ZT200 Series™

Industrial Printers

User Guide

P1048261-005 Rev. A
© 2015 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.

The copyrights in this manual and the software and/or firmware in the printer described therein are owned by ZIH
Corp. and Zebra's licensors. Unauthorized reproduction of this manual or the software and/or firmware in the printer
may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be
subject to civil liability.

This product may contain ZPL®, ZPL II®, Link-OS™, and ZebraLink™ programs; Element Energy Equalizer®
Circuit; E3®; and Monotype Imaging fonts. Software © ZIH Corp. All rights reserved worldwide.

All other brand names, product names, or trademarks belong to their respective holders. For additional trademark
information, please see “Trademarks” on the product CD.

Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation and its
subsidiaries (“Zebra Technologies”). It is intended solely for the information and use of parties operating and
maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed
to any other parties for any other purpose without the express, written permission of Zebra Technologies.

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

specifications and designs are subject to change without notice.

Liability Disclaimer Zebra Technologies takes steps to ensure that its published Engineering specifications and
manuals are correct; however, errors do occur. Zebra Technologies reserves the right to correct any such errors and
disclaims liability resulting therefrom.

Limitation of Liability In no event shall Zebra Technologies or anyone else involved in the creation, production,
or delivery of the accompanying product (including hardware and software) be liable for any damages whatsoever
(including, without limitation, consequential damages including loss of business profits, business interruption, or loss
of business information) arising out of the use of, the results of use of, or inability to use such product, even if Zebra
Technologies has been advised of the possibility of such damages. Some jurisdictions do not allow the exclusion or
limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

Part Number: P1048261-005 Rev. A

 Declaration of Conformity 3

Declaration of Conformity

We have determined that the Zebra printers identified as the

ZT210™, ZT220™, and ZT230™

manufactured by:

Zebra Technologies Corporation

3 Overlook Point
Lincolnshire, Illinois 60069 U.S.A.

Have been shown to comply with the applicable technical standards of the FCC

For Home, Office, Commercial, and Industrial use

If no unauthorized change is made in the equipment,

and if the equipment is properly maintained and operated.

11/5/15 P1048261-005
4 Declaration of Conformity
Compliance Information

Compliance Information

FCC Compliance Statement

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

1. This device may not cause harmful interference, and

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

Note • This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential installation. This
equipment generates, uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver
is connected.
• Consult the dealer or an experienced radio/TV technician for help.

FCC Radiation Exposure Statement

(for printers with RFID encoders)
This equipment complies with FCC radiation exposure limits set forth for an uncontrolled
environment. This equipment should be installed and operated with minimum distance 20cm
between the radiator and your body.

This transmitter must not be co-located or operating in conjunction with any other antenna or
transmitter.

Canadian DOC Compliance Statement

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

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

P1048261-005 11/5/15
 Contents

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Compliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 • Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Navigating through Screens in the ZT230 Printer Display . . . . . . . . . . . . . . . . . . . . . 15
Idle Display, Home Menu, and User Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ribbon Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
When to Use Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Coated Side of Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2 • Printer Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Ship the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Select a Location for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install the Printer Driver and Connect the Printer to the Computer . . . . . . . . . . . . . . . . . 28
Install Zebra Setup Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Connect a Computer to the Printer’s USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connect a Computer to the Printer’s Serial or Parallel Port . . . . . . . . . . . . . . . . . . . 41
Connect to Your Network through the Printer’s Ethernet Port . . . . . . . . . . . . . . . . . . 49
Connect the Printer to Your Wireless Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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6 Contents

Select a Print Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Load the Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Load the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Final Steps for Tear-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Final Steps for Peel-Off Mode (with or without Liner Take-Up) . . . . . . . . . . . . . . . . . 78
Final Steps for Cutter Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Print a Test Label and Make Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3 • Printer Configuration and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Changing Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Print Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Calibration and Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Language Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Sensor Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Port Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Calibrate the Ribbon and Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Adjust the Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Adjust Ribbon Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Remove Used Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

4 • Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Cleaning Schedule and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Clean the Exterior, the Media Compartment, and the Sensors . . . . . . . . . . . . . . . . 135
Clean the Printhead and Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Clean the Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Clean the Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

5 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Meaning of Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Printing Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Miscellaneous Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

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 Contents 7

Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
FEED Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
FEED + PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
CANCEL + PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Communication Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

6 • Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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Notes • ___________________________________________________________________

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P1048261-005 11/5/15
 About This Document

This section provides you with contact information, document structure and organization, and
additional reference documents.

Contents
Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

11/5/15 P1048261-005
10 About This Document
Who Should Use This Document

Who Should Use This Document

This User Guide is intended for use by any person who needs to perform routine maintenance,
upgrade, or troubleshoot problems with the printer.

How This Document Is Organized

The User Guide is set up as follows:

Section Description
Introduction on page 11 This section provides a high-level overview of the
printer and its components.
Printer Setup and Operation This section assists the technician with initial setup
on page 25 and operation of the printer.
Printer Configuration and Adjustment This section assists you with configuration of and
on page 91 adjustments to the printer.
Routine Maintenance on page 133 This section provides routine cleaning and
maintenance procedures.
Troubleshooting on page 149 This section provides information about errors that
you might need to troubleshoot. Assorted
diagnostic tests are included.
Specifications on page 175 This section lists general printer specifications,
printing specifications, ribbon specifications, and
media specifications.
Glossary on page 183 The glossary provides a list of common terms.

P1048261-005 11/5/15
 1
Introduction

This section provides a high-level overview of the printer and its components.

Contents
Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Navigating through Screens in the ZT230 Printer Display . . . . . . . . . . . . . . . . . . . . . . 15
Idle Display, Home Menu, and User Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Types of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ribbon Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
When to Use Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Coated Side of Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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12 Introduction
Printer Components

Printer Components
Note • The components inside your printer are color-coded.
• The touch points that you will need to handle are colored gold inside the printers and are
highlighted in gold in the illustrations in this manual.
• The components associated with the ribbon system are made of black plastic, while the
components associated with media are made of gray plastic. Those components and
others are highlighted in light blue in the illustrations in this manual as needed.

Figure 1 shows the components inside the media compartment of your printer. Depending on
the printer model and the installed options, your printer may look slightly different. The
components that are labeled are mentioned in procedures throughout this manual.

Figure 1 • Printer Components

1 2

3 4 5

ZT230

ZT210 9
ZT220 10

1 Control panel 6 Media supply guide

2 Media door 7 Media dancer assembly
3 Ribbon take-up spindle* 8 Printhead-open lever
4 Ribbon supply spindle* 9 Printhead assembly
5 Media supply hanger 10 Platen roller

* This component appears only in printers that have the Thermal Transfer option installed.

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 Introduction 13
Control Panel

Control Panel
The control panel indicates the printer’s current status and allows the user to control basic
printer operation.

Figure 2 • ZT230 Printer Control Panel

1 2 3 4 5 1 STATUS light These indicator lights

2 PAUSE light show the current status
of the printer. For more
3 DATA light
information, see
4 SUPPLIES light Table 12 on page 150.
5 NETWORK light
6
6 The display shows the printer’s current status and
allows the user to navigate the menu system.
7 RIGHT SELECT These buttons execute
button the commands shown
8 LEFT SELECT button directly above them in
7 the display.
8 9 The UP ARROW button operates as follows in the
menu system:
• Changes the parameter values. Common uses
are to increase a value, to scroll through choices,
9 or to change values while entering the printer
10 password.
• Navigates up in a menu.
The UP ARROW button changes the parameter
11
values. Common uses are to increase a value or to
scroll through choices.
12 10 The OK button selects or confirms what is shown
on the display.
13
11 The LEFT ARROW button, which is active only
in the menu system, navigates to the left.
12 The RIGHT ARROW button, which is active only
in the menu system, navigates to the right.
13 The DOWN ARROW button operates as follows
in the menu system:
• Changes the parameter values. Common uses
are to decrease a value, to scroll through choices,
or to change the cursor position while entering
the printer password.
• Navigates down in a menu.
14 15 16 The DOWN ARROW button changes the
parameter values. Common uses are to decrease a
value or to scroll through choices.

14 The PAUSE button starts or stops printer operation

when pressed.
15 The FEED button forces the printer to feed one

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14 Introduction
Control Panel

Figure 3 • ZT220 Printer Control Panel

1 2 3 4 5

1 STATUS light These indicator lights

2 PAUSE light show the current status of
the printer. For more
3 DATA light
information, see Table 12
4 SUPPLIES light on page 150.
5 NETWORK light
6 The PAUSE button starts or stops printer operation
when pressed.
7 The FEED button forces the printer to feed one blank
label each time the button is pressed.
8 The CANCEL button cancels label formats when the
printer is paused.
• Press once to cancel the next label format.
• Press and hold for 2 seconds to cancel all label
formats.

6 7 8

Figure 4 • ZT210 Printer Control Panel

1 2 3 4 5
1 STATUS light These indicator lights
2 PAUSE light show the current status of
the printer. For more
3 DATA light
information, see Table 12
4 SUPPLIES light on page 150.
5 NETWORK light
6 The PAUSE button starts or stops printer operation
when pressed.
7 The FEED button forces the printer to feed one blank
label each time the button is pressed.
8 The CANCEL button cancels label formats when the
printer is paused.
• Press once to cancel the next label format.
• Press and hold for 2 seconds to cancel all label
formats.

6 7 8

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 Introduction 15
Control Panel

Navigating through Screens in the ZT230 Printer Display

Table 1 shows the following:
• the options available for navigating through the screens in the ZT230 printer control panel
display
• how to select or modify things shown on the display

Table 1 • Navigation

Idle Display

XXXXXXX

XXXXXXX

HOME MENU

SETTINGS

At the Idle Display (Figure 5 on page 17), press LEFT SELECT to go

to the printer’s Home menu (Figure 6 on page 17).
Home Menu

To move from icon to icon in the To select the highlighted menu Press LEFT SELECT to exit the
Home menu, press any of the icon and enter the menu, press Home menu and return to the Idle
ARROW buttons. OK. Display. The printer automatically
When an icon is selected, its returns to the Idle Display after
colors are reversed to highlight it. 15 seconds of inactivity in the
Home menu.
SETTINGS menu icon

SETTINGS menu icon

highlighted

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16 Introduction
Control Panel

Table 1 • Navigation (Continued)

User Menus

XXXXXXX
▼ XXXXXXX ▲

Press LEFT SELECT to return to the Home menu. ▼and ▲ indicate that a value can be changed. Any
The printer automatically returns to the Home menu changes that you make are saved immediately.
after 15 seconds of inactivity in a user menu. Press the UP ARROW or DOWN ARROW to
scroll through accepted values.

XXX

To scroll through the items in a user menu, press the A word in the bottom-right corner of the display
LEFT ARROW or RIGHT ARROW. indicates an available action.
Press OK or press RIGHT SELECT to perform the
action shown.

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 Introduction 17
Control Panel

Idle Display, Home Menu, and User Menus

In the Index, the term “Home menu” will not display properly. There will be a comma
followed by a page number in the correct location, but the term will not be there. Need to
manually type the term into the index after generating.

The ZT230 printer’s control panel includes a display, where you can view the printer’s status
or change its operating parameters. In this section, you will learn how to navigate through the
printer’s menu system and change values for menu items.

After the printer completes the power-up sequence, it moves to the Idle Display (Figure 5). If a
print server is installed, the printer cycles through its IP address and information configured by
the user.

Figure 5 • Idle Display

PRINTER READY 1

V72.18.1Z 2

1 The printer’s current status

2 Information that you set through Idle Display on page 102
Home menu shortcut

Home Menu Use the Home menu (Figure 6) to access the printer’s operating parameters
through the six user menus (Figure 7 on page 18).

Figure 6 • Home Menu

HOME MENU

SETTINGS

Exit and return to the Idle Display (Figure 5).

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Control Panel

User Menus The following are the user menus and the items that appear in each. Click any
of the menu items to go to their descriptions.

Figure 7 • User Menus

SETTINGS TOOLS NETWORK

— DARKNESS — PRINT INFORMATION — ACTIVE PRINT SERVER

— PRINT SPEED — LCD CONTRAST — IP ADDRESS
— MEDIA TYPE — IDLE DISPLAY — SUBNET MASK
— PRINT METHOD — POWER UP ACTION — GATEWAY
— TEAR OFF — HEAD CLOSE ACTION — IP PROTOCOL
— PRINT WIDTH — LOAD DEFAULTS — MAC ADDRESS
— PRINT MODE — MEDIA/RIBBON CAL — ESSID
— LEFT POSITION — DIAGNOSTIC MODE — PRINT INFORMATION
— REPRINT MODE — ZBI ENABLED? — RESET NETWORK
— LABEL LENGTH MAX — RUN ZBI PROGRAM — LOAD DEFAULTS
— LANGUAGE — STOP ZBI PROGRAM — LANGUAGE MENU*
— TOOLS MENU* — NETWORK MENU*

LANGUAGE SENSORS PORTS

— LANGUAGE — SENSOR TYPE — BAUD RATE

— COMMAND LANGUAGE — MEDIA/RIBBON CAL — DATA BITS
— ZPL OVERRIDE — PRINT INFORMATION — PARITY
— COMMAND CHAR — LABEL SENSOR — HOST HANDSHAKE
— CONTROL CHAR — TAKE LABEL — SETTINGS MENU*
— DELIMITER CHAR — PORTS MENU*
— ZPL MODE
— SENSORS MENU*

* Denotes a shortcut to the next user menu

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 Printer Setup and Operation 19
Types of Media

Types of Media
Important • Zebra strongly recommends the use of Zebra-brand supplies for continuous
high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl stock has
been specifically engineered to enhance the printing capabilities of the 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 media uses an adhesive backing that sticks individual
labels or a continuous length of labels to a liner. Standard media can come on rolls or in a
fanfold stack (Table 2).
• Tag stock—Tags are usually made from a heavy paper. Tag stock does not have adhesive
or a liner, and it is typically perforated between tags. Tag stock can come on rolls or in a
fanfold stack (Table 2).

Table 2 • Roll and Fanfold Media

Media Type How It Looks Description

Non-Continuous Roll media is wound on a 3-in. (76-mm) core. Roll media is
Roll Media wound on a core that can be 1 in. to 3 in. (25 to 76 mm) in
diameter. Individual labels or tags are separated by one or
more of the following methods:
• Web media separates labels by gaps, holes, or notches.

• Black mark media uses pre-printed black marks on the

back side of the media to indicate label separations.

• Perforated media has perforations that allow the labels or

tags to be separated from each other easily. The media may
also have black marks or other separations between labels
or tags.

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20 Printer Setup and Operation
Types of Media

Table 2 • Roll and Fanfold Media (Continued)

Media Type How It Looks Description

Non-Continuous Fanfold media is folded in a zigzag pattern. Fanfold media can
Fanfold Media have the same label separations as non-continuous roll media.
The separations would fall on or near the folds.

Continuous Roll media is wound on a 3-in. (76-mm) core. Roll media is

Roll Media wound on a core that can be 1 in. to 3 in. (25 to 76 mm) in
diameter.
Continuous roll media does not have gaps, holes, notches, or
black marks to indicate label separations. This allows the
image to be printed anywhere on the label. Sometimes a cutter
is used to cut apart individual labels.

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 Printer Setup and Operation 21
Ribbon Overview

Ribbon Overview

Note • This section applies only to printers that have the Thermal Transfer option installed.

Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is
transferred to the media during the thermal transfer process. The media determines whether
you need to use ribbon and how wide the ribbon must be.

When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is
narrower than the media, areas of the printhead are unprotected and subject to premature wear.

When to Use Ribbon

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

To perform a media scratch test, complete these steps:

1. Scratch the print surface of the media rapidly with your fingernail.

2. Did a black mark appear on the media?

If a black mark... Then the media is...

Does not appear on the media Thermal transfer. A ribbon is required.
Appears on the media Direct thermal. No ribbon is required.

Coated Side of Ribbon

Ribbon can be wound with the coated side on the inside or outside (Figure 8). This printer can
only use ribbon that is coated on the outside. If you are unsure which side of a particular roll of
ribbon is coated, perform an adhesive test or a ribbon scratch test to determine which side is
coated.

Figure 8 • Ribbon Coated on Outside or Inside

Outside Inside

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22 Printer Setup and Operation
Ribbon Overview

Ribbon can be wound with the coated side on the inside or outside. The ribbon used must
match the Thermal Transfer option installed. The standard Thermal Transfer option (black
ribbon spindle) uses ribbon coated on the outside, and the alternate Thermal Transfer option
(gray ribbon spindle, available on the ZM400 and RZ400 only) uses ribbon coated on the
inside. If you are unsure which side of a particular roll of ribbon is coated, perform an adhesive
test or a ribbon scratch test to determine which side is coated.

Adhesive Test
If you have labels available, perform the adhesive test to determine which side of a ribbon is
coated. This method works well for ribbon that is already installed.

To perform an adhesive test, complete these steps:

1. Peel a label from its liner.

2. Press a corner of the sticky side of the label to the outer surface of the roll of ribbon.

3. Peel the label off of the ribbon.

4. Observe the results. Did flakes or particles of ink from the ribbon adhere to the label?

If ink from the ribbon... Then...

Adhered to the label The ribbon is coated on the outside and can be
used in this printer.

Did not adhere to the label The ribbon is coated on the inside and cannot
be used in this printer.
To verify this, repeat the test on the other
surface of the roll of ribbon.
Adhered to the label The ribbon is coated on the outside and can be
used with the standard Thermal Transfer
option (black ribbon spindle). In the ribbon
loading procedure, instructions are marked
with this symbol.
Did not adhere to the label The ribbon is coated on the inside and can be
used with the alternate Thermal Transfer
option (gray ribbon spindle). In the ribbon
loading procedure, instructions are marked
with this symbol.

Ribbon Scratch Test

Perform the ribbon scratch test when labels are unavailable.

To perform a ribbon scratch test, complete these steps:

1. Unroll a short length of ribbon.

2. Place the unrolled section of ribbon on a piece of paper with the outer surface of the
ribbon in contact with the paper.

