesive on the outer edges of the roller.
After using many rolls of media, these ‘rings’ of adhesive can get dislodged when using the
printer. These particle clumps can then get transferred to other areas in the printer, most
importantly, the printhead.
Procedure: To remove adhesive particles, use the adhesive side of a piece of linerless
media to gently press and remove the particles from the plater roller. Use the Platen
Cleaning and Replacement procedure to get better access for particle removal.
240
Maintenance
Media Path
Interval: Clean as needed.
Method: Clean it thoroughly with fiber-free cleaning swabs and cloths moistened with 99%
isopropyl alcohol. Let alcohol evaporate completely.
Procedure: See Media Path Cleaning.
Interior
Interval: Clean the printer as needed.
Method: Use a soft cloth, brush or compressed air to wipe or blow dust and particles out
of the printer. A 99% isopropyl alcohol and a fiber-free cleaning cloth can be used to dissolve
contaminants like oils and grime.
Exterior
Interval: Clean as needed.
Method: Use a soft cloth, brush or compressed air to wipe or blow dust and particles out
of the printer. The exterior of the printer can be cleaned using plain soap and water
solutions to moisten the cloth. Only use the minimum amount of cleaning to avoid getting
solution in the printer or other areas. Do not clean connectors or interior of the printer. with
this method.
Healthcare Printer Models — The latest models now include Ultra-Violet (UV) and
disinfectant-ready plastics for hospital and other similar environments. The user control’s
are sealed so they can be cleaned with the rest of the printer’s exterior. See the ‘Guide To
Disinfecting and Cleaning Zebra® Healthcare Printers’ on the Zebra Web site for the
latest information on tested and approved cleaning materials, and cleaning methods.
Label Dispenser Option
Interval: As needed to improve label dispensing operations.
Procedure: See Label Dispenser Option cleaning.
241
Maintenance
Cutter Option
Interval: Not an operator serviceable component. Do Not Clean inside the cutter opening
or blade mechanism. You may use the Exterior cleaning to clean the cutter bezel
(housing).
Method: Call a service technician.
Procedure: None
mechanism.
Important • The blade has a special coating to resist adhesives and wear. Cleaning it may
ruin the blade.
Important • Using un-approved tools, cotton swabs, solvents (including alcohol), etc.; all
may damage or shorten the cutter’s usable life or cause the cutter to bind.
242
Maintenance
Cleaning the Printhead

Always use a new cleaning pen on the printhead (an old pen carries contaminants from its
previous use that may damage the printhead).
When you load new media, you should clean the printhead for optimal print operations.
Hot Surface Caution • The printhead becomes hot while printing. To protect from
damaging the printhead and risk of personal injury, avoid touching the printhead. Only use
the cleaning pen to perform printhead maintenance.
ZD620 / ZD420 Direct Thermal Printers
When you load new media, you can also clean the printhead.
1. Rub the cleaning pen across the dark area of the printhead. Clean from the middle to
the outside. This will move adhesive transferred from the edges of media to the
outside of media path.
2. Wait one minute before closing the printer to allow the components to dry.
243
Maintenance
ZD620 / ZD420 Thermal Transfer Printers

When you load new media or ribbon, you can also clean the printhead.
1. If transfer ribbon is installed, remove it before proceeding.
2. Rub the cleaning pen across the dark area of the printhead. Clean from the middle to
the outside. This will move adhesive transferred from the edges of media to the
outside of media path.
3. Wait one minute before closing the printer or loading ribbon to allow all components to
dry.
244
Maintenance
ZD420 Ribbon Cartridge Printers

1. Pull the two (2) Release Arms out to release the Ribbon Drive Transport. See
Accessing the Printhead of the Ribbon Cartridge Printer for more details.
2. Lift the Printhead Actuator Arm up to gain access to the printhead. Rub the cleaning
pen across the dark area of the printhead. Clean from the middle to the outside. This
will move adhesive transferred from the outer edges of media to the area outside of
media path.
3. Wait one minute before closing the printer.
4. Release the Printhead Actuator Arm and then push the Ribbon Drive Transport into
the Printhead Actuator Arm. The Release Arms will snap into place relinking the
Ribbon Drive Transport to the top cover and the Printhead Actuator Arm.
245
Maintenance
Media Path Cleaning

Use a cleaning swab and/or a lint free cloth to remove debris, dust or crust that has built-
up on the holders, guides and media path surfaces. Lightly moisten the swab or cloth with
99% solution medical-grade alcohol. For hard to clean areas, use extra alcohol on a
cleaning swab to soak the debris to break up any adhesive that may have accumulated on
surfaces in the media compartment.
Do not clean the printhead, sensors, or platen as part of this process.
Lower Half of ZD60/ZD420 Printers
The lower half of these printers these printers get cleaned the same.
1. Wipe the inside surfaces of the roll holders and the underside of the media guides
with a cleaning swabs and wipes.
2. Wipe the movable sensor slide channel (but not sensor). Move the sensor to get to all
areas.
3. Wait one minute before closing the printer. Discard used cleaning supplies.
Media Roll Holders
Media Guides
Don’t Clean Sensor
246
Maintenance
Upper Half of ZD620/ZD420 Direct Thermal Printers

1. Wipe the areas (outlined in orange) to remove adhesive and other contaminants. Do
not clean the sensor array.
Upper Half of ZD620/420 Thermal Transfer Printers

1. Wipe the area (outlined in orange) near the printhead on the front of the ribbon
carriage.
247
Maintenance
Upper Half of ZD420 Thermal Transfer Ribbon Cartridge Printers

2. Wipe the areas (outlined in orange) below the Printhead Actuator Arm and the Ribbon
Drive Transport.
3. Release the Printhead Actuator Arm and then push the Ribbon Drive Transport into
the Printhead Actuator Arm. The Release Arms will snap into place relinking the
Ribbon Drive Transport to the top cover and the Printhead Actuator Arm.
248
Maintenance
Cleaning the Cutter and Label Dispenser Options

This is a continuation of cleaning the media path for either option, if installed.
Cutter Option Cleaning
The plastic media path surfaces can be cleaned but not the internal cutter blades or
mechanism.
Important • The cutter blade mechanism does not require maintenance cleaning. DO NOT
clean the blade. This blade has a special coating to resist adhesives and wear.
mechanism.
Note • Using un-approved tools, cotton swabs, solvents (including alcohol), etc. all may
damage or shorten the cutter’s usable life or cause the cutter to jam.
1. Wipe the ridges and the plastic surfaces of the media entry (inside) and exit slot
(outside) of the cutter. Clean inside the areas outlined in blue.
2. Repeat as necessary to remove any adhesive or contaminate residue after it dries.
249
Maintenance
Label Dispenser Option Cleaning

1. Open the door and clean the peel bar, inner surfaces and ridges on the door.
2. Wipe the roller while rotating it. Discard the swab or cloth. Clean again to remove
diluted residue.
3. Clean the sensor window. The window should be clear of streaks and residue.
Inside Wall
Label Taken
Sensor
Peel Bar Pinch Roller Ridges
250
Maintenance
Sensor Cleaning
Dust can accumulate on the media sensors. Do not use an air compressor to remove dust.
Compressors add moisture, fine grit, and lubricant which can contaminate your printer.
Lower Half of ZD60/ZD420 Printers
1. Clean the Movable Sensor’s window. Gently brush away dust or use a can of
compressed air; if necessary, use a dry swab to brush away dust. If adhesives or
other contaminants remain, use an alcohol moistened swab to break it up.
2. Use a dry swab to remove any residue that may be left from the first cleaning.
3. Repeat steps 1 and 2 as required until all residue and streaks are removed from the
sensor.
Movable Sensor
(Black Mark and
Lower Web/Gap)
251
Maintenance
Upper Half of ZD620/ZD420 Direct Thermal Printers

1. Spray the Upper Web (Gap) Array Sensor below the printhead with a can of
compressed air. If necessary, use an alcohol moistened swab to break up adhesive or
other non-dust contaminants. Use a dry swab to remove any residue that may be left
from the first cleaning.
Upper Half of ZD620/ZD420 Thermal Transfer Printers

1. Spray the Upper Web (Gap) Array Sensor below the printhead with a can of
compressed air. Complete sensor cleaning (very rare) requires a service technician
Spray Sensor
Up Here
252
Maintenance
Upper Half of ZD420 Ribbon Cartridge Printers

2. Swing the Printhead Actuator Arm up until it touches the printer’s top cover. Hold the
Printhead Actuator Arm in this position for access to the area below the printhead,
see the next graphic.
3. Spray the Upper Web (Gap) Array Sensor under the Ribbon Drive Transport and the
Ribbon Out Sensor on the underside of the Printhead Actuator Arm with a can of
compressed air. If necessary, use an alcohol moistened swab to break it up. Use a
dry swab to remove any residue that may be left from the first cleaning.
Ribbon Out Sensor
Upper Web (Gap)

Array
253
Maintenance
Cleaning Ribbon Cartridge Sensor
4. Ribbon Cartridge Sensor Pins - Only clean when the cartridges are failing
detection. Clean the Ribbon Cartridge interface pins with a gentle wiping from right to
left. Up and down motions may damage the pins.
Ribbon Cartridge
Sensor
Contact Pins
254
Maintenance
Platen Cleaning and Replacement

