Instruction/ maintenance manual of the product ZE500 Zebra
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P1051584-002 Rev . A Zebra ® ZE500™ User Guide.
© 2012 ZIH Corp. The copyrights in this manual and th e software and/or firmware in the print engine described therein are owned by ZIH Corp. and Zebra’ s licensors. Unaut horized rep roduction of this manual or the software and/or firmware in the print engine may result in impris onment of up to one year and fines of up to $10,000 (17 U.
3 Declaration of Conformity 8/23/12 P1051584-002 DECLARATION OF CONFORMITY ZEBRA TECHNOLOGIES CORPORATION Declares that the following In formation Technology Equipment Zebra ZE500-4 and ZE500-6 compli.
Compliance Information 4 P1051584-002 8/23/12 Compliance Information FCC Compliance S t atement This device compli es with Part 15 of the FCC rules. Operation is subje ct to the follo wing two conditions: 1. This device may not cause harmful in terferen ce, and 2.
8/23/12 P1051584-002 Contents About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents 6 P1051584-002 8/23/12 Print Engine Inst allation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 8 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Contents 8/23/12 P1051584-002 Print Engine Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Power-On Self T est . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents 8 P1051584-002 8/23/12 Notes • ___________ ____________________ _____________________ _______________ ___________ _____________________ ____________________ ____________________ __ ________.
8/23/12 P1051584-002 About This Document This section provides yo u with contact informat ion, document structure and or ganization, an d additional re ference documents. Content s Who Should Use This Document . . . . . . . . . . . . . . . . . . . . .
About This Document Who Shoul d Use This Do cument 10 P1051584-002 8/23/12 Who Should Use This Document This User Guide is intend ed for use by any person who needs to perform routine maintenance , upgrade, or troubleshoot pro blems with the print engine.
11 About This Document Contacts 8/23/12 P1051584-002 Contact s T echnical Supp ort via the Internet is a vailable 24 hours pe r day , 365 days per year . W e b Site: www .zebra.com E-mail Back T e chnical Library: E-mail address: emb@zebra.com Subject line: Email list Self Service Knowledge Base: www .
About This Document Document Conventions 12 P1051584-002 8/23/12 Document Conventions Ta b l e 1 shows the way that certain informat ion is conveyed in this documen t.
8/23/12 P1051584-002 1 Introduction This section provides a high-level over vi ew of the printe r and its compo nents. Content s Print Engine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction Print Engine Orientation 14 P1051584-002 8/23/12 Print Engine Orient ation The ZE500 print engines are availa ble in a right-hand configurat ion (the print mechani sm is on the right) and a left-hand configuration (the print mec hanism is on the left).
15 Introd uction Print Engine Components 8/23/12 P1051584-002 Print Engine Component s Figure 3 shows the components inside the media co mpartmen t of a right-hand print engine. A left-hand unit contain s a mirror image of these components. Famil iarize yourself with these components be fore continuing with the p rint engine setup procedure.
Introduction Control Pane l 16 P1051584-002 8/23/12 Control Panel All controls and in dicators for the prin t engine are located on the cont rol panel ( Figure 4 ).
17 Introd uction Control Panel Display 8/23/12 P1051584-002 Control Panel Display The control p anel includes a displa y , where you can v iew the print engine’ s status or change its operating parameters. In this section, yo u will learn ho w to navigate t hrough the menu syst em and change values for menu items.
Introduction Control Panel Display 18 P1051584-002 8/23/12 Perform an action + indicates that an act ion can be performed. Press PLUS (+) to perform the specified action. Change Parameter V alues - and + indicate tha t a value can be changed. Press PLUS (+) or MINUS (-) to scroll through the accepted values.
19 Introd uction Control Panel Display 8/23/12 P1051584-002 Exit Setup Mode 1. While in Setup Mode, pre ss SETUP to exit the opera ting parame ters. The LCD displays SA VE CHANGES . 2. T o return to the parameters, plu s the LEFT ARROW . OR Press PLUS (+) or MINUS (-) to scroll through th e exit options.
Introduction Control Panel Display 20 P1051584-002 8/23/12 Changing Password-Pr otected Parameters Certain paramet ers, including the communication parameters, are passwo rd-protected by factory defaul t. The first time that you attempt to change a password-pro tected parameter , the print engine displays ENTER PASSWORD .
21 Introd uction Control Panel Display 8/23/12 P1051584-002 Operating Parameters on the Control Panel Items in this menu are shown in the order i n which they appe ar when you press the RIGH T ARROW . For more information about these settings, see Print Settings on page 73 .
Introduction Control Panel Display 22 P1051584-002 8/23/12 Adjust the T ear -Off Position If necessary , adjust the position of the media over t he tear -off bar after printing. See T ear-Off Positi on on page 74 for more information. Select the Print Mode Select a print mo de that is com patible with your print eng ine options.
23 Introd uction Control Panel Display 8/23/12 P1051584-002 Select the Media Sensor Select the media sensor that is appropri ate for the med ia that you are using. See Sensor T ype on pa ge 95 for more information. Select the Print Method Specify if ribbon is bei ng used.
Introduction Control Panel Display 24 P1051584-002 8/23/12 Set Number of Labels Per Roll for Early W arning This value should c o rrespond to the number of labels per roll of the media that you are using. See Early W arning for Media and Ri bbon on page 82 for more information.