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 Printer Setup and Operation 23
Ribbon Overview

3. Scratch the inner surface of the unrolled ribbon with your fingernail.

4. Lift the ribbon from the paper.

5. Observe the results. Did the ribbon leave a mark on the paper?

If the ribbon... Then...

Left a mark on the paper The ribbon is coated on the outside and can be
used in this printer.

Did not leave a mark on the The ribbon is coated on the inside and cannot
paper be used in this printer.
To verify this, repeat the test on the other
surface of the roll of ribbon.
Left a mark on the paper The ribbon is coated on the outside and can be
used with the standard Thermal Transfer
option (black ribbon spindle). In the ribbon
loading procedure, instructions are marked
with this symbol.
Did not leave a mark on the The ribbon is coated on the inside and can be
paper used with the alternate Thermal Transfer
option (gray ribbon spindle). In the ribbon
loading procedure, instructions are marked
with this symbol.

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24 Printer Setup and Operation
Ribbon Overview

Notes • ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

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 2
Printer Setup and
Operation

This section assists the technician with initial setup and operation of the printer.

Contents
Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Ship the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Select a Location for the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install the Printer Driver and Connect the Printer to the Computer . . . . . . . . . . . . . . . . . 28
Install Zebra Setup Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Connect a Computer to the Printer’s USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connect a Computer to the Printer’s Serial or Parallel Port. . . . . . . . . . . . . . . . . . . . . 41
Connect to Your Network through the Printer’s Ethernet Port . . . . . . . . . . . . . . . . . . . 49
Connect the Printer to Your Wireless Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Select a Print Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Load the Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Load the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Final Steps for Tear-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Final Steps for Peel-Off Mode (with or without Liner Take-Up) . . . . . . . . . . . . . . . . . . 78
Final Steps for Cutter Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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Handling the Printer

Handling the Printer

This section describes how to handle your printer.

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.
• Raise the media door, 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.
• Keep all packaging material for shipping company inspection.
• Notify your authorized Zebra reseller

Important • Zebra Technologies is not responsible for any damage incurred during the
shipment of the equipment and will not repair this damage under warranty.

Store the Printer

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

Ship the Printer

If you must ship the printer:
• Turn off (O) the printer, and disconnect all cables.
• Remove any media, ribbon, or loose objects from the printer interior.
• Close the printhead.
• Carefully pack the printer into the original container or a suitable alternate container to
avoid damage during transit. A shipping container can be purchased from Zebra if the
original packaging has been lost or destroyed.

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 Printer Setup and Operation 27
Select a Location for the Printer

Select a Location for the Printer

Select a location for the printer that meets these conditions:
• Surface: The surface where the printer will be located must be solid, level, and of
sufficient size and strength to hold the printer.
• Space: The area where the printer will be located must include enough space for
ventilation and for accessing the printer components and connectors. To allow for proper
ventilation and cooling, leave open space on all sides of the printer.

Caution • Do not place any padding or cushioning material behind or under the printer
because this restricts air flow and could cause the printer to overheat.

• Power: The printer should be within a short distance of an appropriate power outlet that is
easily accessible.
• Data communication interfaces: The printer must be within range of your WLAN radio
(if applicable) or within an acceptable range for other connectors to reach your data source
(usually a computer). For more information on maximum cable lengths and configuration,
see Table on page 176.
• Operating conditions: Your printer is designed to function in a wide range of
environmental and electrical conditions, including a warehouse or factory floor. Table 3
shows the temperature and relative humidity requirements for the printer when it is
operating.

Table 3 • Operating Temperature and Humidity

Mode Temperature Relative Humidity

Thermal Transfer 41° to 104°F (5° to 40°C) 20 to 85% non-condensing
Direct Thermal 32° to 104°F (0° to 40°C)

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Install the Printer Driver and Connect the Printer to the Computer

Install the Printer Driver and Connect the Printer to the

Computer
In this section, you are shown how to use the Zebra Setup Utilities program to prepare a
computer running Microsoft Windows® for the printer driver before connecting the printer to
any of the computer’s data communication interfaces. Use this section for directions to install
this program if you have not already done so. You may connect your printer to your computer
using any of the connections that you have available.

Important • You must install the Zebra Setup Utilities program before connecting the printer
to your computer. Your computer will not install the correct printer drivers if you connect the
printer to it without the Zebra Setup Utilities program.

Install Zebra Setup Utilities

Follow the directions in this section if you do not have Zebra Setup Utilities installed on your
computer or if you want to update an existing version of the program. You do not need to
uninstall any older versions or any Zebra printer drivers to do so.

To install the Zebra Setup Utilities program, complete these steps:

Download the Zebra Setup Utilities Installer

1. Go to http://www.zebra.com/setup.
The Zebra Setup Utilities page appears.

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Install the Printer Driver and Connect the Printer to the Computer

2. On the DOWNLOADS tab, click Download under the ZEBRA SETUP UTILITIES
option.

You are prompted to read and accept the End User License Agreement (EULA).

3. If you agree with the terms of the EULA, click

ACCEPT AND BEGIN DOWNLOAD NOW
Depending on your browser, you are given options to run or save the executable file.

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Run the Zebra Setup Utilities Installer

4. Save the program to your computer. (Optional if your browser gave you the option to run
the program instead of saving it.)

5. Run the executable file. If your computer prompts you for permission to run the file, click
the appropriate button to allow it to run.
What the computer displays next depends on whether Zebra Setup Utilities was already
installed. Follow the instructions based on what your computer prompts you to do.

If your computer... Then...

Did not previously a. The Zebra Setup Utilities - InstallAware Wizard displays the following.
have the Zebra Setup
Utilities installed

b. Continue with New Installations of Zebra Setup Utilities on page 31.

Did previously have a. The Zebra Setup Utilities - InstallAware Wizard displays the following.
the Zebra Setup
Utilities installed

b. Continue with Updating Existing Installations of Zebra Setup Utilities

on page 33.

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Install the Printer Driver and Connect the Printer to the Computer

New Installations of Zebra Setup Utilities

6. Click Next.
You are prompted again to read and accept the End User License Agreement (EULA).

7. If you agree with the terms of the EULA, check the box that says
I accept the terms of the license agreement

8. Click Next.
You are prompted to select where the files will be installed.

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9. Change the destination folder, if necessary, and then click Next.

You are prompted to select a location for program shortcuts.

10. Change the location, if desired, and then click Next.

You are prompted to complete the InstallAware wizard.

11. Skip to Continuing with New or Updated Installations on page 34.

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Install the Printer Driver and Connect the Printer to the Computer

Updating Existing Installations of Zebra Setup Utilities

12. Click Next.

You are prompted to choose the features that you would like to install.

13. Click Next.

You are prompted to complete the InstallAware wizard.

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Continuing with New or Updated Installations

14. Click Next.

Installation begins.

During installation, you are presented with information about drivers.

15. Read the information, and then check the box that says
I have read the information above

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Install the Printer Driver and Connect the Printer to the Computer

16. Click Next.

You are shown options that can take place when the wizard exits the installation.

17. Check the box that says “Run Zebra Setup Utilities now.”

18. Click Finish.

What the computer displays next depends on whether any Zebra printer drivers are already
installed on your computer. Follow the instructions based on what your computer displays.

If your computer... Then...

Did not previously The System Prepare Wizard displays.
have any Zebra
printer drivers
installed

To connect by... Then...

USB port Continue with Connect a Computer to the Printer’s USB
Port on page 37.
Serial or optional Continue with Connect a Computer to the Printer’s Serial or
parallel port Parallel Port on page 41.

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36 Printer Setup and Operation
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If your computer... Then...

Did previously have The Zebra Setup Utilities screen displays.
any Zebra printer
drivers installed

To connect by
Then...
the...
USB port Continue with Connecting the printer to a USB port on your
computer on page 38.
Serial or optional Continue with Adding a Printer from the Zebra Setup
parallel port Utilities Screen on page 44.

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 Printer Setup and Operation 37
Install the Printer Driver and Connect the Printer to the Computer—USB

Connect a Computer to the Printer’s USB Port

Complete the steps in this section only after you have installed the Zebra Setup Utilities
program. If necessary, complete the steps in Install Zebra Setup Utilities on page 28 before
continuing.

Important • You must install the Zebra Setup Utilities program before connecting the printer
to your computer. Your computer will not install the correct printer drivers if you connect the
printer to it without the Zebra Setup Utilities program.

Caution • Ensure that the printer power is off (O) before connecting data communications
cables. Connecting a data communications cable while the power is on (I) may damage the
printer.

To connect the printer to your computer by USB, complete these steps:

Running the System Prepare Wizard

If you are at the Zebra Setup Utilities screen, you do not need to complete this section.
Continue with Connecting the printer to a USB port on your computer on page 38.

The first time that you install the Zebra Setup Utilities program and printer drivers, you are
prompted to follow the System Prepare Wizard.

Figure 9 • System Prepare Wizard

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1. Click Next.
The System Prepare Wizard prompts you to connect the printer to the USB port on your
computer.

2. Click Finish.
The Zebra Setup Utilities screen displays.

Connecting the printer to a USB port on your computer

Complete the steps in this section only after the System Prepare Wizard prompts you to do so
or after you have opened the Zebra Setup Utilities program. If necessary, complete the steps in
Install Zebra Setup Utilities on page 28 before continuing.

Figure 10 • Zebra Setup Utilities Screen

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 Printer Setup and Operation 39
Install the Printer Driver and Connect the Printer to the Computer—USB

3. Connect the USB cord to the USB port on your printer.

4. Connect the other end of the USB cord to your computer.

5. Plug the female end of the A/C power cord into the A/C power connector on the back of
the printer.

6. Plug the male end of the A/C power cord into an appropriate power outlet.

115 VAC

230 VAC

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40 Printer Setup and Operation
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7. Turn on (I) the printer.

As the printer boots up, your computer completes the driver installation and recognizes
your printer.

The installation for the USB connection is complete.

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 Printer Setup and Operation 41
Install the Printer Driver and Connect the Printer to the Computer—Serial or Parallel

Connect a Computer to the Printer’s Serial or Parallel Port

Complete the steps in this section only after you have installed the Zebra Setup Utilities
program. If necessary, complete the steps in Install Zebra Setup Utilities on page 28 before
continuing.

Important • You must install the Zebra Setup Utilities program before connecting the printer
to your computer. Your computer will not install the correct printer drivers if you connect the
printer to it without the Zebra Setup Utilities program.

Caution • Ensure that the printer power is off (O) before connecting data communications
cables. Connecting a data communications cable while the power is on (I) may damage the
printer.

To connect the printer to your computer by USB, complete these steps:

If you are at the Zebra Setup Utilities screen, you do not need to complete this section.
Continue with Adding a Printer from the Zebra Setup Utilities Screen on page 44.

Running the System Prepare Wizard

The first time that you install the Zebra Setup Utilities program and printer drivers, you are
prompted to follow the System Prepare Wizard.

Figure 11 • System Prepare Wizard

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42 Printer Setup and Operation
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1. Select “Other computer ports (Parallel Port, Serial Port, TCP-IP Port, ...), and then click
Next.
The new printer wizard prompts you to begin the installation procedure.

2. Click Finish.
The printer driver wizard displays.

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Install the Printer Driver and Connect the Printer to the Computer—Serial or Parallel

3. Click Next.
You are prompted to select an installation option.

4. Continue with step 6 on page 45.

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Adding a Printer from the Zebra Setup Utilities Screen

Figure 12 • Zebra Setup Utilities Screen

5. On the Zebra Setup Utilities screen, click Install New Printer.

You are prompted to select an installation option.

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 Printer Setup and Operation 45
Install the Printer Driver and Connect the Printer to the Computer—Serial or Parallel

6. Click Install Printer.

You are prompted to select a printer type.

7. Select your printer model and resolution.

The model and resolution are on a part number sticker on the printer, usually located
below the media hanger. The information will be in the following format:
Part Number: XXXXXxY – xxxxxxxx
where
XXXXX = the printer model
Y = the printer resolution (2 = 203 dpi, 3 = 300 dpi, 6 = 600 dpi)
For example, in the part number ZT420x3 – xxxxxxxx
ZT420 indicates that the printer is a ZT420 model
3 indicates that the printhead resolution is 300 dpi

8. Click Next.
You are prompted for a printer name, the port to which the printer will be connected, and
the language for the program.

9. Change the printer name (if desired), and select the appropriate port and language.

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10. Click Next.

You are prompted to launch other setup wizards.

11. Check the desired options, and then click Finish.

The printer driver is installed. If you are prompted that other programs might be affected,
click Next.

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Install the Printer Driver and Connect the Printer to the Computer—Serial or Parallel

Connecting the printer to a serial or parallel port on your computer

12. Connect the desired cord to the appropriate port on your printer.

13. Connect the other end of the cord to the appropriate port on your computer.

14. Plug the female end of the A/C power cord into the A/C power connector on the back of
the printer.

15. Plug the male end of the A/C power cord into an appropriate power outlet.

115 VAC

230 VAC

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48 Printer Setup and Operation
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16. Turn on (I) the printer.

The printer boots up.

Configuring the printer (if necessary)

17. If necessary, adjust the printer’s port settings to match those of your computer. For more
information, see Port Settings on page 120.

The installation for serial or parallel connections is complete.

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 Printer Setup and Operation 49
Install the Printer Driver and Connect the Printer to the Computer—Ethernet

Connect to Your Network through the Printer’s Ethernet Port

If you wish to use a wired print server (Ethernet) connection, you may need to connect the
printer to your computer using one of the other available connections. While the printer is
connected via one of those connections, you would configure the printer to communicate with
your Local Area Network (LAN) through the printer’s wired print server.

For additional information about Zebra print servers, refer to the ZebraNet
Wired and Wireless Print Server User Guide. To download the latest version
of this guide, go to http://www.zebra.com/zt200-info.

To connect the printer to your computer by a wired print server, complete these
steps:

1. Install Zebra Setup Utilities as instructed in Install Zebra Setup Utilities on page 28.

2. Connect the printer to an Ethernet cable that is connected to your network.

The printer attempts to communicate with your network. If it is successful, it fills in your
LAN’s gateway and subnet values and gets an IP address. The printer display will
alternate between the printer’s firmware version and its IP address.

3. Check the display to see if an IP address was assigned to the printer. See IP Address
on page 109 for additional ways to view the IP address.

If the printer’s IP address is... Then...

0.0.0.0 Continue with Configuring the printer
or with your LAN information (if necessary)
000.000.000.000 on page 50.
any other value Continue with Adding a Printer from the
Zebra Setup Utilities Screen on page 51.

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Install the Printer Driver and Connect the Printer to the Computer—Ethernet

Configuring the printer with your LAN information (if necessary)

If your printer connected to your network automatically, you do not need to complete this
section. Continue with Adding a Printer from the Zebra Setup Utilities Screen on page 51.

4. Connect the printer to your computer using a USB, serial, or optional parallel port as
instructed in Connect a Computer to the Printer’s USB Port on page 37 or Connect a
Computer to the Printer’s Serial or Parallel Port on page 41.

5. Configure the following printer settings. You can change the values through the Zebra
Setup Utilities (click Configure Printer Connectivity on the Zebra Setup Utilities screen)
or by the ways listed at the following links. Contact your network administrator for the
proper values for your network.
• IP Protocol on page 111 (change the value from ALL to PERMANENT)
• Gateway on page 110 (match the gateway value of your LAN)
• Subnet Mask on page 109 (match the subnet value of your LAN)
• IP Address on page 109 (assign a unique IP address to the printer)

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Install the Printer Driver and Connect the Printer to the Computer—Ethernet

Adding a Printer from the Zebra Setup Utilities Screen

6. If necessary, open the Zebra Setup Utilities program.

The Zebra Setup Utilities screen displays.

Figure 13 • Zebra Setup Utilities Screen

7. Click Install New Printer.

The printer driver wizard displays.

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Install the Printer Driver and Connect the Printer to the Computer—Ethernet

8. Click Next.
You are prompted to select an installation option.

9. Click Install Printer.

You are prompted to select a printer type.

10. Select your printer model and resolution.

The model and resolution are on a part number sticker on the printer, usually located
below the media hanger. The information will be in the following format:
Part Number: XXXXXxY – xxxxxxxx
where
XXXXX = the printer model
Y = the printer resolution (2 = 203 dpi, 3 = 300 dpi, 6 = 600 dpi)
For example, in the part number ZT230x3 – xxxxxxxx
ZT230 indicates that the printer is a ZT230 model
3 indicates that the printhead resolution is 300 dpi

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Install the Printer Driver and Connect the Printer to the Computer—Ethernet

11. Click Next.

You are notified that the printer is already installed.

12. Click Add new printer.

You are prompted for a printer name, the port to which the printer will be connected, and
the language for the printer display.

13. Click Add Port.

The wizard prompts you for a name for the port and the IP address of your printer.

Note • If you have other applications open, you may be prompted that the driver is
locked by another process. You may click Next to continue or Exit to allow you to save
your work before continuing with this installation.

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Install the Printer Driver and Connect the Printer to the Computer—Ethernet

14. Give the port a name that you can recognize when it appears in the list of available ports.

15. Enter the printer’s IP address. This could be one that was assigned automatically or one
that you specified manually in the previous section.

16. Click OK.

A printer driver is created with the port name that you assigned. The new printer port
appears in the list of available ports.

17. Click Next.

You are prompted to launch other setup wizards.

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Install the Printer Driver and Connect the Printer to the Computer—Ethernet

18. Check the desired options, and then click Finish.

The printer driver is installed. If you are prompted that other programs might be affected,
click the appropriate option to continue.

The installation for wired (Ethernet) connections is complete.

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56 Printer Setup and Operation
Install the Printer Driver and Connect the Printer to the Computer—Wireless

Connect the Printer to Your Wireless Network

If you wish to use the printer’s optional wireless print server, you must first connect the printer
to your computer using one of the other available connections. While the printer is connected
via one of those connections, you configure the printer to communicate with your Wireless
Local Area Network (WLAN) through the wireless print server.