The platen (drive roller) normally does not require cleaning. Normally, paper and liner dust
can accumulate without affecting print operations.
Clean the platen (and media path) whenever the printer has significantly poorer
performance, print quality or media handling. The platen is the print surface and drive roller
for your media. If sticking or jamming continues even after cleaning, you must replace the
platen.
Important • Contaminants on the platen roller can damage the printhead or cause the
media to slip or stick when printing. Adhesive, dirt, general dust, oils and other
contaminants should be cleaned immediately off the platen.
Important • LINERLESS PLATENS — Do not wash or scrub. Only remove adhesive
particles by using the adhesive side of linerless media. Lightly touch the platen roller with
a linerless label to lift particles off the exposed area of the platen roller and the media path
areas.
255
Maintenance
Removing the Platen Roller

The platen can be cleaned with a fiber-free swab (such as a Texpad swab) or a lint free,
clean, damp cloth very lightly moistened with medical grade alcohol (90% pure or better).
1. Open the cover (and dispenser door, if the dispenser is installed). Remove media
from platen area.
2. Pull the platen bearing latch release tabs on the right and left sides towards the front
of the printer and rotate them up.
Platen Bearings
Platen Bearings
256
Maintenance
3. Lift the platen out of the printer’s bottom frame.
Platen Bearings
4. Slide the gear and the two (2) bearings off the shaft of the platen roller.
257
Maintenance
5. Cleaning Only — Clean the platen with the alcohol moistened swab. Clean from the
center out. Repeat this process until all of the roller surface has been cleaned. If there
has been heavy adhesive build-up or label jam, repeat with a new swab to remove
residual contaminants. Adhesives and oils, for example, may be thinned by the initial
cleaning but not completely removed.
Important • LINERLESS PLATENS — Only use the adhesive side of a piece of linerless
media to gently lift the particles from the plater roller for cleaning.
6. Discard the cleaning swabs after use - do not reuse.
7. Make sure the bearings and drive gear are on the shaft of the platen roller.
8. Align the platen with the gear to the left and lower it into the printer’s bottom frame.
9. Rotate the platen bearing latch release tabs down on the right and left sides towards
the rear of the printer and snap them into place.
10. Allow the printer to dry for one minute before closing the dispenser door, media cover
or loading labels.
258
Maintenance
Replacing the Printhead
If you need to replace the printhead, read the procedure and review the removal and
installation steps before actually replacing the printhead.
ESD Caution • Prepare your work area by protecting against static discharge. Your work
area must be static-safe and include a properly grounded conductive cushioned mat to
hold the printer and a conductive wrist strap for yourself.
Caution • Unplug the printer from the power supply and allow the printer to cool to prevent
injuries or damage to printer circuitry.
Use one of the following model specific procedures to replace the printhead.
• ZD620 and ZD420 Direct Thermal
• ZD620 and ZD420 Thermal Transfer Ribbon Roll
• ZD420 Thermal Transfer Ribbon Cartridge
259
Maintenance
ZD620 and ZD420 Direct Thermal

Removing the Printhead
1. Turn the printer OFF. Open the printer.
Printhead
2. Push the printhead release latch away from the printhead. The right side of printhead
releases.
260
Maintenance
3. Swing the loose right side of the printhead out of the printer. Pull it out and to the right
a little to get the left side of the printhead clear. Pull the printhead out and free of the
top cover to gain access to its attached cables on the backside of the printhead. Note,
the red highlights the left side printhead retainer slot.
4. Gently but firmly pull the two printhead cable bundle connectors off of the printhead.
Pull the ground wire off the printhead.
Connectors
Printhead Ground Wire
Printhead Assembly
261
Maintenance

1. Push the right side printhead cable connector into the printhead. The connector is
keyed to only insert one way.
2. Attach the ground wire to the printhead’s ground tab.
3. Push the left side printhead cable connector onto the printhead.
Printhead Ground Wire
Connector with Key
Printhead Ground Tab

Spring Wire Notch
4. Insert the left side of the printhead assembly into the recessed slot (highlighted in red)
on the left side of the printer.
Slot
Tab
262
Maintenance
5. Align the Spring Wire Notch on the backside of the printhead to the Spring Wire. Push
the right side of the printhead into the printer until the latch locks the right side of the
printhead into the printer.
Spring Wire in Notch
263
Maintenance
6. Verify that the printhead moves up and down freely when pressure is applied and
remains locked when released.
7. Clean the printhead. Use a new pen to wipe body oils (finger prints) and debris of the
printhead. Clean from the center of the printhead to the outside. See Cleaning the
Printhead.
8. Reload media. Plug in the power cord, turn on the printer and print a status report to
ensure proper function. See Test Printing with the Configuration Report.
264
Maintenance
ZD620 and ZD420 Thermal Transfer Ribbon Roll

Removing the Printhead
Printhead
2. Push the printhead release latch toward the printhead (shown as green for visibility).
The right side printhead releases down and away from the Printhead Actuator Arm.
265
Maintenance
3. Swing the loose right side of the printhead out of the printer. Pull it to the right a little to
get the left side of the printhead clear. Pull the printhead down and free of the ribbon
carriage to gain access to its attached cables.
Connectors
Printhead Assembly
266
Maintenance

3. Insert the center tab on the printhead assembly into the center slot on the Printhead
Actuator Arm.
267
Maintenance
4. Insert the left side tab of the printhead assembly into the recessed slot on the left side
of the Printhead Actuator Arm.
Slot
Tab
5. Push the right side of the printhead into the printer until the latch locks the right side of
the printhead into the printer.
268
Maintenance
6. Verify that the printhead moves up and down freely when pressure is applied and
remains locked when released.
7. Clean the printhead. Use a new pen to wipe body oils (finger prints) and debris of the
printhead. Clean from the center of the printhead to the outside. See Cleaning the
Printhead.
8. Reload media. Plug in the power cord, turn on the printer and print a status report to
ensure proper function. See Test Printing with the Configuration Report.
269
Maintenance
ZD420 Thermal Transfer Ribbon Cartridge

Printhead Removal
3. Swing the Printhead Actuator Arm up until it touches the printer’s top cover. Hold the
Printhead Actuator Arm in this position for access to the printhead. Push the printhead
release latch toward the printhead (shown as pink for visibility). The right side
printhead releases down and away from the Printhead Actuator Arm.
4. Swing the loose right side of the printhead out of the printer. Pull it to the right a little to
get the left side of the printhead clear. Pull the printhead down and free of the
Printhead Actuator Arm to gain access to its attached cables.
270
Maintenance
Connectors
Printhead Assembly
271
Maintenance
3. Insert the center tab on the printhead assembly into the center slot on the Printhead
Actuator Arm.
Tab Slot
4. Insert the left side tab of the printhead assembly into the recessed slot on the left side
of the Printhead Actuator Arm.
Tab Slots - both sides
272
Maintenance
5. Push the right side of the printhead into the printer until the latch locks the right side of
the printhead into the printer.
Slot
Guide
6. Verify that the printhead moves freely into the printer when pressure is applied (see
arrow) and remains locked when pressure is released.
7. Clean the printhead by using a new cleaning pen to wipe body oils (finger prints) and
debris off the printhead. See Cleaning the Printhead.
8. Reload media. Turn on the printer and print a status report to ensure proper function.
See Test Printing with the Configuration Report.
273
Maintenance
Updating Printer Firmware
The printer’s firmware may need to be updated periodically to get new features,
improvements, and printer upgrades for media handling and communications.
Use Zebra Setup Utilities (ZSU) to load new firmware.
1. Open Zebra Setup Utilities.
2. Select your installed ZD620/ZD420 printer.
3. Click on the ‘Open Printer Tools’ button and a ‘Tools’ window will open.
4. Click on the ‘Action’ tab.
5. Load the printer with media. See Loading Roll Media.
6. Click on the text line - ‘Send file’. The lower half of the window will present a filename
and path with a Browse (...) button to select the latest firmware file you have
downloaded from the Zebra Web site.
7. Observe the user interface and wait.