For additional information about Zebra print servers, refer to the ZebraNet
Wired and Wireless Print Server User Guide. To download the latest version
of this guide, go to http://www.zebra.com/zt400-info.

To connect the printer to your computer by an optional wireless print server,

complete these steps:

1. Install Zebra Setup Utilities as instructed in Install Zebra Setup Utilities on page 28.

2. Connect the printer to your computer using a USB, serial, or optional parallel port as
instructed in Connect a Computer to the Printer’s USB Port on page 37 or Connect a
Computer to the Printer’s Serial or Parallel Port on page 41.

3. Configure the following printer settings. You can change the values through the Zebra
Setup Utilities (click Configure Printer Connectivity on the Zebra Setup Utilities screen)
or by the ways listed at the following links. Contact your network administrator for the
proper values for your network.
• IP Protocol on page 111 (change the value from ALL to PERMANENT)
• Gateway on page 110 (match the gateway value of your WLAN)
• Subnet Mask on page 109 (match the subnet value of your WLAN)
• IP Address on page 109 (assign a unique IP address to the printer)

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Install the Printer Driver and Connect the Printer to the Computer—Wireless

Adding a Printer from the Zebra Setup Utilities Screen

4. If necessary, open the Zebra Setup Utilities program.

The Zebra Setup Utilities screen displays.

Figure 14 • Zebra Setup Utilities Screen

5. Click Install New Printer.

The printer driver wizard displays.

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58 Printer Setup and Operation
Install the Printer Driver and Connect the Printer to the Computer—Wireless

6. Click Next.
You are prompted to select an installation option.

7. Click Install Printer.

You are prompted to select a printer type.

8. Select your printer model and resolution.

The model and resolution are on a part number sticker on the printer, usually located
below the media hanger. The information will be in the following format:
Part Number: XXXXXxY – xxxxxxxx
where
XXXXX = the printer model
Y = the printer resolution (2 = 203 dpi, 3 = 300 dpi, 6 = 600 dpi)
For example, in the part number ZT230x3 – xxxxxxxx
ZT230 indicates that the printer is a ZT230 model
3 indicates that the printhead resolution is 300 dpi

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Install the Printer Driver and Connect the Printer to the Computer—Wireless

9. Click Next.
You are notified that the printer is already installed.

10. Click Add new printer.

You are prompted for a printer name, the port to which the printer will be connected, and
the language for the printer display.

11. Click Add Port.

The wizard prompts you for a name for the port and the IP address of your printer.

Note • If you have other applications open, you may be prompted that the driver is
locked by another process. You may click Next to continue or Exit to allow you to save
your work before continuing with this installation.

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Install the Printer Driver and Connect the Printer to the Computer—Wireless

12. Give the port a name that you can recognize when it appears in the list of available ports.

13. Enter the printer’s IP address. This could be one that was assigned automatically or one
that you specified manually in the previous section.

14. Click OK.

A printer driver is created with the port name that you assigned. The new printer port
appears in the list of available ports.

15. Click Next.

You are prompted to launch other setup wizards.

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Install the Printer Driver and Connect the Printer to the Computer—Wireless

16. Check the desired options, and then click Finish.

The printer driver is installed. If you are prompted that other programs might be affected,
click the appropriate option to continue.

The installation for wireless communication is complete.

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62 Printer Setup and Operation
Select a Print Mode

Select a Print Mode

Use a print mode that matches the media being used and the printer options available
(Table 4).

Table 4 • Print Modes and Printer Options

Print Mode When to Use/Printer Options Required Printer Actions

Tear-Off Use for most applications. This mode can The printer prints label formats as it
(default setting) be used with any printer options and most receives them. The printer operator can tear
media types. off the printed labels any time after they
print.
Roll media in Tear-Off mode
(shown using thermal transfer media with ribbon loaded)

Fanfold media in Tear-Off mode

(shown using direct thermal media and no ribbon)

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Select a Print Mode

Table 4 • Print Modes and Printer Options

Print Mode When to Use/Printer Options Required Printer Actions

Peel-Off Use if the printer has the Peel-Off option or The printer peels the label from the liner
the Liner Take-Up option.* during printing and then pauses until the
label is removed. The liner exits the front of
the printer.
• In Peel-Off mode, the liner exits the
front of the printer.
• In Peel-Off mode with Liner Take-Up,
* The Liner Take-Up option is available only on the liner winds onto the liner take-up
the ZT230 printer. spindle or the rewind spindle.
Peel-Off mode
(shown without a ribbon system)

Peel-Off mode with Liner Take-Up*

(shown using direct thermal media and no ribbon)

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Select a Print Mode

Table 4 • Print Modes and Printer Options

Print Mode When to Use/Printer Options Required Printer Actions

Cutter Use if the printer has a cutter option when The printer prints a label and then cuts it
you want the labels to be cut apart. free.
Cutter mode
(shown using direct thermal media and no ribbon)

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Load the Ribbon

Load the Ribbon

Note • This section applies only to printers that have the Thermal Transfer option installed.

Ribbon is used only with thermal transfer labels. For direct thermal labels, do not load ribbon
in the printer. To determine if ribbon must be used with a particular media, see When to Use
Ribbon on page 21.

Caution • While performing any tasks near an open printhead, remove all rings, watches,
hanging necklaces, identification badges, or other metallic objects that could touch the
printhead. You are not required to turn off the printer power when working near an open
printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose
all temporary settings, such as label formats, and you must reload them before you resume
printing.

Important • Use ribbon that is wider than the media to protect the printhead from wear.
Ribbon must be coated on the outside.

To load ribbon, complete these steps:

1. Raise the media door.

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Load the Ribbon

2.
Caution • The printhead may be hot and could cause severe burns. Allow the
printhead to cool.

Open the printhead assembly by rotating the printhead-open lever.

3. Place the roll of ribbon on the ribbon supply spindle with the loose end of the ribbon
unrolling as shown. Push the roll back as far as it will go.

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Load the Ribbon

4. Your printer shipped with an empty ribbon core on the ribbon take-up spindle. If this core
is no longer there, place an empty ribbon core on the ribbon take-up spindle. Push the core
back as far as it will go.

5. Bring the ribbon under the printhead assembly as shown.

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Load the Ribbon

6. With the ribbon tracking as far back as it can under the printhead assembly, wrap the
ribbon around the core on the ribbon take-up spindle. Rotate the spindle several turns in
the direction shown to tighten and align the ribbon.

7. If media is already loaded, rotate the printhead-open lever downward until it locks the
printhead in place. Otherwise, continue with Load the Media on page 70.

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Load the Ribbon

8. Close the media door.

9. If necessary, press PAUSE to enable printing.

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70 Printer Setup
Load the Media

Load the Media

Use the instructions in this section for loading roll or fanfold media in any print mode.

Caution • While performing any tasks near an open printhead, remove all rings, watches,
hanging necklaces, identification badges, or other metallic objects that could touch the
printhead. You are not required to turn off the printer power when working near an open
printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose
all temporary settings, such as label formats, and you must reload them before you resume
printing.

To load media, complete these steps:

1. Raise the media door.

2.
Caution • The printhead may be hot and could cause severe burns. Allow the
printhead to cool.

Open the printhead assembly by rotating the printhead-open lever.

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Load the Media

3. Insert media into the printer. Follow the instructions for roll or fanfold media, as
appropriate.

Roll Media Fanfold Media

a. Remove and discard any tags or a. Slide out and flip down the media
labels that are dirty or that are held by supply guide.
adhesives or tape.

b. Slide out and flip down the media b. Insert the fanfold media through the
supply guide. rear of the printer.

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Load the Media

Roll Media (Continued) Fanfold Media (Continued)

c. Place the roll of media on the media c. Drape the media over the media
supply hanger. Push the roll back as supply hanger.
far as it will go.

d. Flip up the media supply guide. d. Flip up the media supply guide.

e. Slide in the media supply guide until e. Slide in the media supply guide until
it touches the edge of the roll. it touches the edge of the media.

f. Continue with the remaining steps as

shown for roll media.

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Load the Media

4. Slide the outer media guide all the way out.

5. Slide the media under the media dancer assembly and the printhead assembly. Allow the
end of the media to extend out of the front of the printer.

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Load the Media

6. Make sure that the media passes through the slot in the transmissive media sensor (1) and
under the inner media guide (2). The media should just touch the back of the transmissive
media sensor slot.

1
2

7. In which print mode will your printer be operating? (For more information on print
modes, see Select a Print Mode on page 62.)

If using… Then…
Tear-Off mode Continue with Final Steps for
Tear-Off Mode on page 76.

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 Printer Setup 75
Load the Media

If using… Then…
Peel-Off mode (with or without Liner Take-Up) Continue with Final Steps for
Peel-Off Mode (with or without
Liner Take-Up) on page 78.

Cutter mode Continue with Final Steps for Cutter

Mode on page 84.

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76 Printer Setup
Load the Media

Final Steps for Tear-Off Mode

1. Slide in the outer media guide until it just touches the edge of the media.

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 Printer Setup 77
Load the Media

2. Rotate the printhead-open lever downward until it locks the printhead in place.

3. Set the printer to Tear-Off mode (for more information, see Print Mode on page 97).

4. Close the media door.

5. Press PAUSE to exit pause mode and enable printing.

The printer may perform a label calibration or feed a label, depending on your settings.

6. For best results, calibrate the printer. See Calibrate the Ribbon and Media Sensors
on page 122.

7. If desired, perform the CANCEL Self Test on page 165 to verify that your printer is able to
print.
Media loading in Tear-Off mode is complete.

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78 Printer Setup
Load the Media

Final Steps for Peel-Off Mode (with or without Liner Take-Up)

1. Push down the peel-off mechanism release lever to open the peel assembly.

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Load the Media

2. Extend the media approximately 18 in. (500 mm) out of the printer.

3. Remove the exposed labels so that only the liner remains.

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Load the Media

4. Feed the liner behind the peel assembly. Make sure that the end of the liner falls outside of
the printer.

5. Complete this step only if you want to use Peel-Off mode with Liner Take-Up. Your
printer must have the Liner Take-Up option installed.
5-a. Slide the liner into the slot in the liner take-up spindle (1).

5-b. Push the liner back until it touches the back plate of the liner take-up spindle
assembly.

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Load the Media

5-c. Wrap the liner around the liner take-up spindle and turn the spindle
counterclockwise to tighten the liner.

6.
Caution • Use the peel release lever and your right hand to close the peel assembly.
Do not use your left hand to assist in closing. The top edge of the peel roller/assembly
could pinch your fingers.

Close the peel assembly using the peel-off mechanism release lever.

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Load the Media

7. Slide in the outer media guide until it just touches the edge of the media.

8. Rotate the printhead-open lever downward until it locks the printhead in place.

9. Set the printer to Peel-Off mode (for more information, see Print Mode on page 97).

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Load the Media

10. Close the media door.

11. Press PAUSE to exit pause mode and enable printing.

The printer may perform a label calibration or feed a label, depending on your settings.

12. For best results, calibrate the printer. See Calibrate the Ribbon and Media Sensors
on page 122.

13. If desired, perform the CANCEL Self Test on page 165 to verify that your printer is able to
print.
Media loading in Peel-Off mode is complete.

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Load the Media

Final Steps for Cutter Mode

1.
Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers.

Feed the media through the cutter.

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Load the Media

2. Slide in the outer media guide until it just touches the edge of the media.

3. Rotate the printhead-open lever downward until it locks the printhead in place.

4. Set the printer to Cutter mode (for more information, see Print Mode on page 97).

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Load the Media

5. Close the media door.

6. Press PAUSE to exit pause mode and enable printing.

The printer may perform a label calibration or feed a label, depending on your settings.

7. For best results, calibrate the printer. See Calibrate the Ribbon and Media Sensors
on page 122.

8. If desired, perform the CANCEL Self Test on page 165 to verify that your printer is able to
print.
Media loading in Cutter mode is complete.

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 Printer Setup and Operation 87
Print a Test Label and Make Adjustments

Print a Test Label and Make Adjustments

After you have loaded media, loaded ribbon (if using Thermal Transfer mode), installed the
printer driver, and connected your printer to your computer, use the directions in this section to
print a test label. Printing this label allows you to see if your connection is working and if you
need to adjust any of the printer settings.

To print a test label and adjust the printer (if necessary), complete these steps:

1. Open the Zebra Setup Utilities to return to the Zebra Setup Utilities screen.

2. Click on one of the available print drivers for your printer.

3. Click Open Printer Tools.

The Tools window displays the available printer commands.

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Print a Test Label and Make Adjustments

4. Click Send to print a printer configuration label.

If your connection is working correctly and your printer is correctly loaded with media
and ribbon (if used), a printer configuration label prints.

Figure 15 • Sample Printer Configuration Label

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 Printer Setup and Operation 89
Print a Test Label and Make Adjustments

5. Did the printer configuration label print, and is the print quality acceptable?

If... Then...
The label printed and the Your printer is ready for printing. Continue with the
print quality is acceptable label designer program of your choice. You may use
ZebraDesigner™, which you can download from
http://www.zebra.com.
The label did not print a. Close the Tools window and make sure that you
selected the correct printer driver before you click
Open Printer Tools. Try printing the label again.
b. If the label still did not print, check the connections
between your printer and your computer or your
printer and your network.
c. If necessary, modify the printer’s settings to make
them match your computer’s settings.
The label prints, but with See Printing Issues on page 152 for troubleshooting
poor quality or other issues instructions.

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Print a Test Label and Make Adjustments

Notes • ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

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 3
Printer Configuration
and Adjustment

This section assists you with configuration of and adjustments to the printer.

Contents

Contents
Changing Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Print Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Calibration and Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Language Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Sensor Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Port Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Calibrate the Ribbon and Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Adjust the Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Adjust Ribbon Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Remove Used Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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Changing Printer Settings

Changing Printer Settings

This section presents the printer settings that you can change and identifies the tools for
changing them. These tools include the following:
• ZPL and Set/Get/Do (SGD) commands (See the Zebra® Programming Guide for more
information.)
• For ZT230 printers only, the printer’s user menus (See Idle Display, Home Menu, and
User Menus on page 17 for more information.)
• The printer’s web pages when the printer has an active wired or wireless print server
connection (See the ZebraNet Wired and Wireless Print Servers User Guide for more
information.)

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

This section contains the following subsections:

• Print Settings on page 93
• Calibration and Diagnostic Tools on page 100
• Network Settings on page 109
• Language Settings on page 114
• Sensor Settings on page 118
• Port Settings on page 120

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Changing Printer Settings

Print Settings

Table 5 • Print Settings

DARKNESS

Print Darkness Set the darkness to the lowest setting that provides good print quality. If you set the
darkness too high, the label image may print unclearly, bar codes may not scan
correctly, the ribbon may burn through, or the printhead may wear prematurely.
If desired, use the FEED Self Test on page 167 to determine the best darkness setting.
User menu item: Main Menu > SETTINGS

Accepted values: 0.0 – 30.0

Related ZPL command(s): ^MD, ~SD
SGD command used: print.tone
Printer web page: View and Modify Printer Settings > General Setup >
Darkness
PRINT SPEED

Print Speed Select the speed for printing a label (given in inches per second). Slower print speeds
typically yield better print quality.
User menu item: Main Menu > SETTINGS

Accepted values: 2, 3, 4, 5, 6
Related ZPL command(s): ^PR
SGD command used: media.speed

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Changing Printer Settings

Table 5 • Print Settings (Continued)

MEDIA TYPE

Media Type Select the type of media that you are using.
• If you select CONTINUOUS, you must include a label length in your label format
(^LL if you are using ZPL).
• If you select GAP/NOTCH or MARK for various non-continuous media, the printer
feeds media to calculate the label length.
See Types of Media on page 19 for more information.
User menu item: Main Menu > SETTINGS

Accepted values: • CONTINUOUS

• GAP/NOTCH
• MARK
Related ZPL command(s): ^MN
SGD command used: ezpl.media_type
Printer web page: View and Modify Printer Settings > Media Setup >
Media Type
PRINT METHOD

Print Method Specify if the printer is to use Direct Thermal mode (no ribbon) or Thermal Transfer
mode (using thermal transfer media and ribbon).
User menu item: Main Menu > SETTINGS

Accepted values: • THERMAL TRANS

• DIRECT THERMAL
Related ZPL command(s): ^MT
SGD command used: ezpl.print_method
Printer web page: View and Modify Printer Settings > Media Setup > Print
Method

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Changing Printer Settings

Table 5 • Print Settings (Continued)

TEAR OFF

Tear-Off Position If necessary, adjust the position of the media over the tear-off bar after printing.
User menu item: Main Menu > SETTINGS

Accepted values: –120 to 120

• Higher numbers move the media out (the tear line
moves closer to the leading edge of the next label).
• Lower numbers move the media in (the tear line
moves closer to the edge of the label just printed).

1
2

1 Media direction
2 Factory-set tear line location at
position 000

Related ZPL command(s): ~TA

SGD command used: ezpl.tear_off
Printer web page: View and Modify Printer Settings > General Setup >
Tear Off

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Changing Printer Settings

Table 5 • Print Settings (Continued)

PRINT WIDTH

Print Width Specify the width of the labels being used, in dots. The default value is the maximum
width for the printer, based on the printhead’s DPI value.
User menu item: Main Menu > SETTINGS

Accepted values: Note • Setting the width too narrow can result in
portions of a label format not being printed on
the media. Setting the width too wide wastes
formatting memory and can cause the printer to
print off of the label and onto the platen roller.
This setting can affect the horizontal position of
the label format if the image was inverted using
the ^POI ZPL II command.

0000 to 1248 dots

Related ZPL command(s): ^PW
SGD command used: ezpl.print_width
Printer web page: View and Modify Printer Settings > Media Setup >
Print Width

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Table 5 • Print Settings (Continued)

PRINT MODE

Print Mode 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 Select a Print Mode on page 62.
User menu item: Main Menu > SETTINGS

Accepted values: • TEAR OFF

• CUTTER
• PEEL (use this value for peel-off or liner take-up
printing)
Related ZPL command(s): ^MM
SGD command used: media.printmode
Printer web page: View and Modify Printer Settings > General Setup >
Print Mode
LEFT POSITION

Label Left If necessary, shift the print position horizontally on the label. Positive numbers move
Position the left edge of the image toward the center of the label by the number of dots selected,
while negative numbers move the left edge of the image toward the left edge of the
label.
User menu item: Main Menu > SETTINGS

Accepted values: –9999 to 9999

Related ZPL command(s): ^LS
SGD command used: zpl.left_position
Printer web page: View and Modify Printer Settings > Advanced Setup >
Left Position

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Table 5 • Print Settings (Continued)

REPRINT MODE

Reprint Mode When reprint mode is enabled, you can reprint the last label printed by pressing the
DOWN ARROW on the printer’s control panel.
User menu item: Main Menu > SETTINGS

Accepted values: • ON
• OFF
Related ZPL command(s): ^JZ
SGD command used: ezpl.reprint_mode

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Table 5 • Print Settings (Continued)

LABEL LENGTH MAX

Maximum Label Set the maximum label length.

Length
User menu item: Main Menu > SETTINGS

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

Important • Specify a value that is at least 1.0 in.
(25.4 mm) greater than the actual label length
plus the interlabel gap. If you set the value to one
that is smaller than the label length, the printer
assumes that continuous media is loaded, and the
printer cannot calibrate.
For example, if the label length is 6.0 inches
(152 mm) including the interlabel gap, set the
parameter for at least 7.0 inches (178 mm).

1
3

1 Label length (including interlabel gap)

2 Interlabel gap
3 Set the maximum label length to
approximately this value
Related ZPL command(s): ^ML
SGD command used: ezpl.label_length_max
Printer web page: View and Modify Printer Settings > Media Setup >
Maximum Length

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Calibration and Diagnostic Tools

Table 6 • Calibration and Diagnostic Tools

PRINT INFORMATION

Print Print the specified information on one or more labels.

Information
User menu item: Main Menu > TOOLS

Main Menu > NETWORK

Main Menu > SENSORS

(Continued on next page.)

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Table 6 • Calibration and Diagnostic Tools (Continued)

Print Accepted values: • SETTINGS—prints the printer configuration label.
Information • NETWORK—prints the settings for any print server
(continued) that is installed.
• FORMATS—prints the available formats stored in the
printer’s RAM, Flash memory, or optional memory
card.
• IMAGES—prints the available images stored in the
printer’s RAM, Flash memory, or optional memory
card.
• FONTS—prints the available fonts in the printer,
including standard printer fonts plus any optional
fonts. Fonts may be stored in RAM or Flash memory.
• BARCODES—prints the available bar codes in the
printer. Bar codes may be stored in RAM or Flash
memory.
• ALL—prints the previous six labels.
• SENSOR PROFILE—shows the sensor settings
compared to actual sensor readings. To interpret the
results, see Sensor Profile on page 172.
Related ZPL command(s): SETTINGS: ~WC
NETWORK: ~WL
SENSOR PROFILE: ~JG
Others: ^WD
Control panel key(s): SETTINGS and NETWORK: Do one of the following:
• Hold CANCEL during printer power-up.
• Hold FEED + CANCEL for 2 seconds when the
printer is in the Ready state.
SENSOR PROFILE: Hold FEED + CANCEL during
printer power-up.
Printer web page: View and Modify Printer Settings >
Print Listings on Label
LCD CONTRAST

LCD Contrast Change the contrast on the printer’s display. (ZT230 only)
User menu item: Main Menu > TOOLS

Accepted values: 3 to 15
SGD command used: display.contrast

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Table 6 • Calibration and Diagnostic Tools (Continued)

IDLE DISPLAY

Idle Display Select the information shown on the printer’s display when the printer is idle.
(ZT230 only)
User menu item: Main Menu > TOOLS

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
SGD command used: device.idle_display_format
POWER UP ACTION

Power-Up Action Set the action for the printer to take during the power-up sequence.
User menu item: Main Menu > TOOLS

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.
Related ZPL command(s): ^MF
SGD command used: ezpl.power_up_action
Printer web page: View and Modify Printer Settings > Calibration

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Table 6 • Calibration and Diagnostic Tools (Continued)

HEAD CLOSE ACTION

Head-Close Set the action for the printer to take when you close the printhead.
Action
User menu item: Main Menu > TOOLS

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.
Related ZPL command(s): ^MF
SGD command used: ezpl.head_close_action
Printer web page: View and Modify Printer Settings > Calibration

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Table 6 • Calibration and Diagnostic Tools (Continued)

LOAD DEFAULTS

Load Defaults Restore specific printer, print server, and network settings back to the factory defaults.
Use care when loading defaults because you will need to reload all settings that you
changed manually.
User menu item: Main Menu > TOOLS

Main Menu > NETWORK

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
Control panel key(s): FACTORY: Hold FEED + PAUSE during printer power-
up to reset the printer parameters to factory values.
NETWORK: Hold CANCEL + PAUSE during printer
power-up to reset the network parameters to
factory values.
LAST SAVED: N/A
Printer web page: FACTORY: View and Modify Printer Settings > Restore
Default Configuration
NETWORK: Print Server Settings > Reset Print Server
LAST SAVED: View and Modify Printer Settings >
Restore Saved Configuration

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Table 6 • Calibration and Diagnostic Tools (Continued)

MEDIA/RIBBON CAL

Media and Calibrate the printer to adjust the sensitivity of the media and ribbon sensors.
Ribbon Sensor For complete instructions on how to perform a calibration procedure, see Calibrate the
Calibration Ribbon and Media Sensors on page 122.
User menu item: Main Menu > TOOLS
Main Menu > SENSORS

Related ZPL command(s): ~JC

SGD command used: ezpl.manual_calibration
Control panel key(s): Hold PAUSE + CANCEL for 2 seconds to initiate
calibration.
Printer web page: The calibration procedure cannot be initiated through the
web pages. See the following web page for settings that
are set during sensor calibration:
View and Modify Printer Settings > Calibration

Important • Do not change these settings unless

you are told to do so by Zebra Technical Support
or by an authorized service technician.

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Table 6 • Calibration and Diagnostic Tools (Continued)

DIAGNOSTIC MODE

Communication Use this diagnostics tool to cause the printer to output the hexadecimal values for all
Diagnostics Mode data received by the printer.
For more information, see Communication Diagnostics Test on page 171.
User menu item: Main Menu > TOOLS

Accepted values: • DISABLED

• ENABLED
Related ZPL command(s): ~JD to enable, ~JE to disable
SGD command used: device.diagnostic_print
Control panel key(s): Hold PAUSE + FEED for 2 seconds when the printer is
in the Ready state.

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Table 6 • Calibration and Diagnostic Tools (Continued)

ZBI ENABLED?

Enable ZBI Zebra Basic Interpreter (ZBI 2.0™) is a programming option that may be purchased for
your printer. If you would like to purchase this option, contact your Zebra reseller for
more information.
User menu item: Main Menu > TOOLS

SGD command used: zbi.key (identifies if the ZBI 2.0 option is enabled or
disabled on the printer)
RUN ZBI PROGRAM

Run a ZBI If you have ZBI installed, you may choose to run a ZBI program that you have
Program downloaded to your printer.
User menu item: * Main Menu > TOOLS
* This menu item appears only
if ZBI is enabled on your
printer and no ZBI program is
running.

If ZBI programs exist on your printer, they are listed. If

no program exists, NONE is listed.
If you wish 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.
Related ZPL command(s): ^JI, ~JI
SGD command used: zbi.control.run
Printer web page: Directory Listing

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Table 6 • Calibration and Diagnostic Tools (Continued)

STOP ZBI PROGRAM

Stop a ZBI If your printer is running a ZBI program, you may stop that program.
Program
User menu item: Main Menu > TOOLS
* This menu item appears only
if ZBI is enabled on your
printer and no ZBI program is
running.

If ZBI programs are running, the printer lists them.

If you wish to stop a program:
1. Use the UP ARROW or DOWN ARROW to select
the file from this menu.
2. Press RIGHT SELECT to select STOP.
Related ZPL command(s): ~JQ
SGD command used: zbi.control.terminate
Printer web page: Directory Listing

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Network Settings

Table 7 • Network Settings

IP ADDRESS

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

To save changes to this setting, set IP Protocol on page 111 to PERMANENT, and then
reset the print server (see Reset Network on page 113).
User menu item: * Main Menu > NETWORK
* This menu item appears only if a
wired or wireless print server is
installed in your printer.

Accepted values: 000 to 255 for each field

Related ZPL command(s): ^ND
SGD command used: Wired: internal_wired.ip.addr
Wireless: ip.addr, wlan.ip.addr
Printer web page: View and Modify Printer Settings >
Network Communications Setup >
TCP/IP Settings
SUBNET MASK

Subnet Mask View and, if necessary, change the subnet mask.

To save changes to this setting, set IP Protocol on page 111 to PERMANENT, and then
reset the print server (see Reset Network on page 113).
User menu item: * Main Menu > NETWORK
* This menu item appears only if a
wired or wireless print server is
installed in your printer.

Accepted values: 000 to 255 for each field

Related ZPL command(s): ^ND
SGD command used: Wired: internal_wired.ip.netmask
Wireless: wlan.ip.netmask
Printer web page: View and Modify Printer Settings >
Network Communications Setup >
TCP/IP Settings

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Table 7 • Network Settings (Continued)

View or Set the Default Gateway
GATEWAY

Gateway
View and, if necessary, change the default gateway.
To save changes to this setting, set IP Protocol on page 111 to PERMANENT, and then
reset the print server (see Reset Network on page 113).
User menu item: * Main Menu > NETWORK
* This menu item appears only if a
wired or wireless print server is
installed in your printer.

Accepted values: 000 to 255 for each field

Related ZPL command(s): ^ND
SGD command used: Wired: internal_wired.ip.gateway
Wireless: wlan.ip.gateway
Printer web page: View and Modify Printer Settings >
Network Communications Setup >
TCP/IP Settings

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Table 7 • Network Settings (Continued)

IP PROTOCOL

IP Protocol This parameter tells if the user (permanent) or the server (dynamic) selects the
IP address. When a dynamic option is chosen, this parameter tells the method(s) by
which the wired or wireless print server receives the IP address from the server.
User menu item: * Main Menu > NETWORK
* This menu item appears only if a
wired or wireless print server is
installed in your printer.

Accepted values: • ALL

• GLEANING ONLY
• RARP
• BOOTP
• DHCP
• DHCP & BOOTP
• PERMANENT
Related ZPL command(s): ^ND
SGD command used: Wired: internal_wired.ip.protocol
Wireless: wlan.ip.protocol
Printer web page: View and Modify Printer Settings >
Network Communications Setup >
TCP/IP Settings
ACTIVE PRINT SERVER

Active Print Only one print server (wired or wireless) can be installed at a time. Therefore, the print
Server server installed is the active print server.
User menu item: * Main Menu > NETWORK
* This menu item appears only if a
wired or wireless print server is
installed in your printer. It cannot
be modified from the control
panel.

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Table 7 • Network Settings (Continued)

View the MAC Address
MAC ADDRESS

MAC Address
View the Media Access Control (MAC) address of the print server that is installed in the
printer (wired or wireless).
User menu item: * Main Menu > NETWORK
* This menu item appears only if a
wired or wireless print server is
installed in your printer. It cannot
be modified from the control
panel.

SGD command used: Wired: internal_wired.mac_addr

Wireless: wlan.mac_addr
Printer web page: View and Modify Printer Settings >
Network Communications Setup >
Wireless Setup
View the ESSID Value
ESSID

ESSID
The Extended Service Set Identification (ESSID) is an identifier for your wireless
network. This setting, which cannot be modified from the control panel, gives the
ESSID for the current wireless configuration.
User menu item: * Main Menu > NETWORK
* This menu item appears only if a
wired or wireless print server is
installed in your printer. It cannot
be modified from the control
panel.

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

SGD command used: wlan.essid
Printer web page: View and Modify Printer Settings >
Network Communications Setup >
Wireless Setup

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Table 7 • Network Settings (Continued)

RESET NETWORK

Reset Network This option resets the wired or wireless print server. You must reset the print server to
allow any changes to the network settings to take effect.
User menu item: Main Menu > NETWORK

Related ZPL command(s): ~WR

SGD command used: device.reset
Printer web page: Print Server Settings > Factory Print Server Settings

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Language Settings

Table 8 • Language Settings

LANGUAGE

Language If necessary, change the language that the printer displays.

This change affects the words shown on the following:
• the Home menu
• the user menus
• error messages
• the printer configuration label, the network configuration label, and other labels that
you can select to print through the user menus
User menu item: Main Menu > SETTINGS
Main Menu > LANGUAGE

Note • The selections for this parameter are

displayed in the actual languages to make it
easier for you to find one that you are able to
read.
Accepted values: ENGLISH, SPANISH, FRENCH, GERMAN, ITALIAN,
NORWEGIAN, PORTUGUESE, SWEDISH, DANISH,
SPANISH 2, DUTCH, FINNISH, CZECH, JAPANESE,
KOREAN, ROMANIAN, RUSSIAN, POLISH,
SIMPLIFIED CHINESE, TRADITIONAL CHINESE
Related ZPL command(s): ^KL
SGD command used: display.language
Printer web page: View and Modify Printer Settings > General Setup >
Language

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Table 8 • Language Settings (Continued)

COMMAND LANGUAGE

Command Enable this menu item to allow certain ZPL commands to override the printer’s current
Language settings.
User menu item: Main Menu > LANGUAGE

COMMAND LANGUAGE

▼ EPL_ZPL ▲

Accepted values: • EPL_ZPL

• HYBRID_XML_ZPL
• EPL
SGD command used: device.languages
Enable ZPL Override
ZPL OVERRIDE

ZPL Override
Enable this menu item to prevent the following ZPL commands from changing the
printer’s current settings:
• ^MM (print mode)
• ^MT (Direct Thermal or Thermal Transfer print method)
• ^MN (media type non-continuous or continuous)
When this menu item is disabled, these commands override the printer’s settings.
User menu item: Main Menu > LANGUAGE

Accepted values: • DISABLED

• ENABLED
SGD command used: zpl.zpl_override

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Table 8 • Language Settings (Continued)

Set the Format Command Prefix Value
COMMAND CHAR

Command
Character The format command prefix is a two-digit hex value used as a parameter place marker
in ZPL/ZPL II format instructions. The printer looks for this hex character to indicate
the start of a ZPL/ZPL II format instruction.
Set the format command character to match what is used in your label formats.
Important • You cannot use the same hex value for the format command prefix,
control character, and delimiter characters. The printer must see different
characters to work properly. If you are setting the value through the control
panel, the printer will skip any value that is already in use.
User menu item: Main Menu > LANGUAGE

Accepted values: 00 to FF
Related ZPL command(s): ^CC or ~CC
SGD command used: zpl.caret
Printer web page: View and Modify Printer Settings > ZPL Control
CONTROL CHAR

Control The printer looks for this two-digit hex character to indicate the start of a ZPL/ZPL II
Character control instruction. Set the control prefix character to match what is used in your label
formats.
User menu item: Main Menu > LANGUAGE

Accepted values: 00 to FF
Related ZPL command(s): ^CT or ~CT
SGD command used: zpl.control_character
Printer web page: View and Modify Printer Settings > ZPL Control

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Table 8 • Language Settings (Continued)

Set the Delimiter Character Value
DELIMITER CHAR

Delimiter
Character The delimiter character is a two-digit hex value used as a parameter place marker in
ZPL/ZPL II format instructions.
Set the delimiter character to match what is used in your label formats.
User menu item: Main Menu > LANGUAGE

Accepted values: 00 to FF
Related ZPL command(s): ^CD or ~CD
SGD command used: zpl.delimiter
Printer web page: View and Modify Printer Settings > ZPL Control
Set the ZPL Mode
ZPL MODE

ZPL Mode
Select the mode that matches what is used in your label formats.
This printer accepts label formats written in either ZPL or ZPL II, eliminating the need
to rewrite any ZPL formats that already exist. The printer remains in the selected mode
until it is changed in one of the ways listed here.
User menu item: Main Menu > LANGUAGE

Accepted values: • ZPL II

• ZPL
Related ZPL command(s): ^SZ
SGD command used: zpl.zpl_mode
Printer web page: View and Modify Printer Settings > ZPL Control

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Sensor Settings

Table 9 • Sensor Settings

SENSOR TYPE

Sensor Type Select the media sensor that is appropriate for the media that you are using. The
reflective sensor can be used with all media types. The transmissive sensor should be
used only for simple gap media.
User menu item: Main Menu > SENSORS

Accepted values: • TRANSMISSIVE

• REFLECTIVE
Related ZPL command(s): ^JS
SGD command used: device.sensor_select
Printer web page: View and Modify Printer Settings > Media Setup
LABEL SENSOR

Label Sensor Set the sensitivity of the label sensor.

Important • This value is set during sensor calibration. Do not change this
setting unless you are told to do so by Zebra Technical Support or by an
authorized service technician.
User menu item: Main Menu > SENSORS

Accepted values: 0 – 255

SGD command used: ezpl.label_sensor
Printer web page: View and Modify Printer Settings > Calibration

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Table 9 • Sensor Settings (Continued)

TAKE LABEL

Take Label Set the intensity of the take label LED.