If the firmware version is different than the version installed on the printer, the
firmware will download to the printer. The data indicator will flash green while the
firmware is downloading. The printer will restart with all indicators flashing. When the
firmware update has completed, the STATUS indicator will display solid Green as the
firmware is validated and installed. A printer Configuration Report is automatically
printed and the firmware update has been completed.
274
Maintenance
Other Printer Maintenance
There are no user level maintenance procedures beyond those detailed in this section.
See the Troubleshooting for more information on diagnosing printer and print problems.
RTC Battery
The Real Time Clock (RTC) is included with ZD620 and ZD420 Ribbon Cartridge printers.
Some other ZD420 printer’s may also include this option.
The clock’s battery is rated to provide approximately ten (10) years of service and is not
user replaceable. See a Zebra authorized service technician to replace the battery. See
the warranty for your printer for more details at the Zebra Web site:
www.zebra.com/warranty
Caution • The printer has a three volt lithium battery. You can discern a low or flat battery
if the printer provides a consistently delayed date stamp. Battery replacement must be
performed by a qualified service technician. Only use a Zebra approved replacement
battery.
Important • Recycle batteries according to local your guidelines and regulations. Wrap the
battery when disposing (or storing) to avoid a short circuit.
Caution • DO NOT short circuit the battery. Short circuiting the battery may result in heat
generation, fire or bursting.
Caution • DO NOT heat, disassemble or dispose of battery in fire.
Fuses
There are no replaceable fuses in ZD-Series printers or power supplies.
275
Troubleshooting
This section provides troubleshooting procedures and information.
Resolving Alerts and Errors
Alert: Printhead Open

A print command or a FEED button has been pressed and the printer has detected that the
printhead (cover) is not closed.
HEAD OPEN
CLOSE HEAD
Possible Cause - 1
The cover is open or has not been closed properly.
Resolution
Closed the cover/printhead. Push down on the front top corners of the printer’s cover. You
should normally hear and feel the cover latches snap in place to lock the cover closed for
printing.
See Closing the printer.
Possible Cause - 2
The printer’s Head-Open switch needs service.
Resolution
Call a service technician.
276
Troubleshooting
Alert: Media Out

A print command, a FEED button has been pressed, or you are printing; and the printer
can not detect media in the print path.
MEDIA OUT
LOAD MEDIA
Possible Cause - 1
There is no media (roll) in the printer.
Resolution
Load your chosen media in the printer and close the printer. You may need to press the
FEED button once or the PAUSE button the get the printer to resume your print operation.
See Loading Roll Media.
Possible Cause - 2
Open the printer: If there is a missing label on the roll between two labels at the end of a
roll of labels, then this is the method used by the label roll manufacture to identify the end
of the roll. See Detecting a Media Out Condition.
Resolution
Replace the empty media roll and continue printing. Do not power the print off or you will
loose your print job. See Detecting a Media Out Condition.
Possible Cause - 3
Misaligned media sensor.
Resolution
Check the position of the media sensor. See Using the Movable Sensor.
The printer may need to be calibrated for the media after the adjusting the sensor location.
See Run a SmartCal Media Calibration.
Possible Cause - 4
The printer is set for noncontinuous (labels or black mark) media, but continuous media is
loaded.
Resolution
Check the position of the media sensor is in the center default location. See Using the
Movable Sensor.
The printer may need to be calibrated for the media after the adjusting the sensor location.
See Run a SmartCal Media Calibration.
277
Troubleshooting
Possible Cause - 5
The media sensor is dirty.
Resolution
Clean the Upper Web (Gap) Sensor Array and the lower Movable Media sensors. See
Sensor Cleaning.
Reload your media, adjust the Movable Media sensor’s position for your media, and
recalibrate the printer for the media. See Loading Roll Media and Run a SmartCal Media
Calibration.
Possible Cause - 6
The media sensing is not working. Possible data corruption of memory or faulty
components.
Resolution
1 — Reload the printer’s firmware. See Updating Printer Firmware.
2 — If this does not fix this issue, call a service technician.
278
Troubleshooting
Alert: Ribbon In (ZD420 Cartridge Printer only)

A print command has been sent to the printer and it is in Direct Thermal Mode with Ribbon
installed.
Note • The printer has two different heat settings - one for Direct Thermal and one for
Thermal Transfer. They are designed to have equivalent print density/darkness at the
same setting level.
WARNING
RIBBON IN
Possible Cause - 1
There is a Ribbon Cartridge in the printer while the printer is set to Direct Thermal Mode
(and printing on direct thermal media).
Resolution
Remove the ribbon cartridge from the printer without turning the printer OFF. Close the
printer. You may need to press the FEED button once or the PAUSE button the get the
printer to resume your print operation.
Possible Cause - 2
The printer is incorrectly set to Direct Thermal Mode when you are trying to print using
Transfer Media and Ribbon Cartridge to print.
Resolution
Change the PRINT METHOD to THERMAL TRANS (Thermal Transfer) mode. The print
format/form send for this print job may have Direct Thermal mode set with a ^MTD set
instead of ^MTT. See the ZPL Programmer’s Manual for details on printer programming.
For printer links to manuals, see the About section of this guide.
To change this setting on the dynamically:
• Use the printer’s LCD user interface (if present) to change the setting. See PRINT
METHOD in Printer Configuration Menus chapter.
• Use an Ethernet (LAN or WLAN) printer’s Print Server Web page to access and
set the PRINT METHOD to THERMAL TRANS (Thermal Transfer) mode. See
PRINT METHOD in Printer Configuration Menus chapter for navigating the print
server users interface.
279
Troubleshooting
Alert: Ribbon Out

1 — The printer is printing and stops while printing.
2 — A print job has been sent to the printer and the printer immediately reports this Alert.
ALERT
RIBBON OUT
Possible Cause - 1
The printer has detected the end of the ribbon. The end of the ribbon has a reflective trailer
on the end of Genuine Zebra Transfer Ribbon that the printer ‘sees’ as End of Ribbon.
Resolution
Remove the ribbon and replace the ribbon rolls or ribbon cartridge in the printer without
turning the printer OFF. Close the printer. You may need to press the FEED button once
or the PAUSE button the get the printer to resume your print operation. See Detecting a
Ribbon Out Condition.
Possible Cause - 2 (ZD420 Cartridge Printer only)
A ribbon cartridge needs to be loaded in the printer. The printer is set for Thermal Transfer
Mode. See Loading the ZD420 Ribbon Cartridge.
Possible Cause - 3 (ZD420 Cartridge Printer only)
The media sensing is not working. Possible dirty ribbon cartridge data chip or cartridge
sensor contacts; data corruption of memory; or faulty cartridge or printer components.
Resolution
1 — Try another working ribbon cartridge, if available.
2 — Clean the Ribbon Cartridge chip with an alcohol moistened swab.
3 — Clean the Ribbon Cartridge Sensor’s contact pins. See Upper Half of ZD420 Thermal
Transfer Ribbon Cartridge Printers for cleaning instructions.
Possible Cause - 4 (Standard Roll - Thermal Transfer Printers)
The media sensing is not working.
Resolution
280
Troubleshooting
Alert: Ribbon Low (ZD420 Cartridge Printer only)

The printer reports this Alert.
ALERT
RIBBON LOW
Possible Cause - 1
The printer has calculated that the ribbon cartridge has only 10% of the ribbon left in the
cartridge. The ribbon low value can be changed by programming.
Resolution
Check for the availability of ribbon cartridges. To change the Ribbon Low warning point,
see the SGD commands - Ribbon Cartridge Programming Commands. See the ZPL
Programmer’s Manual for details on printer programming. For printer links to manuals, see
the About section of this guide.
281
Troubleshooting
Alert: CUT ERROR

The cutter blade is bound and is not moving properly
ERROR CONDITION
CUT ERROR
Possible Cause - 1
Media, adhesive, or external object has stopped the cutter blade from operating.
Resolution
1 — Turn the printer off by holding the power using the POWER button down for 5
seconds. Wait for thee printer to shutdown completely. Turn the printer on.
2 — If the printer does not recover from this error, call a service technician. This is not a
operator serviceable item.
mechanism.
Note • Using unapproved tools, cotton swabs, solvents (including alcohol), etc. all may
damage or shorten the cutter’s usable life or cause the cutter to jam.
282
Troubleshooting
Alert: PRINTHEAD OVER TEMP

1. The printhead is over temperature and paused to allow the printhead to cool.
PRINTHEAD OVER TEMP

PRINTING HALTED
Possible Cause - 1
The printer is printing a large batch job, typically with large amounts of print.
Resolution
The print operation will resume after the printhead has cooled.
Possible Cause - 2
The ambient temperature at the printers location exceeds the specified operating range.
Sometimes, ambient temperatures in the printer can be higher if it is in direct sunlight.
Resolution
Move the printer location or cool ambient temperature where the printer is operating.
283
Troubleshooting
Alert: PRINTHEAD SHUTDOWN

1. The printhead is below operating temperature for proper printing.
PRINTHEAD SHUTDOWN
PRINTING HALTED
Possible Cause - 1
Printhead has had a critical temperature or power failure
Resolution
operator serviceable item.
284
Troubleshooting
Alert: PRINTHEAD UNDER TEMP

1. The printhead is below operating temperature for proper printing.
PRINTHEAD UNDER TEMP

PRINTING HALTED
THERMISTOR
REPLACE PRINTHEAD
Possible Cause - 1
The ambient temperature at the printers location is below the specified operating range.
Resolution
Turn the printer off. Move the printer location and wait for it to warm naturally. Moisture may
condense in and on the printer if the temperature changes too quickly.
Possible Cause - 2
The printhead thermistor has failed.
Resolution
2 — If the printer does not recover from this error, call a service technician.
285
Troubleshooting
Alert: OUT OF MEMORY

Can not store data in the printer in the specified memory location. There is not enough
memory to perform the function specified on the second line of the error message.
OUT OF MEMORY
STORING GRAPHIC
OUT OF MEMORY
STORING FORMAT
OUT OF MEMORY
STORING BITMAP
OUT OF MEMORY
STORING FONT
Possible Cause - 1
There is not enough memory to perform the function specified on the second line of the
error message.
Resolution 1
1 — Free up some of the printer’s memory by adjusting the label format or printer
parameters to make the print area smaller.
2 — Remove unused graphics, fonts, or formats.
3 — Ensure that the data is not directed to a device that is not installed or is unavailable.
286
Troubleshooting
Resolving Print Issues
This section helps you identify issues with printing or print quality, the possible causes, and
the recommended solutions.
Issue: General Print Quality Issues