Important • This value is set during sensor calibration. Do not change this
setting unless you are told to do so by Zebra Technical Support or by an
authorized service technician.
User menu item: Main Menu > SENSORS

Accepted values: 0 – 255

SGD command used: ezpl.take_label
Printer web page: View and Modify Printer Settings > Calibration

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Port Settings

Table 10 • Port Settings

BAUD RATE

Baud Rate Select the baud value that matches the one being used by the host computer.
User menu item: Main Menu > PORTS

Accepted values: • 115200

• 57600
• 38400
• 28800
• 19200
• 14400
• 9600
• 4800
Related ZPL command(s): ^SC
SGD command used: comm.baud
Printer web page: View and Modify Printer Settings >
Serial Communications Setup
DATA BITS

Data Bits Select the data bits value that matches the one being used by the host computer.
User menu item: Main Menu > PORTS

Accepted values: • 7 or 8
Related ZPL command(s): ^SC
SGD command used: comm.data_bits
Printer web page: View and Modify Printer Settings >
Serial Communications Setup

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Table 10 • Port Settings (Continued)

PARITY

Parity Select the parity value that matches the one being used by the host computer.
User menu item: Main Menu > PORTS

Accepted values: • NONE

• EVEN
• ODD
Related ZPL command(s): ^SC
SGD command used: comm.parity
Printer web page: View and Modify Printer Settings >
Serial Communications Setup
HOST HANDSHAKE

Host Handshake Select the handshake protocol that matches the one being used by the host computer.
User menu item: Main Menu > PORTS

Accepted values: • XON/XOFF

• RTS/CTS
• DSR/DTR
Related ZPL command(s): ^SC
SGD command used: comm.handshake
Printer web page: View and Modify Printer Settings >
Serial Communications Setup

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Calibrate the Ribbon and Media Sensors

Calibrate the Ribbon and Media Sensors

Use the procedure in this section to calibrate the printer, which adjusts the sensitivity of the
media and ribbon sensors.
• For issues that may be resolved by sensor calibration, see Printing Issues on page 152.
• For a summary of the options for initiating calibration, see Media and Ribbon Sensor
Calibration on page 105.

Important • Follow the calibration procedure exactly as presented. All of the steps must be
performed even if only one of the sensors requires adjustment. You may press and hold
CANCEL at any step in this procedure to cancel the process.

To perform sensor calibration, complete these steps:

1. With the printer in the Ready state, initiate media and ribbon calibration in one of these
ways:
• Press and hold PAUSE + CANCEL for 2 seconds.
• Send the ezpl.manual_calibration SGD command to the printer. See the
Zebra Programming Guide for more information about this command.
• ZT230 printer only:
a. Navigate to the following menu item on the control panel display. This item is
located under the TOOLS menu and the SENSORS menu. See Idle Display,
Home Menu, and User Menus on page 17 for information about using the control
panel and accessing the menus.

MEDIA/RIBBON CAL

START

b. Press RIGHT SELECT to select START.

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Calibrate the Ribbon and Media Sensors

The printer does the following:

• The STATUS light and SUPPLIES light flash yellow once.
• The PAUSE light blinks yellow.
• The control panel (ZT230 printer only) displays:

MEDIA/RIBBON CAL
LOAD BACKING
REMOVE RIBBON

2.
Caution • The printhead may be hot and could cause severe burns. Allow the
printhead to cool.

Open the printhead assembly by rotating the printhead-open lever.

3. Extend the media approximately 8 in. (203 mm) out of the printer.

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4. Remove the exposed labels so that only the liner remains.

5. Pull the media into the printer so that only the backing is between the media sensors.

6. Remove the ribbon (if used).

7. Rotate the printhead-open lever downward until it locks the printhead in place.

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8. Press PAUSE to begin the media calibration process.

• The PAUSE light turns off.
• The SUPPLIES light flashes.
• The control panel (ZT230 printer only) displays:

MEDIA/RIBBON CAL
CALIBRATING
PLEASE WAIT

When the process is complete:

• The SUPPLIES light stops flashing.
• The PAUSE light flashes yellow.
• The control panel (ZT230 printer only) displays:

MEDIA/RIBBON CAL
RELOAD ALL
CONTINUE

9. Open the printhead assembly by rotating the printhead-open lever.

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10. Pull the media forward until a label is positioned under the media sensors.

11. Reload the ribbon (if used).

12. Close the printhead.

13. Close the media door.

14. Press PAUSE to enable printing.

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Adjust the Printhead Pressure

Adjust the Printhead Pressure

You may need to adjust printhead pressure if printing is too light on one side, if you use thick
media, or if the media drifts from side to side during printing. Use the lowest printhead
pressure necessary to produce good print quality.

See Figure 16. The printhead pressure adjustment dials have setting marks from 1 to 4 in
half-mark increments.

Figure 16 • Printhead Pressure Adjustment Dials

1 Inside dial
2 Outside dial

If necessary, adjust the printhead pressure adjustment dials as follows:

If the media... Then...

Requires higher pressure to print Increase both dials one position.
well

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128 Printer Configuration and Adjustment
Adjust the Printhead Pressure

If the media... Then...

Shifts left while printing Increase the outside dial setting one position.

OR
Decrease the inside dial setting one position.

Shifts right while printing Increase the inside dial setting one position.

OR
Decrease the outside dial setting one position.

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Adjust the Printhead Pressure

If the media... Then...

Prints too lightly on the left side Increase the inside dial setting one position.
of the label.

Prints too lightly on the right side Increase the outside dial setting one position.
of the label.

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130 Printer Configuration and Adjustment
Adjust Ribbon Tension

Adjust Ribbon Tension

For the printer to operate correctly, the ribbon supply spindle and ribbon take-up spindle must
use the same tension setting (normal or low tension). Use the normal tension setting
(Figure 17) for most applications. If you are using narrow ribbon or experience certain ribbon
issues, you may need to lower the ribbon tension (Figure 18).

Normal Tension Setting To place the ribbon spindles in the normal position, firmly pull
out each spindle end cap until it extends and clicks in place, as shown in Figure 17. Use this
setting for most applications.

Figure 17 • Normal Tension Setting (Spindle End Caps Pulled Out)

Low Tension Setting To place a spindle in the low-tension position, firmly push in the
end cap until it retracts and clicks in place, as shown in Figure 18. Use this setting only when
necessary, such as if the ribbon causes scuff marks at the beginning of a roll or if normal
tension causes the ribbon to stall at the end of the roll.

Figure 18 • Ribbon Spindles— Low Tension Setting

(Spindle End Caps Pushed In)

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Remove Used Ribbon

Remove Used Ribbon

Remove used ribbon from the ribbon take-up spindle each time you change the roll of ribbon.

To remove used ribbon, complete these steps:

1. Has the ribbon run out?

If the ribbon... Then

Ran out Continue with the next step.
Did not run out a. Cut or break the ribbon before the ribbon take-up
spindle.

b. Continue with the next step.

2. Slide the core with the used ribbon off of the ribbon take-up spindle.

3. Discard the used ribbon. You may reuse the empty core from the ribbon supply spindle by
moving it to the ribbon take-up spindle.

4. Reload the ribbon following the instructions in Load the Ribbon on page 65.

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Remove Used Ribbon

Notes • ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

P1048261-005 11/5/15
 4
Routine Maintenance

This section provides routine cleaning and maintenance procedures.

Contents
Cleaning Schedule and Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Clean the Exterior, the Media Compartment, and the Sensors . . . . . . . . . . . . . . . . . 135
Clean the Printhead and Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Clean the Peel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Clean the Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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134 Routine Maintenance
Cleaning Schedule and Procedures

Cleaning Schedule and Procedures

Routine preventive maintenance is a crucial part of normal printer operation. By taking good
care of your printer, you can minimize the potential problems that you might have with it and
help to achieve and to maintain your standards for print quality.

Over time, the movement of media or ribbon across the printhead wears through the protective
ceramic coating, exposing and eventually damaging the print elements (dots). To avoid
abrasion:
• Clean the printhead frequently.
• Minimize printhead pressure and burn temperature (darkness) settings by optimizing the
balance between the two.
• When using Thermal Transfer mode, ensure that the ribbon is as wide or wider than the
media to prevent exposing the printhead elements to the more abrasive label material.

Important • Zebra is not responsible for damage caused by the use of cleaning fluids on this
printer.

Specific cleaning procedures are provided on the following pages. Table 11 shows the
recommended cleaning schedule. These intervals are intended as guidelines only. You may
have to clean more often, depending upon your application and media.
.

Table 11 • Recommended Cleaning Schedule

Area Method Interval

Printhead Solvent* Direct Thermal Mode: After every roll of
Platen roller Solvent* media (or 500 feet of fanfold media).
Thermal Transfer Mode: After every roll of
Media sensors Air blow
ribbon.
Ribbon sensor Air blow
Media path Solvent*
Ribbon path Solvent*
Pinch roller (part of Peel-Off option) Solvent*
Cutter If cutting continuous, Solvent* After every roll of media (or more often,
module pressure-sensitive media depending upon your application and media).
If cutting tag stock or label Solvent* and After every two or three rolls of media.
liner material air blow
Tear-off/peel-off bar Solvent* Once a month.
Take-label sensor Air blow Once every six months.
* Zebra recommends using Preventive Maintenance Kit (part number 47362). In place of this kit, you may use a clean swab
dipped in a solution of isopropyl alcohol (minimum 90%) and deionized water (maximum 10%).

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Cleaning Schedule and Procedures

Clean the Exterior, the Media Compartment, and the Sensors

Over time, dust, grime, and other debris may build up on the outside and inside of your printer,
particularly in a harsh operating environment.

Printer Exterior
You may clean the exterior surfaces of the printer with a lint-free cloth and a small amount of a
mild detergent, if necessary. Do not use harsh or abrasive cleaning agents or solvents.

Important • Zebra is not responsible for damage caused by the use of cleaning fluids on this
printer.

Media Compartment and Sensors

To clean the sensors, complete these steps:

1. Brush, air blow, or vacuum any accumulated paper lint and dust away from the media and
ribbon paths.

2. Brush, air blow, or vacuum any accumulated paper lint and dust away from the
sensors (1).

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Cleaning Schedule and Procedures

Clean the Printhead and Platen Roller

Inconsistent print quality, such as voids in the bar code or graphics, may indicate a dirty
printhead. For the recommended cleaning schedule, see Table 11 on page 134.

Caution • While performing any tasks near an open printhead, remove all rings, watches,
hanging necklaces, identification badges, or other metallic objects that could touch the
printhead. You are not required to turn off the printer power when working near an open
printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose
all temporary settings, such as label formats, and you must reload them before you resume
printing.

Note • For printers with a peel assembly, keep the peel assembly closed while cleaning the
platen roller to reduce the risk of bending the tear-off/peel-off bar.

Figure 19 • Location of the Printhead and Platen Roller

1 Printhead assembly
2 Platen roller

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Cleaning Schedule and Procedures

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

Caution • Before touching the printhead assembly, discharge any built-up static electricity
by touching the metal printer frame or by using an antistatic wriststrap and mat.

To clean the printhead and platen roller, complete these steps:

1. Raise the media door.

2.
Caution • The printhead may be hot and could cause severe burns. Allow the
printhead to cool.

Rotate the printhead-open lever upward to release the printhead assembly.

3. Remove the ribbon (if used) and the media.

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138 Routine Maintenance
Cleaning Schedule and Procedures

4. Using the swab from a Zebra Preventive Maintenance Kit, wipe along the brown strip on
the printhead assembly from end to end. In place of the Preventive Maintenance Kit, you
may use a clean swab dipped in 99.7% isopropyl alcohol. Allow the solvent to evaporate.

5. While manually rotating the platen roller, clean it thoroughly with the swab. Allow the
solvent to evaporate.

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Cleaning Schedule and Procedures

6. Reload the ribbon (if used) and the media. For instructions, see Load the Ribbon
on page 65 or Load the Media on page 70.

7. Rotate the printhead-open lever downward until it locks the printhead in place.

8. Close the media door.

The printer is ready to operate.

9. Press PAUSE to exit pause mode and enable printing.

The printer may perform a label calibration or feed a label, depending on your settings.

Note • If performing this procedure does not improve print quality, try cleaning the
printhead with Save-A-Printhead cleaning film. This specially coated material removes
contamination buildup without damaging the printhead. Call your authorized Zebra
reseller for more information.

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140 Routine Maintenance
Cleaning Schedule and Procedures

Clean the Peel Assembly

The peel assembly, which is part of the Peel-Off and Liner Take-Up options, consists of
several spring-loaded rollers to ensure the proper roller pressure. Clean the pinch roller and
tear-off/peel-off bar if adhesive buildup begins to affect peel performance.

Caution • Do not use your left hand to assist in closing the Peel assembly. The top edge of
the Peel roller/assembly could pinch your fingers.

If adhesive buildup affects peel-off performance, complete these steps:

1. Raise the media door.

2.
Caution • The printhead may be hot and could cause severe burns. Allow the
printhead to cool.

Open the printhead assembly by rotating the printhead-open lever.

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Cleaning Schedule and Procedures

3. Push down the peel-off mechanism release lever to open the peel assembly.

4. Remove any media liner to expose the pinch roller.

5. While manually rotating the pinch roller, clean it thoroughly with the swab from the
Preventive Maintenance Kit (part number 47362). In place of the Preventive Maintenance
Kit, you may use a clean swab dipped in 99.7% isopropyl alcohol. Allow the solvent to
evaporate.

6. Use the swab to remove excess adhesive from the tear-off/peel-off bar. Allow the solvent
to evaporate.
Important • Apply minimum force when cleaning the tear-off/peel-off bar. Excessive
force can cause the tear-off/peel-off bar to bend, which could have a negative effect on
peel performance.

7. Reload the media liner through the peel mechanism. For instructions, see Final Steps for
Peel-Off Mode (with or without Liner Take-Up) on page 78.

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142 Routine Maintenance
Cleaning Schedule and Procedures

8.
Caution • Use the peel release lever and your right hand to close the peel assembly.
Do not use your left hand to assist in closing. The top edge of the peel roller/assembly
could pinch your fingers.

Close the peel assembly using the peel-off mechanism release lever.

9. Rotate the printhead-open lever downward until it locks the printhead in place.

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 Routine Maintenance 143
Cleaning Schedule and Procedures

10. Close the media door.

The printer is ready to operate.

11. Press PAUSE to exit pause mode and enable printing.

The printer may perform a label calibration or feed a label, depending on your settings.

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144 Routine Maintenance
Cleaning Schedule and Procedures

Clean the Cutter Module

If the cutter is not cutting the labels cleanly or if it jams with labels, clean the cutter.

Caution • For personnel safety, always power off and unplug the printer before performing
this procedure.

To clean the cutter module, complete these steps:

1. Raise the media door.

2. Turn the printer off (O), and unplug the printer from its power source.

3. Remove media that is loaded through the cutter module.

4. Loosen and remove the thumbscrew and lock washer on the cutter shield.

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 Routine Maintenance 145
Cleaning Schedule and Procedures

5.
Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers.

Remove the cutter shield.

6. If necessary, rotate the cutter motor thumbscrew to fully expose the V-shaped cutter
blade (1).

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146 Routine Maintenance
Cleaning Schedule and Procedures

7. Using the swab from the Preventive Maintenance Kit (part number 47362), wipe along the
upper cutting surface (1) and the cutter blade (2). In place of the Preventive Maintenance
Kit, you may use a clean swab dipped in 99.7% isopropyl alcohol. Allow the solvent to
evaporate.
1 2

8.
Caution • The cutter blade is sharp. For operator safety, replace the cutter shield.

Replace the cutter shield (1) and secure it with the thumbscrew and lock washer that you
removed earlier (2).
1

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Cleaning Schedule and Procedures

9. Close the media door.

10. Plug the printer into its power source, and then turn on (I) the printer.
The cutter blade returns to its operating position.

11. If the cutter continues to perform unsatisfactorily, contact an authorized service

technician.

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148 Routine Maintenance
Replacing Printer Components

Replacing Printer Components

Some printer components, such as the printhead and platen roller, may wear out over time and
can be replaced easily. Regular cleaning may extend the life of some of these components. See
Table 11 on page 134 for the recommended cleaning intervals.

Ordering Replacement Parts

For optimal printing quality and proper printer performance across our product line, Zebra
strongly recommends the use of genuine Zebra™ supplies as part of the total solution.
Specifically, the ZT210, ZT220, and ZT230 printers are designed to work only with genuine
Zebra™ printheads, thus maximizing safety and print quality.

Contact your authorized Zebra reseller for part ordering information.

Recycling Printer Components

The majority of this printer’s components are recyclable. The printer’s main logic board may
include a battery that you should dispose of properly.

Do not dispose of any printer components in unsorted municipal waste. Please dispose of the
battery according to your local regulations, and recycle the other printer components
according to your local standards. For more information, see
http://www.zebra.com/environment.

Lubrication
No lubrication is needed for this printer.

Caution • Some commercially available lubricants will damage the finish and the
mechanical parts if used on this printer.

P1048261-005 11/5/15
 5
Troubleshooting

This section provides information about errors that you might need to troubleshoot. Assorted
diagnostic tests are included.

For videos of some common procedures, go to http://www.zebra.com/zt200-info.

Contents

Printing Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Miscellaneous Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
FEED Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
FEED + PAUSE Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
CANCEL + PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Communication Diagnostics Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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150 Troubleshooting
Meaning of Indicator Lights

Meaning of Indicator Lights

The indicator lights on the control panel show the current status of the printer (Table 12
on page 150).

Table 12 • Status of Printer As Shown by Indicator Lights

STATUS light steady green (other lights steady yellow for

2 seconds during printer power-up)
The printer is ready.
PAUSE light steady yellow.
The printer is paused.

STATUS light steady red

SUPPLIES light steady red
The media supply is out. The printer needs attention and
cannot continue without user intervention.
STATUS light steady red
SUPPLIES light flashing red
The ribbon supply is out. The printer needs attention and
cannot continue without user intervention.
STATUS light steady yellow
SUPPLIES light flashing yellow
The printer is in Direct Thermal mode, which does not
require ribbon; however, ribbon is installed in the printer.
STATUS light steady red
PAUSE light steady yellow
The printhead is open. The printer needs attention and
cannot continue without user intervention.
STATUS light steady yellow
The printhead is over temperature.
Caution • The printhead may be hot and could
cause severe burns. Allow the printhead to cool.