The printed image does not look right.
Possible Cause - 1
The printer is set at an incorrect darkness level and/or print speed.
Resolution
Perform the Print Quality Report (FEED self test) to determine the ideal darkness and
speed settings for your application. Do not set print speeds above the manufacturer’s
maximum rated speed for your media (print material and ribbons both).See Print Quality
Report (FEED self test) and Adjusting the Print Quality.
Possible Cause - 2
The printhead is dirty.
Resolution
Clean the printhead. See Cleaning the Printhead.
Possible Cause - 3
The platen roller is dirty or damaged.
Resolution
Clean or replace the platen. The platen can wear out or get damaged. See Platen Cleaning
and Replacement.
Possible Cause - 4
The printhead has worn out.
Resolution
Replace the printhead. The printhead can wear out and be damaged. See Replacing the
Printhead.
Possible Cause - 5
Thermal Transfer printing - Printing looks fuzzy, has smudge marks, or has voids or holes
in print with no particular pattern.
Resolution
The print material (wax, wax-resin, or resin) may not match the material (paper, media
coating, or synthetics) in use.
Set the printer for no higher than the maximum recommended print speed of the ribbon
cartridge. See Ribbon Cartridge Programming Commands for reading cartridge features.
287
Troubleshooting
Possible Cause - 6
You may be using the wrong power supply.
Resolution
Verify you are using the power supply that came with this printer.
Issue: No Print on the Label

The printed image does not look right.
Possible Cause - 1
The media may not be direct thermal media (and is thermal media made for thermal
transfer printers).
Resolution
See the test procedure, Determining Thermal Media Types.
Possible Cause - 2
Media has been loaded incorrectly.
Resolution
The media printable surface must face up towards the printhead. See Getting Ready to
Print followed by Loading Roll Media.
288
Troubleshooting
Issue: Labels Are Distorted in Size or Print Area Start Position Varies
Includes printed image that skips between labels (mis-registration).
Possible Cause - 1
Media has been loaded incorrectly or the movable media sensor is not set properly.
Resolution
Verify that the sensor is set and positioned correctly for your media type and sensing
location. See Loading Roll Media ,Setting Media Sensing by Media type, and Using the
Movable Sensor.
Possible Cause - 2
The media sensors are not calibrated for your media length, physical properties, or
sensing type (gap/notch, continuous, or mark).
Resolution
See Run a SmartCal Media Calibration. or if it still skips labels try a Manual Media
Calibration.
Possible Cause - 3
The platen (drive) roller is slipping or damaged.
Resolution
Clean or replace the platen. The platen can wear out or get damaged. See Platen Cleaning
and Replacement.
Possible Cause - 4
The printer has communication issues with cables or communication settings.
Resolution
See Communication Issues.
289
Troubleshooting
Communication Issues
This section identifies problems with communications, the possible causes, and the
recommended solutions.
Issue: Label Job Sent, No Data Transfer

A label format was sent to the printer but was not recognized. The DATA light does not flash.
Possible Cause
The communication parameters are incorrect.
Resolution - 1
Check the printer driver or software communications settings (if applicable).
Resolution - 2
Serial Port Only - Check the printer’s handshake protocol and serial port settings. The
setting used must match the one being used by the host computer. See Serial Interface for
the printer’s default serial port settings.
Resolution - 3
The serial cable you are trying to use may not be a standard DTE or DCE type cable, is
damaged, or is too long per the RS-232 Serial ports specifications. See Serial Port
Interface.
Issue: Label Job Sent, Skips Labels or Prints Bad Content

A label format was sent to the printer. Several labels print, then the printer skips, misplaces, misses,
or distorts the image on the label.
Possible Cause
The serial communication settings are incorrect.
Resolution - 1
Check the printer driver or software communications settings (if applicable). Ensure that
the flow control settings and other serial port handshake setting match the host system.
290
Troubleshooting
Issue: Label Job Sent, Data Transfers, But No Print

A label format was sent to the printer but was not recognized. The DATA light flashes but
no printing occurs.
Possible Cause - 1
The prefix and delimiter characters set in the printer do not match the ones in the label
format.
Resolution
Verify the ZPL programmings prefix (COMMAND CHAR) and delimiter (DELIM./CHAR)
characters. Configuration Setting to Command Cross-reference.
Possible Cause - 2
Incorrect data is being sent to the printer.
Resolution
Check the communication settings on the computer. Ensure that they match the printer
settings.
Possible Cause - 3
Incorrect data is being sent to the printer.
Resolution
Check the label format. See the ZPL Programmer’s Manual for details on printer
programming. For printer links to manuals, see the About section of this guide.
291
Troubleshooting
Miscellaneous Issues
This section identifies miscellaneous issues with the printer, the possible causes, and the
recommended solutions.
Issue: Settings are Lost or Ignored

Some parameters are set incorrectly.
Possible Cause - 1
Printer settings were changed without saving them.
Resolution
The ZPL ^JU command was not used to save your configuration before turning the printer
off. Cycle the printer OFF and then back ON to verify settings have been saved.
Possible Cause - 2
The label format/form commands or commands sent directly to the printer have syntax
errors or have been used incorrectly.
• A firmware command turned off the ability to change the parameter.
• A firmware command changed the parameter back to default setting.
Resolution
See the ZPL programmer’s guide to verify command usage and syntax. See the About
section for support links. to view the programmer’ guide for your printer model.
Possible Cause - 3
The prefix and delimiter characters set in the printer do not match the ones in the label
format.
Resolution
Verify the ZPL programming settings of the Control, Command and Delimiter settings are
correct for your system software environment. Print a Configuration Report or use display’s
Language Menu (if present) for these three (3) menu items and compare it the commands
in label format/form you are trying to print. See Test Printing with the Configuration Report,
LANGUAGE Menu, and ZPL Configuration.
Possible Cause - 4
The Main Logic board may not be working properly. Firmware is corrupted or the Main
Logic board needs service
Resolution
1 — Reset the printer to factory defaults. See LOAD DEFAULTS or use the Zebra Setup
Utility and Open Printer Tools > Action > Load printer defaults.
2 — Reload printer firmware. See Updating Printer Firmware.
292
Troubleshooting
user serviceable item.
Issue: Non-continuous labels act as Continuous labels.

A non-continuous label format with matching media loaded in the printer, was sent to the
printer but prints like it is continuous media.
Possible Cause - 1
The printer was not calibrated for the media being used.
Possible Cause - 2
The printer is configured for continuous media.
Resolution
Set the printer for the correct media type (gap/notch, continuous, or mark) and calibrate
the printer using Run a SmartCal Media Calibration, if necessary use Manual Media
Calibration for hard to calibrate media types. See MEDIA TYPE (SETTINGS menu item)
for ZD620 printers with the display to check and set media type.
293
Troubleshooting
Issue: Printer Locks-Up

All indicator lights are on and the printer locks up or the printer locks up while restarting.
Possible Cause - 1
The printer memory has been corrupted by an unknown event.
Resolution - 1
1 — Reset the printer to factory defaults. See LOAD DEFAULTS or use the Zebra Setup
Utility and Open Printer Tools > Action > Load printer defaults.
Issue: Erroneous Ribbon Cartridge Faults

1 — Ribbon Out warning, but a ribbon cartridge is installed.
2 — Ribbon Cartridge Authentication error, but a Genuine Zebra Ribbon Cartridge is
installed and has not been refurbished or altered.
Possible Cause
The Ribbon Cartridge Sensor Contact Pins or the Ribbon Cartridge’s Smart Chip’s
contacts may be dirty or the chip may be damaged.
Resolution
1 — Clean the ribbon cartridge’s smart chip contact, if they look contaminated, with alcohol
and a lightly moistened cotton. Try a different cartridge if this does not work.
2 — Clean the Ribbon Cartridge Sensor Contact Pins - see Cleaning Ribbon Cartridge
Sensor.
294
Tools
This section provides a variety of tools and utilities built into your printer. They are
designed to assist you with setup, configuration, and debugging (printer and command
programming)
Printer Diagnostics
Diagnostic reports, calibration procedures, restoring factory defaults and other diagnostics
provide specific information about the condition of the printer.
Important • Use full-width media when performing self tests. If your media is not wide
enough, the test labels may print on the platen (drive) roller.
Note • Diagnostic Testing Tips:

• When performing these self tests, do not send data to the printer 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 completion, always reset the printer by turning it
OFF and then ON.
• If the printer is in dispense mode and the liner is being taken up by the applicator, the
operator must manually remove the labels as they become available.
Each self test is enabled by pressing a specific user interface button or combination of
buttons while turning ON the printer power. Keep the button(s) pressed until the first
indicator light turns off. The selected self test automatically starts at the end of the Power-
On Self Test.
Power-On Self Test

A Power-On Self Test (POST) is performed each time the printer power is turned ON.
During this test, the control panel indicators turn on and off to ensure proper operation. At
the end of this self test, only the STATUS indicator remains lit.
295
Tools
SmartCal Media Calibration

SmartCal is used to quickly calibrate the printer to the media currently loaded. During
SmartCal, the printer will automatically determine the media sensing type (gap, black line
or notch) and then measure the length of the media.
To activate Smart Calibration, complete these steps:
1. Make sure media is properly loaded, the printer cover is closed, and printer power is
ON.
2. Press and hold PAUSE + CANCEL buttons for two seconds.
3. The printer will FEED and measure several labels. When done, the printer will return
to READY status.
If the printer should fail to recognize and correctly calibrate to the media, please refer to
the Manual Media Calibration procedure later in this section.
296
Tools
Configuration Report (CANCEL Self Test)

The Configuration Report diagnostic prints a set of printer and network configuration
reports.
To print the configuration report, complete these steps:
1. Make sure media is loaded, the printer cover is closed, and printer power is ON.
2. If printer power is OFF, press and hold CANCEL button while turning the printer
power ON. Hold CANCEL button down until the STATUS indicator is the only
indicator lit.
- or -
If printer power is ON, press FEED + CANCEL for two seconds.
3. The Printer and Network Configuration Reports (below) will be printed and the printer
will return to READY status.
Sample Printer Configuration Sample Network Configuration
297
Tools
Printer Network (and Bluetooth) Configuration Report

ZD-Series printers with Wired or Wireless connectivity options installed will print an
additional printer configuration report. This information needed to establish and trouble
shoot Ethernet (LAN and WLAN), Bluetooth 4.1 and Bluetooth LE network printing. The
following printout is printed with the ZPL ~WL command.
iOS Support Setting
iOS Bluetooth Support
• iOS devices have Bluetooth Classic 4.X (with 3.0 compatibility) when the Wi-Fi
and Bluetooth Classic wireless connectivity option is installed in your printer and is
noted as ‘supported’ on the bottom of the Bluetooth Configuration report.
• Some ZD420 series printers only have the Bluetooth LE (without Wi-Fi and classic
Bluetooth). The iOS setting is noted on the bottom of the Bluetooth Configuration
report as ‘not supported’ when the wireless connectivity option is not installed.
Print Quality Report (FEED self test)

Different types of media may require different darkness settings. This section contains a
simple but effective method for determining the ideal darkness for printing barcodes that
are within specifications.
298
Tools
During the Print Quality Report (FEED self test), a series of labels are printed at different
darkness settings at two different print speeds. The relative darkness and the print speed
are printed on each label. The barcodes on these labels may be ANSI-graded to check
print quality.
During this test, one set of labels is printed at low speed, and another set is printed at the
high speed. The darkness value starts at three settings lower than the printer’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).
The speed at which labels are printed during this print quality test depends on the dot
density of the printhead.
• 300 dpi printers: prints 7 labels at 51mm/sec (2 ips) and 102 mm/sec (4 ips) print
speeds.
• 203 dpi printers: prints 7 labels at 51mm/sec (2 ips) and 152 mm/sec (6 ips) print
speeds.
To perform a Print Quality Report, complete these steps:
4. Print a configuration report to show the printer’s current settings. Press and hold the
FEED and CANCEL buttons for two (2) seconds to print the report.
5. Turn OFF the printer.
6. Press and hold FEED while setting the printer power to ON. Hold FEED until the
Status indicator is the only indicator lit.
The printer prints a series of labels (Figure 1) at various speeds and darkness
settings higher and lower than the darkness value shown on the configuration label.
Figure 1 • Print Quality Report
299
Tools
7. See Figure 2 and Table 1. Inspect the test labels and determine which one has the
best print quality for your application. If you have a barcode verifier, use it to measure
bars/spaces and calculate the print contrast. If you do not have a barcode verifier, use
your eyes or the system scanner to choose the optimal darkness setting based on the
labels printed in this self test.
Figure 2 • Barcode Darkness Comparison
Table 1 • Visual Darkness Descriptions

Print Quality Description
Too dark Labels that are too dark are fairly obvious. They may be
readable but not “in-spec.”
• The normal barcode bars increase in size.
• The openings in small alphanumeric characters may
appear filled in.
• Rotated barcode have bars and spaces run
together.
Slightly dark Slightly dark labels are not as obvious.
• The normal barcode will be “in-spec.”
• Small character alpha numerics will be bold and
could be slightly filled in.
• The rotated barcode spaces are small when
compared to the “in-spec” code, possibly making the
code unreadable.
300
Tools
Table 1 • Visual Darkness Descriptions

Print Quality Description
“In-spec” The “in-spec” barcode can only be confirmed by a verifier,
but it should exhibit the following visible characteristics.
• The normal barcode will have complete, even bars
and clear, distinct spaces.
• The rotated barcode will have complete, even bars
and clear, distinct spaces. Although it may not look
as good as a slightly dark barcode, the barcode 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” barcodes.
• Both normal and rotated barcodes 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 barcodes have incomplete
bars and spaces.
• Small alphanumeric characters are unreadable.
8. Note the relative darkness value and the print speed printed on the best test label.
9. 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.
10. If necessary, change the current darkness value to the darkness value on the best
test label.
11. If necessary, change the current print speed to the speed value on the best test label.
301
Tools
Reset Printer Factory Defaults (PAUSE + FEED Self Test)

This resets the printer configuration to the factory default values for the non-network printer
settings. Perform a sensor calibration after this procedure. (See Manual Media
Calibration.)
To perform a Reset Printer Factory Defaults procedure, complete these steps:
13. Press and hold PAUSE + FEED while turning ON the printer.
14. Hold PAUSE + FEED until the STATUS indicator ( ) is the only indicator lit.
The printer configuration is reset to the factory default values. No labels print at the
end of this action.
Note • The printer has a reset button under the printer, See the Reset Button.
Reset Network Factory Defaults (PAUSE + CANCEL Self Test)

This procedure resets the network configuration settings only to the factory default values.
To perform a Reset Network Factory Defaults procedure, complete these steps:
16. Press and hold PAUSE + CANCEL while turning ON the printer.
17. Hold PAUSE + CANCEL until the STATUS indicator ( ) is the only indicator lit.
The printer’s network configuration is reset to the factory default values. No labels
print at the end of this action.
302
Tools
Reset Button
In addition to the power on configurations described previously, the ZD-Series printer has
a dedicated reset button located on the bottom of the printer which can be pressed with a
paperclip or similar small object.
Pressing the button has the following results based on the length of the button press:
0-1 second No action

1-5 seconds Printer reset – Printer performs a factory reset and will automatically
print a configuration label (and network label if present)
6-10 seconds Network reset – Printer drops connection to the network, and a
network factory default reset occurs. Upon completion of the reset, a
configuration and network configuration label are automatically
printed.
More than 10 seconds Exits the factory defaults function without resetting the printer or
making changes
Reset Access Hole
303
Tools
Communication Diagnostics Test

The communication diagnostics test is a troubleshooting tool for checking the connection
between the printer and the host computer. When the printer is in diagnostics mode, it
prints all data received from the host computer as straight ASCII characters with the hex
values below the ASCII text. The printer prints all characters received, including control
codes such as CR (carriage return). Figure 3 shows a typical test label from this test.
Note • The test label prints upside-down as it exits the printer.
Figure 3 • Communications Diagnostics Test Label
To use communications diagnostics mode, complete these steps:
18. Ensure media is loaded and printer power is ON.
19. Set the print width equal to or less than the label width being used for the test.
20. Press and hold Pause + FEED for two seconds. When active, the STATUS indicator
( ) will alternate between green and yellow.
The printer enters diagnostics mode and prints any data received from the host
computer on a test label
21. 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.
22. Press and hold Pause + FEED for two seconds or turn the printer power off (O) and
then back ON to exit this self test and return to normal operation.
304
Tools
Sensor Profile
Use the sensor profile image (which will extend across several labels or tags) to
troubleshoot the following situations:
• The printer experiences difficulty in determining gaps (web) between labels.
• The printer incorrectly identifies preprinted areas on a label as gaps (web).
• The printer cannot detect ribbon.
With the printer in the Ready state, print a sensor profile in one of these ways:
Using the buttons on the a. Turn OFF the printer.

user interface b. Press and hold FEED + CANCEL while turning ON the printer.
c. Hold FEED + CANCEL until the STATUS indicator ( ) is the
only indicator lit.
Using ZPL d. Send the ~JG command to the printer. See the Zebra
Programming Guide for more information about this command.
Compare your results to the examples shown earlier in this section. If the sensitivity of the
sensors must be adjusted, calibrate the printer (see Manual Media Calibration).
305
Tools
Media Sensor Profile (Figures 5 and 6)
The line labeled MEDIA (1) on the sensor profile indicates the media sensor readings. The
media sensor threshold settings is indicated by WEB (2). The media out threshold is
indicated by OUT (3).The upward spikes (4) indicate gaps between labels (the web), the
lines between the spikes (5) indicate where labels are located, and the numbered line at
the top (6) provides measurement in dots from the start of the printout.
If you compare the sensor profile printout to a length of your media, the spikes should be
the same distance apart as the gaps on the media. If the distances are not the same, the
printer may be having difficulty determining where the gaps are located.
Figure 4 • Sensor Profile (Gap Media)
4 4 3
2
5 5 5 1
Figure 5 • Sensor Profile (Black Mark Tag Media)
5 5 1
2
4 4
3
306
Tools
Advanced Mode
Advanced Mode is used to access several manual adjustment modes in the printer. Each
manual adjustment mode is described in detail in the following sections.
To activate Advanced Mode, complete these steps:
1. Ensure media is loaded and printer power is ON.
2. Press PAUSE for two seconds, all indicators will flash yellow.
3. The STATUS indicator ( ) will show solid yellow, indicating the currently selected
mode is:
Manual Media Calibration.
4. Pressing FEED will sequentially cycle through all available modes.
5. Pressing PAUSE will activate the selected mode.
6. Pressing CANCEL will exit Advanced Mode.
307
Tools
Manual Media Calibration