STATUS light flashing yellow

This indicator light flashing indicates one of the following:
• The printhead is under temperature.
• The power supply is over temperature.
• The main logic board (MLB) is over temperature.
STATUS light steady red
PAUSE light steady red
DATA light steady red
The printhead was replaced with one that is not a genuine
Zebra™ printhead. Install a genuine Zebra™ printhead to
continue.

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Meaning of Indicator Lights

Table 12 • Status of Printer As Shown by Indicator Lights (Continued)

STATUS light flashing red
The printer is unable to read the dpi setting of the
printhead.

Printers with a ZebraNet wired Ethernet option

NETWORK light off
No Ethernet link is available.

NETWORK light steady green

A 100 Base link was found.

NETWORK light steady yellow

A 10 Base link was found.

NETWORK light steady red

An Ethernet error condition exists. The printer is not
connected to your network.
Printers with a ZebraNet wireless option
NETWORK light off
A radio was found during power-up. The printer is
attempting to associate with the network. The light flashes
red while the printer associates with the network. The light
then flashes yellow while the printer is authenticating with
the network.

NETWORK light steady green

The radio is associated with your network and
authenticated, and the WLAN signal is strong.
NETWORK light flashing green
WLAN—The radio is associated with your network and
authenticated, but the WLAN signal is weak.
NETWORK light steady red
A WLAN error condition exists. The printer is not
connected to your network.

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152 Troubleshooting
Printing Issues

Printing Issues
Table 13 identifies possible issues with printing or print quality, the possible causes, and the
recommended solutions.

Table 13 • Printing Issues

Issue Possible Cause Recommended Solution

General print quality The printer is set at the For optimal print quality, set the print speed to
issues incorrect print speed. the lowest possible setting for your application
via control panel, the driver, or the software. You
may want to perform the FEED Self Test
on page 167 to determine the optimal settings for
your printer.
See Print Speed on page 93 for how to change
the print speed.
You are using an incorrect 1. Switch to a different type of media or ribbon
combination of labels and to try to find a compatible combination.
ribbon for your application. 2. If necessary, consult your authorized Zebra
reseller or distributor for information and
advice.
The printer is set at an incorrect For optimal print quality, set the darkness to the
darkness level. lowest possible setting for your application. You
may want to perform the FEED Self Test
on page 167 to determine the ideal darkness
setting.
See Print Darkness on page 93 for how to
change the darkness setting.
The printhead is dirty. Clean the printhead and platen roller. See Clean
the Printhead and Platen Roller on page 136.
Incorrect or uneven printhead Set the printhead pressure to the minimum
pressure. needed for good print quality. See Adjust the
Printhead Pressure on page 127.
Loss of printing The platen roller is dirty. Clean the printhead and platen roller. See Clean
registration on labels. the Printhead and Platen Roller on page 136.
Excessive vertical Media guides are positioned Ensure that the media guides are properly
drift in top-of-form improperly. positioned. See Load the Media on page 70.
registration.
The media type is set Set the printer for the correct media type
incorrectly. (gap/notch, continuous, or mark). See Media
Type on page 94.
The media is loaded incorrectly. Load media correctly. See Load the Media
on page 70.
Long tracks of Print element damaged. (UGs) Call a service technician.
missing print on
several labels Wrinkled ribbon. See wrinkled ribbon causes and solutions in
Ribbon Problems on page 155.

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 Troubleshooting 153
Printing Issues

Table 13 • Printing Issues (Continued)

Issue Possible Cause Recommended Solution

Fine, angular gray Wrinkled ribbon. See wrinkled ribbon causes and solutions in
lines on blank labels Ribbon Problems on page 155.
Printing too light or The media or ribbon is not Replace supplies with those recommended for
too dark over the designed for high-speed high-speed operation.
entire label operation.
You are using an incorrect 1. Switch to a different type of media or ribbon
combination of media and to try to find a compatible combination.
ribbon for your application. 2. If necessary, consult your authorized Zebra
reseller or distributor for information and
advice.
You are using ribbon with Direct thermal media does not require ribbon. To
direct thermal media. determine if you are using direct thermal media,
perform the label scratch test in When to Use
Ribbon on page 21.
Incorrect or uneven printhead Set the printhead pressure to the minimum
pressure. needed for good print quality. See Adjust the
Printhead Pressure on page 127.
Smudge marks on The media or ribbon is not Replace supplies with those recommended for
labels designed for high-speed high-speed operation.
operation.
Misregistration/skips The printer is not calibrated. Calibrate the printer. See Calibrate the Ribbon
labels and Media Sensors on page 122.
Improper label format. Check your label format and correct it as
necessary.
Misregistration and The platen roller is dirty. Clean the printhead and platen roller. See Clean
misprint of one to the Printhead and Platen Roller on page 136.
three labels Media does not meet Use media that meets specifications. See Media
specifications. Specifications on page 181.
Vertical drift in The printer is out of calibration. Calibrate the printer. See Calibrate the Ribbon
top-of-form position and Media Sensors on page 122.
The platen roller is dirty. Clean the printhead and platen roller. See Clean
the Printhead and Platen Roller on page 136.

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154 Troubleshooting
Printing Issues

Table 13 • Printing Issues (Continued)

Issue Possible Cause Recommended Solution

Vertical image or The printer is using Set the printer for the correct media type
label drift non-continuous labels but is (gap/notch, continuous, or mark—see Media
configured in continuous mode. Type on page 94) and calibrate the printer, if
necessary (see Calibrate the Ribbon and Media
Sensors on page 122).
The media sensor is calibrated Calibrate the printer. See Calibrate the Ribbon
improperly. and Media Sensors on page 122.
The platen roller is dirty. Clean the printhead and platen roller. See Clean
the Printhead and Platen Roller on page 136.
Improper printhead pressure Adjust the printhead pressure to ensure proper
settings (toggles). functionality. See Adjust the Printhead Pressure
on page 127.
The media or ribbon is loaded Ensure that the media and ribbon are loaded
incorrectly. correctly. See Load the Ribbon on page 65 and
Load the Media on page 70.
Incompatible media. You must use media that meets the printer
specifications. Ensure that the interlabel gaps or
notches are 2 to 4 mm and consistently placed
(see Media Specifications on page 181).
The bar code printed The bar code is not within Perform the FEED Self Test on page 167. Adjust
on a label does not specifications because the print the darkness or print speed settings as necessary.
scan. is too light or too dark.
There is not enough blank Leave at least 1/8 in. (3.2 mm) between the bar
space around the bar code. code and other printed areas on the label and
between the bar code and the edge of the label.
Auto Calibrate failed. The media or ribbon is loaded Ensure that the media and ribbon are loaded
incorrectly. correctly. See Load the Ribbon on page 65 and
Load the Media on page 70.
The sensors could not detect the Calibrate the printer. See Calibrate the Ribbon
media or ribbon. and Media Sensors on page 122.
The sensors are dirty or Ensure that the sensors are clean and properly
positioned improperly. positioned.
The media type is set Set the printer for the correct media type
incorrectly. (gap/notch, continuous, or mark). See Media
Type on page 94.

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 Troubleshooting 155
Ribbon Problems

Ribbon Problems
Table 14 identifies problems that may occur with ribbon, the possible causes, and the
recommended solutions.

For videos of some common procedures, go to http://www.zebra.com/zt200-info.

Table 14 • Ribbon Problems

Problem Possible Cause Recommended Solution

Broken or melted Darkness setting too high. 1. Reduce the darkness setting. See Print
ribbon Darkness on page 93 for how to change the
darkness setting.
2. Clean the printhead thoroughly. See Clean
the Printhead and Platen Roller
on page 136.
The ribbon is coated on the Replace the ribbon with one coated on the
wrong side and cannot be used correct side. For more information, see Coated
in this printer. Side of Ribbon on page 21.
Ribbon slips or does Ribbon tension is set Change the tension settings on the ribbon
not advance correctly incorrectly. spindles. See Adjust Ribbon Tension
on page 130.
Wrinkled ribbon Ribbon was loaded incorrectly. Load the ribbon correctly. See Load the Ribbon
on page 65.
Incorrect burn temperature. For optimal print quality, set the darkness to the
lowest possible setting for your application. You
may want to perform the FEED Self Test
on page 167 to determine the ideal darkness
setting.
See Print Darkness on page 93 for how to
change the darkness setting.
Incorrect or uneven printhead Set the printhead pressure to the minimum
pressure. needed for good print quality. See Adjust the
Printhead Pressure on page 127.
Media not feeding properly; Make sure that media is snug by adjusting the
“walking” from side to side. media guide, or call a service technician.
The printhead or platen roller Call a service technician.
may be installed incorrectly.

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156 Troubleshooting
Ribbon Problems

Table 14 • Ribbon Problems (Continued)

Problem Possible Cause Recommended Solution

The printer does not The printer may have been 1. Make sure that ribbon is loaded correctly so
detect when the calibrated without ribbon or that it can be detected by the ribbon sensor.
ribbon runs out. without the ribbon loaded Under the printhead, the ribbon should track
In thermal transfer properly. all the way back, near the printer’s firewall.
mode, the printer did See Load the Ribbon on page 65.
not detect the ribbon 2. Calibrate the printer. See Calibrate the
even though it is Ribbon and Media Sensors on page 122.
loaded correctly.
The printer indicates The printer was not calibrated Calibrate the printer. See Calibrate the Ribbon
that ribbon is out, for the label and ribbon being and Media Sensors on page 122.
even though ribbon is used.
loaded correctly.

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Error Messages

Error Messages
The ZT230 control panel displays messages when there is an error. See Table 15 for errors, the
possible causes, and the recommended solutions.

QuickHelp Pages Most error messages will include the option to view a QuickHelp page.
The lower right-hand corner of the message displays QR.

To access a QuickHelp page from an error message, do the following:

1. Press RIGHT SELECT to select QR.

The printer displays a QuickHelp page specific to that error message. This page includes a
QR code, such as this.

2. Scan the QR code with a smartphone.

Your phone accesses either a video specific to that error message or the Zebra support
page for your printer.

Table 15 • Error Messages

Display/
Possible Cause Recommended Solution
Indicator Lights
The printhead is not fully Close the printhead
HEAD OPEN
CLOSE HEAD
closed. completely.
The printhead open sensor is Call a service technician to
STATUS light steady red not working properly. replace the sensor.
PAUSE light steady yellow
The media is not loaded or is Load media correctly.
MEDIA OUT
LOAD MEDIA
loaded incorrectly.
Misaligned media sensor. Check the position of the
STATUS light steady red media sensor.
SUPPLIES light steady red The printer is set for 1. Install the proper media
noncontinuous media, but type, or reset printer for the
continuous media is loaded. current media type.
2. Calibrate the printer. See
Media and Ribbon Sensor
Calibration on page 105.

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158 Troubleshooting
Error Messages

Table 15 • Error Messages (Continued)

Display/
Possible Cause Recommended Solution
Indicator Lights
Ribbon is loaded, but the Ribbon is not required with
WARNING
RIBBON IN
printer is set for direct thermal direct thermal media. If you
mode. are using direct thermal media,
remove the ribbon. This error
STATUS light steady yellow message will not affect
SUPPLIES light flashing yellow printing.
If you are using thermal
transfer media, which requires
ribbon, set the printer for
Thermal Transfer mode. See
Print Method on page 94.
In thermal transfer mode: 1. Load ribbon correctly. See
ALERT
RIBBON OUT • ribbon is not loaded Load the Ribbon
• ribbon is loaded incorrectly on page 65.
• the ribbon sensor is not 2. Calibrate the printer. See
STATUS light steady yellow
detecting ribbon Media and Ribbon Sensor
SUPPLIES light flashing yellow Calibration on page 105.
• media is blocking the
ribbon sensor
In thermal transfer mode, the 1. Print a sensor profile (see
printer did not detect the Print Information
ribbon even though it is loaded on page 100). The ribbon
correctly. out threshold (2) is likely
too high, above the line that
indicates where the ribbon
is detected (1).

1
2

2. Calibrate the printer (see

Media and Ribbon Sensor
Calibration on page 105)
or load printer defaults (see
Load Defaults
on page 104).
If you are using direct thermal Set the printer for Direct
media, the printer is waiting Thermal mode. Refer to the
for ribbon to be loaded User Guide for information
because it is incorrectly set for about changing the print
thermal transfer mode. method.

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 Troubleshooting 159
Error Messages

Table 15 • Error Messages (Continued)

Display/
Possible Cause Recommended Solution
Indicator Lights
The printhead was replaced Install a genuine Zebra™
PH NOT AUTHENTICATED
REPLACE PRINTHEAD
with one that is not a genuine printhead.
Zebra™ printhead.
STATUS light steady red
PAUSE light steady red
DATA light steady red

PRINT HEAD OVERTEMP Caution • The printhead may be hot enough to cause
PRINTING HALTED severe burns. Allow the printhead to cool.

STATUS light steady yellow The printhead is over Allow the printer to cool.
temperature. Printing automatically resumes
when the printhead elements
cool to an acceptable operating
temperature.
If this error persists, consider
changing where the printer is
located or using a slower print
speed.

HEAD COLD Caution • An improperly connected printhead data or

PRINTING HALTED power cable can cause these error messages. The
printhead may be hot enough to cause severe burns.
Allow the printhead to cool.
THERMISTOR
REPLACE PRINTHEAD The printhead data cable is not Call a service technician to
properly connected. hook up the printhead
STATUS light steady yellow properly.
The printer shows one of these messages The printhead has a faulty Call a service technician to
or cycles between them. thermistor. replace the printhead.

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160 Troubleshooting
Error Messages

Table 15 • Error Messages (Continued)

Display/
Possible Cause Recommended Solution
Indicator Lights

HEAD COLD Caution • An improperly connected printhead data or

PRINTING HALTED power cable can cause this error message. The
printhead may be hot enough to cause severe burns.
Allow the printhead to cool.
STATUS light flashing yellow
The printhead temperature is Continue printing while the
approaching its lower printhead reaches the correct
operating limit. operating temperature. If the
error remains, the environment
may be too cold for proper
printing. Relocate the printer
to a warmer area.
The printhead data cable is not Call a service technician to
properly connected. hook up the printhead
properly.
The printhead has a faulty Call a service technician to
thermistor. replace the printhead.

CUT ERROR Caution • The cutter blade is sharp. Do not touch or

rub the blade with your fingers.

STATUS light steady red The cutter blade is in the Turn off the printer power and
media path. unplug the printer. Inspect the
PAUSE light steady yellow
cutter module for debris and
clean as needed following the
cleaning instructions in Clean
the Cutter Module
on page 144.
There is not enough memory Free up some of the printer’s
OUT OF MEMORY
STORING GRAPHIC
to perform the function memory by adjusting the label
specified on the second line of format or printer parameters.
the error message. One way to free up memory is
OUT OF MEMORY to adjust the print width to the
STORING FORMAT actual width of the label
instead of leaving the print
width set to the default. See
OUT OF MEMORY Print Width on page 96.
STORING BITMAP
Ensure that the data is not
directed to a device that is not
OUT OF MEMORY installed or is unavailable.
STORING FONT
If the problem persists, call a
service technician.

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Communications Problems

Communications Problems
Table 16 identifies problems with communications, the possible causes, and the recommended
solutions.

Table 16 • Communications Problems

Problem Possible Cause Recommended Solution

A label format was sent to The communication Check the printer driver or software
the printer but was not parameters are incorrect. communications settings (if applicable).
recognized. The DATA If you are using serial communication, check
light does not flash. the serial port settings. See Port Settings
on page 120.
If you are using serial communication, make
sure that you are using a null modem cable or a
null modem adapter.
Check the printer’s handshake protocol setting.
The setting used must match the one being
used by the host computer. See Host
Handshake on page 121.
If a driver is used, check the driver
communication settings for your connection.
A label format was sent to The serial communication Ensure that the flow control settings match.
the printer. Several labels settings are incorrect. Check the communication cable length. See
print, then the printer General Specifications on page 176 for
skips, misplaces, misses, or requirements.
distorts the image on the
label. Check the printer driver or software
communications settings (if applicable).
A label format was sent to The prefix and delimiter Verify the prefix and delimiter characters. See
the printer but was not characters set in the printer Control Character on page 116 and Delimiter
recognized. The DATA do not match the ones in the Character on page 117.
light flashes but no label format.
printing occurs. Incorrect data is being sent Check the communication settings on the
to the printer. computer. Ensure that they match the printer
settings.
If the problem continues, check the label
format.

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162 Troubleshooting
Miscellaneous Issues

Miscellaneous Issues
Table 17 identifies miscellaneous issues with the printer, the possible causes, and the
recommended solutions.

For videos of some common procedures, go to http://www.zebra.com/zt200-info.

Table 17 • Miscellaneous Printer Problems

Problem Possible Cause Recommended Solution

The control panel The language parameter was 1. On the control panel display, scroll
display shows a changed through the control to LANGUAGE Menu.
language that I panel or a firmware command. 2. Press OK to access the items in this
cannot read menu.
3. Use the UP ARROW or DOWN ARROW
to scroll through the language selections.
The selections for this parameter are
displayed in the actual languages to make it
easier for you to find one that you are able to
read.
4. Select the language that you want to display.
The display is missing The display may need Call a service technician.
characters or parts of replacing.
characters
Changes in Some parameters are set 1. Check the parameters and change or reset if
parameter settings incorrectly. necessary.
did not take effect 2. Turn the printer off (O) and then on (I).
A firmware command turned Refer to the Programming Guide for ZPL, ZBI,
off the ability to change the Set-Get-Do, Mirror, and WML or call a service
parameter. technician.
A firmware command changed
the parameter back to the
previous setting.
If the problem persists, there Call a service technician.
may be a problem with the
main logic board.
Non-continuous The printer was not calibrated Calibrate the printer. See Calibrate the Ribbon
labels are being for the media being used. and Media Sensors on page 122.
treated as continuous The printer is configured for Set the printer for the correct media type
labels. continuous media. (gap/notch, continuous, or mark). See Media
Type on page 94.