While in Advanced Mode, pressing PAUSE while the Status indicator ( ) is illuminated
yellow will start Manual Media Calibration.
7. The MEDIA indicator ( ) will flash yellow then the Pause indicator ( ) will flash.
Open the printer and verify the media sensor is in the center position for label gap
(transmissive) sensing. Remove 3 inches or 80mm of labels from the liner. Place the
label-less area of the liner over the platen (drive) roller with the leading edge of the
first label under the media guides.
8. Close the printer and press PAUSE once. The MEDIA indicator ( ) will flash as the
media liner is measured. When complete, the Pause indicator ( ) will begin flashing.
9. Open the printer and reposition the media so that a label is located directly above the
movable sensor. Close the printer.
10. Press PAUSE once. The printer will FEED and measure several labels. If the printer is
able to determine the correct media type (gap, black mark or notch) and measure the
media length, the printer will return to the READY state.
This advanced mode is typically used to calibrate the printer to media that is not correctly
recognized during Smart Calibration. If your media uses black mark or notch sensing,
ensure the media sensor is in to the proper location to “see” the mark or notch. If your
media is pre-printed, either on the front of the label or on the back of the liner, position the
sensor so that it is in a position with minimal printing. You may need to perform Manual
Media Calibration several times, moving the media sensor, until the printer completes the
calibration process and returns to the READY state.
308
Tools
Manual Print Width Adjustment

While in Advanced Mode, pressing the PAUSE button while the Pause indicator ( ) is
illuminated yellow will start Manual Print Width Adjustment while in Advanced mode, see
Advanced Mode. The printer will print a 16mm (0.63 inch) box and pause momentarily. The
printer will then print a slightly larger box and again pause. When you see the printer print
a box that matches the width of your media, press FEED to set the print width and return
to READY state.
To return to the maximum print width setting, allow the printer to proceed without pressing
the FEED button.
309
Tools
Manual Print Darkness Adjustment

Pressing PAUSE while the DATA indicator( ) is illuminated yellow will start Manual Print
Darkness Adjustment. The printer will print a test pattern showing the current darkness
number and several barcode patterns and then pause momentarily. The printer will then
repeat the pattern with the next darkness level. When you see the printer print a pattern
with solid even black lines, press FEED to set the darkness value and return to the READY
state.
310
Tools
Factory Test Modes
The printer includes print modes that are intended for factory test only.
Test mode 1
Initiated by holding PAUSE button while turning ON printer power. When activated, the
printer will begin printing various test patterns used to evaluate printer performance.
Test mode 2
Initiated by holding PAUSE + FEED + CANCEL button for two seconds while printer power
is ON. When activated, the printer will begin printing various test patterns used to evaluate
printer performance.
Note • Both of these test modes will consume a considerable amount of media as the tests
are performed.
You can exit either of these test modes by pressing and holding POWER button until the
printer power is switched OFF.
311
Interface Connector Wiring
Universal Serial Bus (USB) Interface
The figure below displays the cable wiring required to use the printer’s USB two interfaces.
Important • When using third party cables, the printer requires USB cables or the cable
packaging that bears the “Certified USB ™ ” mark to guarantee USB 2.0 compliance.

A
B

http://www.usb.org
Wiring - USB Connector “A” Style for “connecting to” the printer or device
Pin 1 — Vbus (+5VDC). (Pin 2 — D- (Data Signal, Negative Side)

Pin 3 — D+ (Data Signal, Positive Side)
Pin 4 — Shell (Shield/Drain Wire) Shell
Wiring - USB Connector “B” Style for “connecting to” the printer or device
Pin 1 — Vbus (Not Connected)

Pin 2 — D- (Data Signal, Negative Side)
Pin 3 — D+ (Data Signal, Positive Side)
Pin 4 — Shell (Shield/Drain Wire) Shell
Important • USB Host +5 VDC power source is shared with serial port phantom power. It
is limited to 0.5mA per USB Specification and with on-board current limiting. The maximum
current available through the serial port and USB port will not exceed a total of 0.75 Amps.
312
Serial Port Interface

Zebra Auto-Detecting DTE and DCE for 9-Pin RS-232 Interface
Pin DTE DCE Description (DTE)

1 — 5V Not used
2 RXD TXD RXD (receive data) input to the printer
3 TXD RXD TXD (transmit data) output from the printer
4 DTR DSR DTR (data terminal ready) output from the printer -- controls when the
host may send data
5 GND GND Circuit ground
6 DSR DTR DSR (data set ready) input to the printer
7 RTS CTS RTS (request to send) output from the printer -- always in the
ACTIVE condition when the printer is turned on
8 CTS RTS CTS (clear to send) - Not used by the printer
9 5V — +5 V @ 0.75 A - FET Circuit current limited
Important • The maximum current available through the serial port, USB port or both will not
exceed a total of 0.75 Amps.
When XON/XOFF handshaking is selected in the printer driver, data flow is controlled by
the ASCII control codes DC1 (XON) and DC3 (XOFF). The DTR control lead will have no
effect.
Connecting the Printer to a DTE Device

DB-25S DB-9P DB-9S DB-9P
Connector Connector Connector Connector
to DTE Device (PC) to Printer to DTE Device (PC) to Printer
Interconnecting to DTE Devices — The printer is configured as data terminal equipment

(DTE). To connect the printer to other DTE devices (such as the serial port of a personal
computer), use an RS-232 null modem (crossover) cable.
313
Connecting the Printer to a DCE Device

DB-25S DB-9P DB-9S DB-9P
Connector Connector Connector Connector
to DCE Device to Printer to DCE Device to Printer
Interconnecting to DCE Devices — When the printer is connected via its RS-232
interface to data communication equipment (DCE) such as a modem, a STANDARD
RS-232 (straight-through) interface cable must be used.
314
Dimensions
This section provides external printer dimensions. for the following printers:
• ZD620 / ZD420 Thermal Transfer Models

• ZD620 / ZD420 Ribbon Cartridge Thermal Transfer Models
• ZD620 / ZD420 Direct Thermal Models
315
Dimensions
ZD620 / ZD420 Thermal Transfer Models

All dimension are in millimeters

Standard Printer

Standard Printer

316
Dimensions

Standard Printer
Printer with Label Dispenser (open)
317
Dimensions
23(1
&/26('

318
Dimensions

0

Printer with Cutter
Printer with Cutter
Printer with Cutter

319
Dimensions

Printer with Attached Power Supply Base
264.6
285.2
320
Dimensions

321
Dimensions
Use M3 thread forming screws with maximum hole depth of 6 mm into the printer body.
Note - Do not remove the rubber feet or the printer can overheat.
148.8
Mounting Holes
Hardware Reset
Access
(Provide 20-25
mm hole in
mounting plate or
surface)
139.0
Mounting Holes
9.0
130.8
Dimensions are in millimeters (mm)
322
Dimensions
ZD620 / ZD420 Ribbon Cartridge Thermal Transfer Models


Standard Printer

Standard Printer

323
Dimensions

Standard Printer
Printer with Label Dispenser (closed)
324
Dimensions
23(1
&/26('

325
Dimensions

Printer with Cutter
Printer with Cutter
Printer with Cutter

326
Dimensions

264.6
272.7
327
Dimensions

328
Dimensions
148.8
Mounting Holes
Hardware Reset
Access
(Provide 20-25
mm hole in
mounting plate or
surface)
139.0
Mounting Holes
9.0
130.8
329
Dimensions
ZD620 / ZD420 Direct Thermal Models

67$1'$5'23(1
330
Dimensions

Optional: Locking
Media Cabinet
Lock and Key

Optional: Locking
Media Cabinet
Lock and Key

331
Dimensions

67$1'$5'
&877(5

(DISPENSER)
',63(16(5
',63(16(523(1
332
Dimensions

235.3
286.3
333
Dimensions
Mounting Holes
55.4
10
Hardware Reset
Access
(Provide 20-25 mm
hole in mounting
plate or surface)
133.4
Mounting Holes
130.8
334
Media
This section provides a simple media overview for your printer.
335
Media
Types of Thermal Media

Important • Zebra strongly recommends the use of Zebra-brand supplies in order to ensure
consistent high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl
stock has been specifically engineered to enhance the printing capabilities of the printer and
to prevent premature printhead wear.
To purchase supplies, go to http://www.zebra.com/howtobuy.
• Your printer can use various types of media:
• Standard media—Most standard (non-continuous) media uses an adhesive
backing that sticks individual labels or a continuous length of labels to a liner.
• Continuous roll media—Most continuous roll media is direct thermal media
(similar to FAX paper) and is used for receipt or ticket style printing.
• Tag stock—Tags are usually made from a heavy paper (up to 0.0075in./0.19mm
thick). Tag stock does not have adhesive or a liner, and it is typically perforated
between tags.
For more information on basic media types, see Table 1.
The printer typically uses roll media, but you can use fan-fold or other continuous media
too.
Determining Thermal Media Types

Thermal transfer media requires ribbon for printing while direct thermal media does not.
To determine if ribbon must be used with a particular media, perform a media scratch test.
To perform a media scratch test, complete these steps:

1. Scratch the print surface of the media with a finger nail or pen cap. Press firmly and
quickly while dragging it across the media surface. Direct thermal media is chemically
treated to print (expose) when heat is applied. This test method uses friction heat to
expose the media.
2. Did a black mark appear on the media?
If a black mark... Then the media is...

Appears on the media Direct thermal. No ribbon is required.
Does not appear on the media Thermal transfer. A ribbon is required.
Not supported by this printer.
336
Media
General Media and Print Specifications
• Direct Thermal — Max. Media width: 108mm (4.25 inches)

• Thermal Transfer — Max. Media width: 118mm (4.65 inch)
• All Printers — Min. Media width: 15mm (0.585 inch)
• Media length:
• 990mm (39 inches) max.
• 6.35mm (0.25 inches) min. – Tear Off or Label
• 12.7mm(0.50 inches) min. – Peel
• 25.4mm (1.0 inch) min. - Cutter
• Media thickness:
• 0.06mm (0.0024 inches) min. – all requirements
• 0.1905mm (0.0075 inches) max. – all requirements
• Media Roll Outer Diameter (O.D.) max.: 127mm (5.0 inches)
• Media Roll Core Inner Diameter (I.D.):

• 12.7mm (0.5 inch) I.D. - Standard roll configuration
• 25.4mm (1 inch) I.D. - Standard roll configuration
• 38.1mm (1.5 inches) I.D. - with optional media roll adapter
• Ribbon Rolls - 74 meter

• Ribbon Length - 74 m (243 feet)
• Ribbon Width Max. - 110 mm (4.33 inches)
• Ribbon Width Min. - 33 mm (1.3 inches) ‡
• Ribbon Core I.D. - 12.7mm (0.5 inches)
• Wax, Wax/Resin, and Resin transfer materials
• Ribbon Rolls - 300 meter

• Wax, Wax/Resin, and Resin transfer materials
‡ - Transfer ribbon should always cover the entire width of the media (and liner) to prevent damaging the printhead.
• ZD420 Ribbon Cartridges
337
Media

• Colors available in Black - Wax, Wax Resin, and Resin transfer materials
• Dot pitch:
• 203 dpi: 0.125mm (0.0049 inches)
• 300 dpi: 0.085mm (0.0033 inches)
• Barcode modulus x-dim:
• 203 dpi: 0.005-0.050 inches
• 300 dpi: 0.00327 - 0.03267 inches
Label Dispenser (Peeler)

The printer supports a field installed label dispense option with label taken sensor for batch
processing of labels.
• Paper Thickness:
• Min. 0.06 mm (0.0024 inches)
• Max. 0.1905 mm (0.0075 inches)
• Media Width:
• Min.15 mm (0.585 inches)
• Thermal Transfer Printers Max. 118 mm (4.65 inches)
• Direct Thermal Printers Max. 108 mm (4.25 inches)
• Label Length:
• All Printers Max. (theoretical): 990mm (39 inches)
• Thermal Transfer Printers Max. (tested): 279.4mm (11 inches)
• Direct Thermal Printers Max. (tested): 330mm (13 inches).
• All Printers Min.: 12.7mm (0.5 inches).
338
Media
Standard (Media) Cutter

The printer supports a field installed media cutter option for full width cutting of label liner,
tag or receipt media.
• A medium duty cutter for cutting label liner and light tag media (LINER/TAG). Do
not cut through labels, adhesive or embedded circuitry.
• Min. 0.06 mm (0.0024 inches)
• Max. 0.1905 mm (0.0075 inches)
• Cut Width:
• Thermal Transfer Printers Max. 118 mm (4.65 inches)
• Direct Thermal Printers Max. 109 mm (4.29 inches)
• Minimum distance between cuts (label length): 25.4 mm (1 inch). Cutting shorter
media lengths between the cuts may cause the cutter to jam or error.
• By design, the cutter is self cleaning and does not require preventive maintenance
of the internal cutter mechanism.
Linerless (Media) Cutter - Direct Thermal only

The printer supports a field installed media cutter option for full width cutting of linerless
media.
• A full width linerless media cutter (LINERLESS CUT).
• Min. 0.06 mm (0.0024 inches)
• Max. 0.1905 mm (0.0075 inches)
• Cut Width:
• Max. 118 mm (4.65 inches)
• Minimum distance between cuts (label length): 25.4 mm (1 inch). Cutting shorter
media lengths between the cuts may cause the cutter to jam or error.
• By design, the cutter is self cleaning and does not require preventive maintenance
of the internal cutter mechanism. See Linerless Platen (Drive) Roller cleaning
and Media Path Cleaning to maintain optimal linerless media cut operation.
339
Media
Table 1 • Types of Media Roll and Fanfold Media

Media Type How It Looks Description
Non-Continuous Labels have adhesive backing that sticks them to a liner. Tags (or
Roll Media tickets) are separated by perforations.
Individual labels or tags are tracked and position controlled by one

or more of the following methods:
1. Web media separates labels by gaps, holes, or notches.
2. Black mark media uses pre-printed black marks on the back

side of the media to indicate label separations.
3. Perforated media has perforations that allow the labels or

tags to be separated from each other easily in addition to
position control marks, notches or label gaps.
Non-Continuous Fan-Fold 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.
This type of media uses black marks or notches to track media

format positioning.
340
Media
Table 1 • Types of Media Roll and Fanfold Media (Continued)

Media Type How It Looks Description
Continuous Continuous roll media does not have gaps or typically holes,
Roll Media notches, or black marks either to indicate label separations. This
allows the image to be printed anywhere on the label. A cutter can
be used to cut apart individual labels. With continuous media, use
the transmissive (gap) sensor so the printer can detect when the
media runs out.
341
ZPL Configuration
This section provides an overview of managing printer configuration, the Configuring

Status Report, and Printer and Memory Printouts.
Managing the ZPL Printer Configuration
The ZPL printer is designed to allow you to change printer settings dynamically for fast first
label out printing. Printer parameters that are persistent will be retained for future formats
to use. Those settings will remain in effect until they are changed by subsequent
commands, the printer is reset, power is cycled, or when you restore a parameter that has
a factory default by resetting the printer to factory defaults. The ZPL Configuration Update
command (^JU) saves and restores printer configurations to initialize (or re-initialize) the
printer with pre-configured settings.
• To keep settings after a power cycle or printer reset, a ^JUS can be sent to the
printer to save all current persistent settings.
• The values are recalled with a ^JUR command to restore the last saved values to
the printer.
ZPL stores all parameters at once with a single command mentioned above. The legacy
EPL programming language (supported by this printer) changes and saves individual
commands immediately. Most printer settings are shared between ZPL and EPL. For
example, changing the speed setting with EPL will also change the speed set for ZPL
operations. The changed EPL setting will persist even after a power cycle or reset issued
by either printer language.
A printer Configuration Report is available to assist the developer. The Configuration
Report lists operating parameters, sensor settings, and printer status. It can be accessed
by using the procedure in Test Printing with the Configuration Report. The Zebra Setup
Utility and the ZebraDesigner ™ Windows driver also print this report and other printer
reports to help you manage your printer.
342
ZPL Configuration
ZPL Printer Configuration Format

Managing more than one printer can be done by creating a printer configuration
programming file to send to one or more printers or ZebraNet ™ Bridge can be used to
clone a printer’s setup. Figure 1 below shows the basic structure of a ZPL programming
configuration file.
See the ZPL programmer’s guide and the Configuration Setting to Command Cross-
reference to create a programming file. The Zebra Setup Utility (ZSU) can be used to send
programming files to the printer. Windows Notepad (text editor) can be used to create
programing files.
Figure 1 • Configuration Parameter Format Structure
343
ZPL Configuration
Configuration Setting to Command Cross-reference
The Printer Configuration Report, shown below, provides a listing of a majority of the
configurations settings that can be set by ZPL command.
Figure 2 • Configuration Report Printout
Sensor Settings
used for
Service Purposes
344
ZPL Configuration
Table 1 • ZPL Commands and Configuration Report Callout Cross-Reference