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Miscellaneous Issues

Table 17 • Miscellaneous Printer Problems (Continued)

Problem Possible Cause Recommended Solution

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

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164 Troubleshooting
Printer Diagnostics

Printer Diagnostics
Self tests and other diagnostics provide specific information about the condition of the printer.
The self tests produce sample printouts and provide specific information that helps determine
the operating conditions for the printer.

Important • Use full-width media when performing self tests. If your media is not wide
enough, the test labels may print on the platen roller. To prevent this from happening, check
the print width, and ensure that the width is correct for the media that you are using.

Each self test is enabled by pressing a specific control panel key or combination of keys while
turning on (I) the printer power. Keep the key(s) pressed until the first indicator light turns off.
The selected self test automatically starts at the end of the Power-On Self Test.

Note •
• When performing these self tests, do not send data to the 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 its actual completion, always reset the printer by
turning it off (O) and then on (l).
• If the printer is in applicator mode and the liner is being taken up by the applicator, the
operator must manually remove the labels as they become available.

Power-On Self Test

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

To initiate the Power-On Self Test, complete these steps:

1. Turn on (I) the printer.

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

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Printer Diagnostics

CANCEL Self Test

The CANCEL self test prints a printer configuration label and a network configuration label.
For other ways to print these labels, see Print Information on page 100.

To perform the CANCEL Self Test, complete these steps:

1. Turn off (O) the printer.

2. Press and hold CANCEL while turning on (I) the printer. Hold CANCEL until the first
control panel light turns off.
The printer prints a printer configuration label (Figure 20) and then a network
configuration label (Figure 21).

Figure 20 • Sample Printer Figure 21 • Sample Network

Configuration Label Configuration Label

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166 Troubleshooting
Printer Diagnostics

PAUSE Self Test

This self test can be used to provide the test labels required when making adjustments to the
printer’s mechanical assemblies or to determine if any printhead elements are not working.
Figure 22 shows a sample printout.

To perform a PAUSE self test, complete these steps:

1. Turn off (O) the printer.

2. Press and hold PAUSE while turning on (I) the printer. Hold PAUSE until the first control
panel light turns off.
• The initial self test prints 15 labels at the printer’s slowest speed, and then
automatically pauses the printer. Each time PAUSE is pressed, an additional 15 labels
print. Figure 22 shows a sample of the labels.

Figure 22 • PAUSE Test Label

• While the printer is paused, pressing CANCEL alters the self test. Each time PAUSE
is pressed, 15 labels print at 6 in. (152 mm) per second.
• While the printer is paused, pressing CANCEL again alters the self test a second
time. Each time PAUSE is pressed, 50 labels print at the printer’s slowest speed
• While the printer is paused, pressing CANCEL again alters the self test a third time.
Each time PAUSE is pressed, 50 labels print at 6 in. (152 mm) per second.
• While the printer is paused, pressing CANCEL again alters the self test a fourth time.
Each time PAUSE is pressed, 15 labels print at the printer’s maximum speed.

3. To exit this self test at any time, press and hold CANCEL.

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Printer Diagnostics

FEED Self Test

Different types of media may require different darkness settings. This section contains a
simple but effective method for determining the ideal darkness for printing bar codes that are
within specifications.

During the FEED self test, labels are printed at different darkness settings at two different print
speeds. The relative darkness and the print speed are printed on each label. The bar codes on
these labels may be ANSI-graded to check print quality.

During this test, one set of labels is printed at 2 ips, and another set is printed at 6 ips. The
darkness value starts at three settings lower than the 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: 7 labels are printed at the 2 ips and 8 ips print speeds.
• 203 dpi printers: 7 labels are printed at the 2 ips and 12 ips print speeds.

To perform a FEED self test, complete these steps:

1. Print a configuration label to show the printer’s current settings.

2. Turn off (O) the printer.

3. Press and hold FEED while turning on (I) the printer. Hold FEED until the first control
panel light turns off.
The printer prints a series of labels (Figure 23) at various speeds and at darkness settings
higher and lower than the darkness value shown on the configuration label.

Figure 23 • FEED Test Label

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168 Troubleshooting
Printer Diagnostics

4. See Figure 24 and Table 18. Inspect the test labels and determine which one has the best
print quality for your application. If you have a bar code verifier, use it to measure
bars/spaces and calculate the print contrast. If you do not have a bar code verifier, use your
eyes or the system scanner to choose the optimal darkness setting based on the labels
printed in this self test.

Figure 24 • Bar Code Darkness Comparison

Table 18 • Judging Bar Code Quality

Print Quality Description

Too dark Labels that are too dark are fairly obvious. They may be
readable but not “in-spec.”
• The normal bar code bars increase in size.
• The openings in small alphanumeric characters may fill in
with ink.
• Rotated bar code bars and spaces run together.
Slightly dark Slightly dark labels are not as obvious.
• The normal bar code will be “in-spec.”
• Small character alpha numerics will be bold and could be
slightly filled in.
• The rotated bar code spaces are small when compared to
the “in-spec” code, possibly making the code unreadable.

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 Troubleshooting 169
Printer Diagnostics

Table 18 • Judging Bar Code Quality (Continued)

Print Quality Description

“In-spec” The “in-spec” bar code can only be confirmed by a verifier,
but it should exhibit some visible characteristics.
• The normal bar code will have complete, even bars and
clear, distinct spaces.
• The rotated bar code will have complete, even bars and
clear, distinct spaces. Although it may not look as good as
a slightly dark bar code, the bar code will be “in-spec.”
• In both normal and rotated styles, small alphanumeric
characters look complete.
Slightly light Slightly light labels are, in some cases, preferred to slightly
dark ones for “in-spec” bar codes.
• Both normal and rotated bar codes will be in spec, but
small alphanumeric characters may not be complete.
Too light Labels that are too light are obvious.
• Both normal and rotated bar codes have incomplete bars
and spaces.
• Small alphanumeric characters are unreadable.

5. Note the relative darkness value and the print speed printed on the best test label.

6. Add or subtract the relative darkness value from the darkness value specified on the
configuration label. The resulting numeric value is the best darkness value for that specific
label/ribbon combination and print speed.

7. If necessary, change the darkness value to the darkness value on the best test label.

8. If necessary, change the print speed to the same speed as on the best test label.

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Printer Diagnostics

FEED + PAUSE Self Test

Performing this self test resets the printer configuration to the factory default values. Perform a
sensor calibration after this self test. (See Calibrate the Ribbon and Media Sensors
on page 122.)

Performing this self test temporarily resets the printer configuration to the factory default
values. These values are active only until power is turned off unless you save them
permanently in memory. If the factory default values are permanently saved, a media
calibration procedure must be performed, and you must reset the head resistance value and the
applicator port setting to their required values.

To perform a FEED and PAUSE self test, complete these steps:

1. Turn off (O) the printer.

2. Press and hold FEED + PAUSE while turning on (I) the printer.

3. Hold FEED + PAUSE until the first control panel light turns off.
The printer configuration is reset to the factory default values. No labels print at the end of
this test.

CANCEL + PAUSE Self Test

Performing this self test resets the network configuration to the factory default values.

Performing this self test temporarily resets the printer configuration to the factory default
values. These values are active only until power is turned off unless you save them
permanently in memory. If the factory default values are permanently saved, a media
calibration procedure must be performed, and you must reset the head resistance value and the
applicator port setting to their required values.

To perform a CANCEL and PAUSE self test, complete these steps:

1. Turn off (O) the printer.

2. Press and hold CANCEL + PAUSE while turning on (I) the printer.

3. Hold CANCEL + PAUSE until the first control panel light turns off.
The printer’s network configuration is reset to the factory default values. No labels print at
the end of this test.

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 Troubleshooting 171
Printer Diagnostics

Communication Diagnostics Test

The communication diagnostics test is a troubleshooting tool for checking the interconnection
between the printer and the host computer. When the printer is in diagnostics mode, it prints all
data received from the host computer as straight ASCII characters with the hex values below
the ASCII text. The printer prints all characters received, including control codes such as CR
(carriage return). Figure 25 shows a typical test label from this test.

Note • The test label prints upside-down.

Figure 25 • Communications Diagnostics Test Label

To use communications diagnostics mode, complete these steps:

1. Set the print width equal to or less than the label width being used for the test. See Print
Width on page 96 for more information.

2. Set the DIAGNOSTICS MODE option to ENABLED. For methods, see Communication
Diagnostics Mode on page 106.
The printer enters diagnostics mode and prints any data received from the host computer
on a test label

3. Check the test label for error codes. For any errors, check that your communication
parameters are correct.
Errors show on the test label as follows:
• FE indicates a framing error.
• OE indicates an overrun error.
• PE indicates a parity error.
• NE indicates noise.

4. Turn the printer off (O) and then back on (I) to exit this self test and return to normal
operation.

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172 Troubleshooting
Printer Diagnostics

Sensor Profile
Use the sensor profile image (which will extend across several actual labels or tags) to
troubleshoot the following situations:
• The printer experiences difficulty in determining gaps (web) between labels.
• The printer incorrectly identifies preprinted areas on a label as gaps (web).
• The printer cannot detect ribbon.

With the printer in the Ready state, print a sensor profile in one of these ways:

Using the buttons on a. Turn off (O) the printer.

the control panel b. Press and hold FEED + CANCEL while turning on (I) the
printer.
c. Hold FEED + CANCEL until the first control panel light
turns off.
Using ZPL a. Send the ~JG command to the printer. See the Zebra
Programming Guide for more information about this
command.
ZT230 printer only a. On the control panel display, navigate to the following
item under the SENSORS menu. See Idle Display, Home
Menu, and User Menus on page 17 for information about
using the control panel and accessing the menus.

b. Press RIGHT SELECT to select PRINT.

Compare your results to the examples shown in this section. If the sensitivity of the sensors
must be adjusted, calibrate the printer (see Calibrate the Ribbon and Media Sensors
on page 122).

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 Troubleshooting 173
Printer Diagnostics

Ribbon Sensor Profile (Figure 26) The line labeled RIBBON (1) on the sensor profile
indicates the ribbon sensor readings. The ribbon sensor threshold setting is indicated by
OUT (2). If the ribbon readings are below the threshold value, the printer does not
acknowledge that ribbon is loaded.

Figure 26 • Sensor Profile (Ribbon Section)

1
2

Media Sensor Profile (Figure 27) 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 downward spikes (4) indicate gaps
between labels (the web), and the lines between the spikes (5) indicate where labels are
located.

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 27 • Sensor Profile (Media Section)

4 4 4 1
2
5 5 5
3

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Printer Diagnostics

Notes • ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

P1048261-005 11/5/15
 6
Specifications

This section lists general printer specifications, printing specifications, ribbon specifications,
and media specifications.

Contents
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Ribbon Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

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176 Specifications
General Specifications

General Specifications

Model ZT230 ZT220 ZT210

Height 10.9 in. (277 mm) 11.0 in. (280 mm) 10.9 in. (277 mm)
Width 9.5 in. (242 mm) 9.4 in. (239 mm) 9.5 in. (242 mm)
Depth 17 in. (432 mm) 17 in. (432 mm) 17 in. (432 mm)
Weight 20 lb (9.1 kg) 17 lb (7.8 kg) 20 lb (9.1 kg)
Electrical 100–240 VAC, 47-63 Hz, 3 Amps (100 W)
Temperature Operating Thermal Transfer: 41° to 104°F (5° to 40°C)
Direct Thermal: 32° to 104°F (0° to 40°C)
Storage –40° to 140°F (–40° to 60°C)
Relative Operating 20% to 85%, non-condensing
Humidity Storage 5% to 85%, non-condensing
Communication Standard USB 1.1 Data Interface
Interface Limitations and Requirements
Specifications • Maximum cable length of 16.4 ft (5 m).
Connections and Configuration
No additional configuration is necessary.
• Optional interface (one of the following):
• 8-bit parallel data interface; nibble mode compliant
• 802.11a/b/g/n wireless card support
RS-232/CCITT V.24 Serial Data Interface
• 2400 to 115000 baud
• parity, bits/character
• 7 or 8 data bit
• XON-XOFF, RTS/CTS, or DTR/DSR handshake protocol
required
• 750mA at 5 V from pins 1 and 9
Limitations and Requirements
• You must use a null-modem cable to connect to the printer or
a null-modem adaptor if using a standard modem cable.
• Maximum cable length of 50 ft (15.24 m).
• You may need to change printer parameters to match the host
computer.
Connections and Configuration
The baud rate, number of data and stop bits, the parity, and the
XON/XOFF or DTR control must match those of the host
computer.
(Continued on next page.)

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 Specifications 177
General Specifications

Model ZT230 ZT220 ZT210

Communication Optional Wired 10/100 Internal Ethernet Print Server
Interfaces (only one of the Limitations and Requirements
(continued) following may be • The printer must be configured to use your LAN.
installed at a
• A second wired print server can be installed in the bottom
time)
option slot.
Connections and Configuration
Refer to the ZebraNet Wired and Wireless Print Servers User
Guide for configuration instructions. A copy of this manual is
available at http://www.zebra.com/manuals.
Wireless print server
802.11 b
• 2.4GHz
• DSSS (DBPSK, DQPSK and CCK)
• RF power 10 mW (ZebraNet b/g Print Server)
802.11 g
• 2.4GHz
• OFDM (16-QAM and 64-QAM with BPSK and QPSK)
• RF power 10 mW (ZebraNet b/g Print Server)
Limitations and Requirements
• Can print to the printer from any computer on your Wireless
Local Area Network (WLAN).
• Can communicate with the printer through the printer’s web
pages.
• The printer must be configured to use your WLAN.
• Can be installed only in the top option slot.
Configuration
Refer to the ZebraNet Wired and Wireless Print Servers User
Guide for configuration instructions. A copy of this manual is
available at http://www.zebra.com/manuals.
8-bit Parallel data interface
nibble mode compliant
Limitations and Requirements
• Maximum cable length of 10 ft (3 m).
• Recommended cable length of 6 ft (1.83 m).
• No printer parameter changes required to match the host
computer.
• Can be installed in either the top or bottom option slot.
Connections and Configuration
No additional configuration is necessary.
Firmware • ZPL II®
• Zebra Global Printing Solution
• EPL™ (optional, 203 dpi models only)
• WebView and Alert
• ZBI 2.0 (optional)

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178 Specifications
General Specifications

Power Cord Specifications

Caution • For personnel and equipment safety, always use an approved three-conductor
power cord specific to the region or country intended for installation. This cord must use an
IEC 320 female connector and the appropriate region-specific, three-conductor grounded
plug configuration.

Depending on how your printer was ordered, a power cord may or may not be included. If one
is not included or if the one included is not suitable for your requirements, see <X-
refBlue>Figure 28 and refer to the following guidelines:
• The overall cord length must be less than 9.8 ft. (3 m).
• The cord must be rated for at least 10 A, 250 V.
• The chassis ground (earth) must be connected to ensure safety and reduce electromagnetic
interference.

Figure 28 • Power Cord Specifications

3
1

1 AC power plug for your country—This should bear the certification

mark of at least one of the known international safety organizations
(<X-refBlue>Figure 29).
2 3-conductor HAR cable or other cable approved for your country.
3 IEC 320 connector—This should bear the certification mark of at
least one of the known international safety organizations (<X-
refBlue>Figure 29).
4 Length  9.8 ft. (3 m). Rating 10 Amp, 250 VAC.

P1048261-005 11/5/15
 Specifications 179
General Specifications

Figure 29 • International Safety Organization Certification Symbols

11/5/15 P1048261-005
180 Specifications
Printing Specifications

Printing Specifications

Print resolution 203 dpi (dots per inch) (8 dots/mm)

300 dpi (12 dots/mm)
Dot size (nominal) 203 dpi 0.0043 in. x 0.0052 in.
(width x length) (0.110 mm x 0.132 mm)
300 dpi 0.0043 in. x 0.0052 in.
(0.110 mm x 0.132 mm)
Maximum print width 203 dpi 4.25 in. (108 mm)
300 dpi 4.16 in. (105.7 mm)
Bar code modulus (X) 203 dpi 5 mil to 50 mil
dimension 300 dpi 3.3 mill to 33 mil
Programmable constant 203 dpi and 300 dpi Per second:
print speeds • 2 in. (51 mm)
• 3 in. (76 mm)
• 4 in. (102 mm)
• 5 in. (127 mm)
• 6 in. (152 mm)

Ribbon Specifications

Model ZT230 ZT220 ZT210

Ribbon Minimum > 2 in.** (>51 mm**)
width* Maximum 4.3 in. (110 mm)
Maximum ribbon length 1476 ft (450 m) 984 ft (300 m) 984 ft (300 m)
3:1 media to ribbon 2:1 media to ribbon 2:1 media to ribbon
roll ratio roll ratio roll ratio
Ribbon core inside diameter 1 in. (25 mm)
* Zebra recommends using ribbon that is at least as wide as the media to protect the printhead from wear.
** Depending on your application, you may be able to use ribbon narrower than 2 in. (51 mm), as long as the ribbon is wider
than the media being used. To use a narrower ribbon, test the ribbon’s performance with your media to assure that you get the
desired results.