Command Listing Name Description
~SD DARKNESS Default: 10.0
— DARKNESS SWITCH LOW (Default), MEDIUM, or HIGH
^PR PRINT SPEED Default: 152.4 mm/s / 6 IPS (max.) - 203 dpi
　　　　 101.6 mm/s / 4 IPS (max.) - 300 dpi
~TA TEAR OFF Default: +000
^MN MEDIA TYPE Default: GAP/NOTCH
SENSOR SELECT Default: AUTO (^MNA - Auto-Detect)
^MT PRINT METHOD THERMAL-TRANS or DIRECT-THERMAL
^PW PRINT WIDTH Default: 448 (dots for 203 dpi) or
640(dots for 300 dpi)
^LL LABEL LENGTH Default: 1225 (dots) (dynamically updated while
printing)
^ML MAXIMUM LENGTH Default: 39.0IN 989MM
— USB COMM. Connection Status: Connected / Not Connected
^SCa BAUD Default: 9600
^SC,b DATA BITS Default: 8 BITS
^SC,,c PARITY Default: NONE
^SC,,,,e HOST HANDSHAKE Default: AUTO
^SC,,,,,f PROTOCOL Default: NONE
— SGD —** COMMUNICATIONS Default: NORMAL MODE
SER COMM. MODE Default: AUTO
^CT / ~CT CONTROL CHAR Default: <~> 7EH
^CC / ~CC COMMAND CHAR Default: <^> 5EH
^CD / ~CD DELIM./CHAR Default: <,> 2CH
^SZ ZPL MODE Default: ZPL II
— SGD —** COMMAND OVERRIDE Default: INACTIVE
^MFa MEDIA POWER UP Default: NO MOTION
^MF,b HEAD CLOSE Default: FEED
~JS BACKFEED Default: DEFAULT
^LT LABEL TOP Default: +000
^LS LEFT POSITION Default: +0000
~JD / ~JE HEXDUMP Default: NO (~JE)
REPRINT MODE Default: DISABLED
From this point in the Configuration Receipt listing, the printout has sensor settings and
values displayed to troubleshoot sensor and media operations. These are typically used
by Zebra Tech Support to diagnose printer problems.
** - Not supported with a ZPL command, uses the Set Get Do command in the ZPL
manual. See device.command_override.xxxxx in the ZPL Programmer’s manual.
345
ZPL Configuration
The configuration settings listed here resume after the TAKE LABEL sensor value. These
listings contain printer features seldom changed from default or provide status information.
Table 2 • ZPL Commands and Configuration Receipt Callout Cross-Reference
Command Listing Name Description
^MP MODES ENABLED Default: CWF (See ^MP Command)
MODES DISABLED Default: (nothing set)
^JM RESOLUTION Default: 448 8/mm FULL (203 dpi)
640 8/mm FULL (300 dpi)
— FIRMWARE Lists ZPL Firmware Version
— XML SCHEMA 1.3
— HARDWARE ID Lists Firmware Boot-block Version
LINK-OS VERSION
— CONFIGURATION CUSTOMIZED (after first use)
— RAM 2104k........ R:
— ONBOARD FLASH 6144k.........E:
^MU FORMAT CONVERT NONE
RTC DATE Date Displayed
RTC TIME Time Displayed
^JI / ~JI ZBI DISABLED (Requires key to enable)
— ZBI VERSION 2.1 (Displayed if installed)
— ZBI STATUS READY
^JH LAST CLEANED X,XXX IN
^MA HEAD USAGE X,XXX IN
~RO
TOTAL USAGE X,XXX IN
RESET CNTR1 X,XXX IN
NONRESET CNTR0 (1, 2) X,XXX IN
SLOT1 EMPTY / SERIAL / WIRED
MASS STORAGE 0
COUNT
HID COUNT 0
USB HOST LOCK OUT OFF /ON
— SERIAL NUMBER XXXXXXXXXXX
^JH EARLY WARNING MAINT. OFF
The printer has the ability to set a command or a group of commands once for all receipts
(or labels) that follow. Those settings will remain in effect until they are changed by
subsequent commands, the printer is reset, or you restore factory defaults.
346
ZPL Configuration
Printer Memory Management and Related Status Reports
To help you manage printer resources, the printer supports a variety of format commands
to manage memory, transfer objects (between memory areas, import and export), object
naming, and provide various printer operating status reports. They are very similar to the
old DOS commands like DIR (directory listing) and DEL (delete file). The most common
reports are also part of the Zebra Setup Utility and ZebraDesigner ™ Windows driver.
It is recommended that a single command be processed within this type of format (form).A
single command is easily reused as a maintenance and development tool.
Many of the commands that transfer objects, manage and report on memory are control
(~) commands. They do not need the be within a format (form). They will be processed
immediately upon receipt by the printer whether in a format (form) or not.
ZPL Programming for Memory Management

ZPL has various printer memory locations that are used to run the printer, assemble the
print image, store formats (forms), graphics, fonts and configuration settings.
• ZPL treats Formats (Forms), Fonts, and Graphics like files; and memory locations
like disk drives in the DOS operating system environment:
• Memory Object Naming: Up to sixteen (16) alphanumeric characters followed
by a three (3) alphanumeric character file extension, for example:
123456789ABCDEF.TTF
Legacy ZPL printers with V60.13 firmware and earlier can only use the 8.3 file
name format verses today’s 16.3 file name format.
• Allows moving objects between memory locations and deleting objects.
• Supports DOS directory style file list reports as printouts or status to the host.
• Allows use of ‘wild cards’ (*) in file access
347
ZPL Configuration
Table 3 • Object Management and Status Report Commands

Command Name Description
^WD Print Directory Prints a list of objects and resident barcodes and fonts in all
Label addressable memory locations
~WC Print Configuration Prints a configuration Status Receipt (Label)
Label Same as FEED Button mode one flash routine
ÎD Object Delete Deletes objects from printer memory
^TO Transfer Object Used to copy an object or group of objects from one
memory area to another.
^CM Change Memory Reassigns a letter designation to a printer memory area.
Letter Designation
^JB Initialize Flash Similar to formatting a disk - erases all objects from the
memory specified memory locations B: or E:.
~JB Reset Optional Similar to formatting a disk - erases all objects from the B:
Memory memory (factory option).
~DY Download Objects Downloads and installs wide variety of printer usable
programming objects: fonts (OpenType and TrueType),
graphics, and other object data types.
Recommendation: Use ZebraNet™ Bridge for downloading
graphics and fonts in the printer.
~DG Download Graphic Downloads an ASCII Hex representation of a graphic
image. This is used by ZebraDesigner ™ (label creation
application) for graphics.
^FL Font Linking Appends secondary TrueType font or fonts to the primary
TrueType font to add glyphs (characters).
^LF List Font Links Prints a list of the linked fonts
^CW Font Identifier Assigns a single alphanumeric character as an alias to a
font stored in memory.
Important • Some factory installed ZPL fonts in your printer cannot be copied, cloned or
restored to your printer by reloading or updating firmware. If these license restricted ZPL
fonts are removed by an explicit ZPL object delete command, they must be repurchased
and reinstalled via a font activation and installation utility. EPL fonts do not have this
restriction.
348

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ZD620 and ZD420

Desktop Printers with Link-OS®

Proprietary Statement: This manual contains proprietary information of Zebra

Use these links to get to your Online printer support resources:

Other Valuable Printer Resources

Zebra OneCare Printer Service and Support

Using This Document and Its Internally Attached Files

Accessing the Printhead of the Ribbon Cartridge Printer. . . . . . . . . . . . . . . . . . . .33

• Install Hardware Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

• Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Ribbon Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

• Printer Configuration Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

SETTINGS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

• Setup for Windows® OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Configure Using the ZebraNet Bridge’s Connectivity Wizard . . . . . . . . . . . . . . . . . . .182

• Print Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

• USB Host Port and Link-OS Demonstration Examples . . . . . . . . . . . . . . 225

USB Host and Printer Usage Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227

Lower Half of ZD60/ZD420 Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251

Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282

Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293

• Interface Connector Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

• ZPL Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Link-OS 4 inch Desktop Thermal Printers

Common Desktop Link-OS Printer Features:

• Printhead maintenance reporting enabled and customizable by the user.

Link-OS 4 inch Desktop Printer Options:

Zebra Label Printing Solution

What’s in the Box?

Printer USB Cable Printer Documentation

Included with Thermal Transfer Printer (uses ribbon rolls)

Empty Starter Ribbon Cores Non-Zebra 300 Meter Ribbon

Unpack and Inspect the Printer

Open the Printer

For more details on printer controls, see Controls and Indicators

DC Power Interface and Connectivity

Inside the ZD620 Dual Capacity Ribbon Roll Printer

Upper Web (Gap)

Media Guide Stop

Platen (Drive) Roller

Dual Capacity Ribbon Chassis - Ribbon Roll Holders

Supply Spindles (full ribbon rolls)

Media Dancer - ZD620 Printer Models Only

Inside the ZD620 and ZD420 Direct Thermal Printers

Upper Web (Gap)

Media Guide Stop

Platen (Drive) Roller

Inside the ZD420 Ribbon Cartridge Printer

Upper Web (Gap)

Media Guide Stop

Platen (Drive) Roller

Accessing the Printhead of the Ribbon Cartridge Printer

PRINTHEAD ACCESS Printhead

3. Lift printhead actuator arm up

Label Dispenser Option (field installable) - All Models

Label Taken Label Liner

Label Peel Bar

Door Latch Dispenser Door

Cutter Option (field installable) - All Models