P1048261-005 11/5/15
 Specifications 181
Media Specifications

Media Specifications

Label length Minimum (Tear-Off) 0.7 in. (17.8 mm)

Minimum (Peel-Off) 0.5 in (12.7 mm)
Minimum 0.8 in (20.3 mm)
(Liner Take-Up)
Minimum (Cutter) 1.0 in. (25.4 mm)
Maximum 39 in. (991 mm)
Label width Minimum 0.75 in. (19 mm)
Maximum 4.5 in. (114 mm)
Total thickness Minimum 0.003 in (0.076 mm)
(includes liner, if any) Maximum 0.010 in. (0.25 mm)
Maximum roll outside 3-in. (76 mm) core 8 in. (203 mm)
diameter 1-in. (25 mm) core 6 in. (152 mm)
Inter-label gap Minimum 0.079 in. (2 mm)
Preferred 0.118 in. (3 mm)
Maximum 0.157 in. (4 mm)
Ticket/tag notch size (width x length) 0.25 in. x 0.12 in. (6 mm x 3 mm)
Hole diameter 0.125 in. (3.18 mm)
Notch or hole position Minimum 0.15 in. (3.8 mm)
(centered from inner Maximum 2.25 in. (57 mm)
media edge)
Density, in Optical Density Units (ODU) > 1.0 ODU
(black mark)
Maximum media density ≤ 0.5 ODU
Transmissive media sensor (fixed position) 7/16 in. (11 mm) from inside edge

11/5/15 P1048261-005
182 Specifications
Media Specifications

Notes • ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

P1048261-005 11/5/15
 Glossary

alphanumeric Indicating letters, numerals, and characters such as punctuation marks.

backfeed When the printer pulls the media and ribbon (if used) backward into the printer so
that the beginning of the label to be printed is properly positioned behind the printhead.
Backfeed occurs when operating the printer in Tear-Off and Applicator modes.

bar code A code by which alphanumeric characters can be represented by a series of

adjacent stripes of different widths. Many different code schemes exist, such as the universal
product code (UPC) or Code 39.

black mark A registration mark found on the underside of the print media that acts as a start-
of-label indication for the printer. (See non-continuous media.)

calibration (of a printer) A process in which the printer determines some basic
information needed to print accurately with a particular media and ribbon combination. To do
this, the printer feeds some media and ribbon (if used) through the printer and senses whether
to use the direct thermal or thermal transfer print method, and (if using non-continuous media)
the length of individual labels or tags.

configuration The printer configuration is a group of operating parameters specific to the

printer application. Some parameters are user selectable, while others are dependent on the
installed options and mode of operation. Parameters may be switch selectable, control panel
programmable, or downloaded as ZPL II commands. A configuration label listing all the
current printer parameters may be printed for reference.

continuous media Label or tag-stock media that has no notch, gap, or web (media liner
only) to separate the labels or tags. The media is one long piece of material.

core diameter The inside diameter of the cardboard core at the center of a roll of media or
ribbon.

diagnostics Information about which printer functions are not working that is used for
troubleshooting printer problems.

11/5/15 P1048261-005
184 Glossary

die-cut media A type of label stock that has individual labels stuck to a media liner. The
labels may be either lined up against each other or separated by a small distance. Typically the
material surrounding the labels has been removed. (See non-continuous media.)

direct thermal A printing method in which the printhead presses directly against the media.
Heating the printhead elements causes a discoloration of the heat-sensitive coating on the
media. By selectively heating the printhead elements as the media moves past, an image is
printed onto the media. No ribbon is used with this printing method. Contrast this with thermal
transfer.

direct thermal media Media that is coated with a substance that reacts to the application of
direct heat from the printhead to produce an image.

dynamic RAM The memory devices used to store the label formats in electronic form while
they are being printed. The amount of DRAM memory available in the printer determines the
maximum size and number of label formats that can be printed. This is volatile memory that
loses the stored information when power is turned off.

fanfold media Media that comes folded in a rectangular stack. Contrast this with roll media.

firmware This is the term used to specify the printer’s operating program. This program is
downloaded to the printer from a host computer and stored in FLASH memory. Each time the
printer power is turned on, this operating program starts. This program controls when to feed
the media forward or backward and when to print a dot on the label stock.

FLASH memory FLASH memory is non-volatile and maintains the stored information
intact when power is off. This memory area is used to store the printer’s operating program. In
addition, this memory can be used to store optional printer fonts, graphic formats, and
complete label formats.

Font A complete set of alphanumeric characters in one style of type. Examples include
CG Times™, CG Triumvirate Bold Condensed™.

ips (inches-per-second) The speed at which the label or tag is printed. Many Zebra
printers can print from 1 ips to 12 ips.

label An adhesive-backed piece of paper, plastic, or other material on which information is

printed.

label backing (liner) The material on which labels are affixed during manufacture and
which is discarded or recycled by the end-users.

light emitting diode (LED) Indicators of specific printer status conditions. Each LED is
either off, on, or blinking depending on the feature being monitored.

liquid crystal display (LCD) The LCD is a back-lit display that provides the user with
either operating status during normal operation or option menus when configuring the printer
to a specific application.

media Material onto which data is printed by the printer. Types of media include: tag stock,
die-cut labels, continuous labels (with and without media liner), non-continuous media,
fanfold media, and roll media.

P1048261-005 11/5/15
 Glossary 185

media sensor This sensor is located behind the printhead to detect the presence of media
and, for non-continuous media, the position of the web, hole, or notch used to indicate the start
of each label.

media supply hanger The stationary arm that supports the media roll.

non-continuous media Media that contains an indication of where one label/printed

format ends and the next one begins. Examples are die-cut labels, notched tag-stock, and stock
with black mark registration marks.

non-volatile memory Electronic memory that retains data even when the power to the
printer is turned off.

notched media A type of tag stock containing a cutout area that can be sensed as a start-of-
label indicator by the printer. This is typically a heavier, cardboard-like material that is either
cut or torn away from the next tag. (See non-continuous media.)

peel-off A mode of operation in which the printer peels a printed label away from the
backing and allows the user to remove it before another label is printed. Printing pauses until
the label is removed.

print speed The speed at which printing occurs. For thermal transfer printers, this speed is
expressed in terms of ips (inches per second).

printhead wear The degradation of the surface of the printhead and/or the print elements
over time. Heat and abrasion can cause printhead wear. Therefore, to maximize the life of the
printhead, use the lowest print darkness setting (sometimes called burn temperature or head
temperature) and the lowest printhead pressure necessary to produce good print quality. In the
thermal transfer printing method, use ribbon that is as wide or wider than the media to protect
the printhead from the rough media surface.

registration Alignment of printing with respect to the top (vertical) or sides (horizontal) of a
label or tag.

ribbon A band of material consisting of a base film coated with wax or resin “ink.” The
inked side of the material is pressed by the printhead against the media. The ribbon transfers
ink onto the media when heated by the small elements within the printhead. Zebra ribbons
have a coating on the back that protects the printhead from wear.

ribbon wrinkle A wrinkling of the ribbon caused by improper alignment or improper

printhead pressure. This wrinkle can cause voids in the print and/or the used ribbon to rewind
unevenly. This condition should be corrected by performing adjustment procedures.

roll media Media that comes supplied rolled onto a core (usually cardboard). Contrast this
with fanfold media.

supplies A general term for media and ribbon.

symbology The term generally used when referring to a bar code.

tag A type of media having no adhesive backing but featuring a hole or notch by which the
tag can be hung on something. Tags are usually made of cardboard or other durable material.

11/5/15 P1048261-005
186 Glossary

tear-off A mode of operation in which the user tears the label or tag stock away from the
remaining media by hand.

thermal transfer A printing method in which the printhead presses an ink or resin coated
ribbon against the media. Heating the printhead elements causes the ink or resin to transfer
onto the media. By selectively heating the printhead elements as the media and ribbon move
past, an image is printed onto the media. Contrast this with direct thermal.

void A space on which printing should have occurred, but did not due to an error condition
such as wrinkled ribbon or faulty print elements. A void can cause a printed bar code symbol
to be read incorrectly or not at all.

P1048261-005 11/5/15
 Index

A C
active print server, 111 calibration
adhesive test for ribbon coating, 22 Auto Calibrate failed, 154
adjustments how to set as head-close action, 103
display contrast, 101 how to set as power-up action, 102
label left position, 97 procedure, 122
maximum label length, 99 SHORT CAL
print darkness, 93 how to set for head-close action, 103
print width, 96 how to set for power-up action, 102
printhead pressure, 127 ways to initiate, 105
ribbon spindle tension, 130 Canadian DOC compliance, 4
tear-off position, 95 CANCEL button
CANCEL self test, 165
B ZT210 printer control panel, 14
ZT220 printer control panel, 14
bar codes
ZT230 printer control panel, 13
bar code does not scan, 154
changing printer parameters, 18
bar codes label, 100
cleaning
darkness comparison during FEED self test, 167
cutter module, 144
battery disposal, 148
exterior of printer, 135
baud rate, 120
media compartment, 135
black mark media
peel-off assembly, 140
described, 19
printhead and platen roller, 136
selecting media type, 94
recommended cleaning schedule, 134
broken ribbon, 155
sensors, 135
buttons on control panel, 13
command character, 116
command language, 115
communication diagnostics mode
how to initiate, 106
overview, 171
communication interfaces, 28
communications problems, 161

11/5/15 P1048261-005
188 Index

configuration label E
print through Zebra Setup Utilities, 87 electronics cover, 12
print using CANCEL self test, 165 enable ZBI, 107
various ways to print, 100 error messages, 157
conformity declaration, 3 ESSID, 112
connecting printer to computer or network, 28 Ethernet
continuous media characteristics of a wired connection, 177
described, 20 characteristics of wireless connection, 177
selecting media type, 94 connecting the printer to a wired network, 49
control character, 116 connecting the printer to a wireless network, 56
control panel external view of printer, 12
button function, 13
error messages, 157
location, 12 F
navigation, 15 factory defaults, 104
CUT ERROR message, 160 fanfold media
Cutter mode described, 20
cleaning the cutter module, 144 loading, 71
CUT ERROR message, 160 FCC compliance, 4
description and media path, 64 FCC radiation exposure limits, 4
how to select, 97 feed a label
how to set as head-close action, 103
how to set as power-up action, 102
D ZT210 printer, 14
darkness ZT220 printer, 14
adjustments, 93 ZT230 printer, 13
print quality too light or too dark, 153 FEED button
data bits, 120 FEED and PAUSE self test, 170
data source FEED self test, 167
connections, 28 ZT210 printer control panel, 14
site selection considerations, 27 ZT220 printer control panel, 14
declaration of conformity, 3 ZT230 printer control panel, 13
default gateway, 110 fonts label, 100
default reset, 104 formats label, 100
delimiter character, 117
diagnostic mode
how to initiate, 106, 171 G
diagnostics, 164 gap/notch
Direct Thermal mode illustrations, 19
media scratch test, 21 selecting media type, 94
setting, 94 ways to select media sensor type, 118
display gateway, 110
contrast adjustment, 101
display language, 114 H
missing characters, 162
HEAD COLD message
ZT230 printer control panel, 13
cycling with other messages, 159
display language
displaying alone, 160
how to change from unfamiliar language, 162
HEAD OPEN message, 157
disposal of printer parts, 148
head-close action, 103
driver installation, 28
Home menu, 17
host handshake, 121

P1048261-005 11/5/15
 Index 189

I M
idle display MAC address, 112
accessing the Home menu from the Idle Display, 17 manual calibration
how to change what displays, 102 procedure, 122
images distorted on labels, 161 ways to initiate, 105
images label, 100 maximum label length, 99
indicator lights media
combined with error message on ZT230, 157 black mark, 19
troubleshooting, 150 continuous roll media, 20
ZT210 printer control panel, 14 fanfold, 20
ZT220 printer control panel, 14 non-continuous roll media, 19
ZT230 printer control panel, 13 perforated, 19
initiate manual calibration, 105 tag stock, 19
inspect for shipping damage, 26 types of media, 19
IP addresses, 109 web, 19
IP protocol, 111 media door, 12
IP resolution MEDIA OUT message, 157
IP protocol, 111 media scratch test, 21
media sensor calibration
L procedure, 122
ways to initiate, 105
label length maximum, 99
media sensor selection, 118
label sensor sensitivity, 118
media type selection, 94
label shift, 97
melted ribbon, 155
label width, 96
menu structure, 18
labels did not print, 161
misregistration of labels, 153
labels not printing, 161
missing print on labels, 152
language
how to change from unfamiliar language, 162
languages supported on display, 114 N
last saved settings, 104 navigation, 15
LCD contrast, 101 network configuration label
LCD error messages, 157 print using CANCEL self test, 165
left position adjustment, 97 various ways to print, 100
LENGTH network defaults, 104
how to set as head-close action, 103 network settings
how to set as power-up action, 102 load defaults, 104
liability, 2 reset network, 113
Liner Take-Up mode NO MOTION
description and media path, 63 how to set as head-close action, 103
how to select, 97 how to set as power-up action, 102
load defaults, 104 non-continuous media
location for printer, 27 described, 19
lubrication, 148 problem with labels, 162
selecting media type, 94

O
operating conditions, 27
ordering replacement parts, 148
OUT OF MEMORY message, 160

11/5/15 P1048261-005
190 Index

P printer configuration label, 100

parallel port printer diagnostics, 164
characteristics of parallel connection, 177 printer driver, 28
connecting the printer to a computer, 41 printer locks up, 163
specifications, 176, 177 printer parameters, 18
parity, 121 printer settings
PAUSE button darkness, 93
FEED and PAUSE self test, 170 label left position, 97
PAUSE self test, 166 maximum label length, 99
ZT210 printer control panel, 14 media type, 94
ZT220 printer control panel, 14 print method, 94
ZT230 printer control panel, 13 print mode, 97
Peel-Off mode print speed, 93
cleaning peel-off assembly, 140 print width, 96
description and media path, 63 reprint mode, 98
how to select, 97 settings not taking effect, 162
perforated media, 19 tear-off position, 95
PH NOT AUTHENTICATED message, 159 printhead
power adjust printhead pressure, 127
power cord specifications, 178 HEAD COLD message, 159
site selection, 27 how to clean, 136
Power-On Self Test (POST), 164 PH NOT AUTHENTICATED message, 159
power-up action, 102 PRINT HEAD OVERTEMP message, 159
print darkness setting, 93 THERMISTOR PREPLACE PRINTHEAD
PRINT HEAD OVERTEMP message, 159 message, 159
print information
how to print various printer information, 100 Q
print method specification, 94 QR codes with error messages, 157
print mode selection, 97 QuickHelp pages, 157
print quality
bar code does not scan, 154
darkness comparison during FEED self test, 167 R
printhead pressure adjustment, 127 radiation exposure limits, 4
troubleshooting, 152 recycling printer parts, 148
print server reflective sensor selection, 118
active print server user menu item, 111 registration loss during printing, 152
characteristics of wired connection, 177 reinitialize printer server, 104
characteristics of wireless connection, 177 relative humidity
default gateway, 110 operating, 27
ESSID, 112 operating and storage, 176
IP addresses, 109 reload last saved settings, 104
IP protocol, 111 replacement parts, 148
MAC address, 112 report shipping damage, 26
network configuration label, 100 reprint mode, 98
reset network settings, 113 reset network settings, 113
subnet mask, 109 reset printer to default values, 104
print speed, 93 reset to defaults, 104
print width adjustment, 96

P1048261-005 11/5/15
 Index 191

ribbon SHORT CAL

adhesive test, 22 how to set as head-close action, 103
broken or melted ribbon, 155 how to set as power-up action, 102
determining coated side, 21 site selection for printer, 27
removal, 131 smart phone
ribbon not detected correctly, 156 QuickHelp pages, 157
ribbon slips or does not advance, 155 smudge marks on labels, 153
scratch test, 22 spacing requirements, 27
setting Thermal Transfer mode, 94 stop a ZBI program, 108
when to use, 21 storing the print engine, 26
wrinkled ribbon, 155 storing the printer, 26
RIBBON IN message, 158 subnet mask, 109
RIBBON OUT message, 158 surface for printer, 27
ribbon sensor calibration
procedure, 122 T
ways to initiate, 105
tag stock
ribbon spindle tension adjustment, 130
described, 19
roll media
take label sensor sensitivity, 119
described, 19
Tear-Off mode
loading, 71
description and media path, 62
routine cleaning schedule, 134
how to select, 97
run a ZBI program, 107
tear-off position adjustment, 95
temperature
S operating, 27
scratch test operating and storage, 176
media type, 21 tension setting for ribbon, 130
ribbon coated side, 22 Thermal Transfer mode
self tests, 164 media scratch test, 21
CANCEL, 165 setting, 94
communication diagnostics, 171 THERMISTOR REPLACE PRINTHEAD
FEED, 167 message, 159
FEED and PAUSE, 170 transmissive sensor selection, 118
PAUSE, 166 troubleshooting
Power-On Self Test (POST), 164 communications problems, 161
sensor profile, 100 diagnostic tests, 164
sensor type selection, 118 error messages, 157
sensors indicator lights, 150
interpreting sensor profile, 172 print quality problems, 152
transmissive sensor selection, 118 ribbon problems, 155
serial port types of media
characteristics of serial connection, 176 black mark media, 19
connecting the printer to a computer, 41 continuous roll media, 20
specifications, 176 fanfold media, 20
setup non-continuous roll media, 19
install the printer driver, 28 perforated media, 19
unpack the print engine, 26 tag stock, 19
unpack the printer, 26 web media, 19
shipping
report damage, 26
reshipping the print engine, 26
reshipping the printer, 26

11/5/15 P1048261-005
192 Index

U wired print server

unpack the print engine, 26 characteristics, 177
unpack the printer, 26 specifications, 176, 177
USB port wireless print server
characteristics of USB connection, 176 characteristics, 177
connecting the printer to a computer, 37 specifications, 176, 177
specifications, 176 wrinkled ribbon causes, 155
user menus, 18
Z
V Zebra Basic Interpreter (ZBI)
ventilation requirements, 27 enable, 107
vertical drift run a ZBI program, 107
top-of-form position, 153 stop a ZBI program, 108
Zebra Setup Utilities
installation, 28
W print a test label, 87
web media ZebraDesigner, 89
described, 19 ZPL mode, 117
ZPL override, 115

P1048261-005 11/5/15
Corporate Headquarters
Zebra Technologies Corporation
3 Overlook Point
Lincolnshire, IL 60069 USA
T: +1 847 634 6700
Toll-free +1 866 230 9494
F: +1 847 913 8766

http://www.zebra.com

P1048261-005