25 Introd uction Control Panel Display 8/23/12 P1051584-002 Set Early W arning for Maintenance When this feature is enable d, the print engine pro vides warnings when the p rinthead n eeds to be cleaned. See Early W arning for Maintenance on page 82 for more information.
Introduction Control Panel Display 26 P1051584-002 8/23/12 V iew the Non- Resettable Counter This parameter displ ays the total l ength of me dia that the p rinter has printed.
27 Introd uction Control Panel Display 8/23/12 P1051584-002 Print Bar Code List This option pr ints a label that lists the a vailable bar co des in the print engine. Bar codes may be sto red in RAM or Flash memory . See Print Information on page 84 for more information.
Introduction Control Panel Display 28 P1051584-002 8/23/12 Print All Labels This option print s labels that list the available fonts, bar codes, images, formats, and the curr ent print engine and ne twork configurations. See Print Information on page 84 for more information.
29 Introd uction Control Panel Display 8/23/12 P1051584-002 Set Parallel Communications Select the communication s port that matches the one being used by the host computer . See Parallel Commu nications on page 96 for more information. Set Serial Communications Select the communication s port that matches the one being used by the host computer .
Introduction Control Panel Display 30 P1051584-002 8/23/12 Set the Host Handshake Protocol V alue Select the hand shake protocol that matches the one being used by the host computer . See Host Handshake on page 98 for more information. Set the Zebra Protocol V alue Protocol is a type of error checkin g system.
31 Introd uction Control Panel Display 8/23/12 P1051584-002 Set the Format Command Prefix V alue Set the format c ommand pref ix charac ter to match what is used in your label f ormats.
Introduction Control Panel Display 32 P1051584-002 8/23/12 Set the Head-Close Action Set the action for the printer to t ake when you close the printhead. See Head-C lose Action on pa ge 85 for more information. Set the Backfeed Sequence This parameter se ts when label b ackfeed occurs after a label is removed in some print modes.
33 Introd uction Control Panel Display 8/23/12 P1051584-002 Set Applicator Error Signal When Print Engine Pauses When this opti on is enabled and the print e n gine is paused , the print engine sets the appl icator error state. See Err or on Pause on page 80 for more information.
Introduction Control Panel Display 34 P1051584-002 8/23/12 V iew Sensor Settings The following parameters are automatically set during the calibration procedure an d should be changed only by a qualified service technician . Select Format Conversion Scaling Factor Selects the bitmap scaling factor .
35 Introd uction Control Panel Display 8/23/12 P1051584-002 Set the Real-Time Clock (R TC) Date This parameter a llows you to set the date to display in the Idle Display . See RTC Date on page 88 for more information. Set the Real-Time Clock (R TC) Time This parameter a llows you to set the date to display in the Idle Display .
Introduction Control Panel Display 36 P1051584-002 8/23/12 V iew the Active Print Server* This menu item displa ys which print server is be ing used. This tells which devic e’ s settings such as IP protocol and IP address are being displayed under t hose menu items.
37 Introd uction Control Panel Display 8/23/12 P1051584-002 Set the Default Gateway* V iew and, if necessary , change the default gateway . Changes are saved only if IP PROT OCOL is set to PERMANENT . T o allow any saved changes to take ef fect, use RESET NETWORK on page 37 to reset the print server .
Introduction Control Panel Display 38 P1051584-002 8/23/12 Specify the Password Level This option resets th e wired or wireless pri nt server . Y ou must reset the print server to al low any changes to the network setting s to take effec t. See Passwor d Level on page 88 for more information.
39 Printer Setup and Operation T ypes of Media 8/23/12 P1051584-002 T ypes of Media Y our print eng ine can use various types of media: • S tandar d media —Most standard media uses an adhesive backing that sti cks individual labels or a continuo us length of labels to a liner .
Printer Setup and Operation T ypes of Media 40 P1051584-002 8/23/12 Non-Continuous Fanfold Media Fanfold media is folded in a zi gzag pattern. Fanfold media can have the same label separation s as non-continuo us roll media. The separations would fall on or near the folds.
41 Printer Setup and Operation Ribbon Overview 8/23/12 P1051584-002 Ribbon Overview Ribbon is a t hin film that is co ated on one side with wax, resin, o r wax resin, whi ch is transferred to the media duri ng the therm al transfer process. The me dia determine s whether you need to use ribbon and how wide the ribb on must be.
Printer Setup and Operation Ribbon Overview 42 P1051584-002 8/23/12 Adhesive T est If you have lab els available, p erform the adhesive test to determine wh ich side of a ri bbon is coated. This method works well for ribbon that is already insta lled.
8/23/12 P1051584-002 2 Printer Setup and Operation This section assists the technician with init ial setup and operation o f the print en gine. Content s Handling the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Setup and Operation Handling the Print Engine 44 P1051584-002 8/23/12 Handling the Print Engine This section describ es how to handle your print en gine. Unp ack and Inspect the Print Engine When you receiv e the print eng ine, do the fo llowing: 1.
45 Printer Setup and Operation Handling the Print Engine 8/23/12 P1051584-002 2. Remove the metal spacer that ships ne xt to the printhead-rel ease latch. (Right-hand unit shown.) a. Cut the cable tie ( 1 ) that secured the printhead-rel ease latch during shipping.
Printer Setup and Operation Handling the Print Engine 46 P1051584-002 8/23/12 c. Remove the metal spacer . d. Rotate the printhead-rele ase latch to the closed position. 3. Cut and remove other cable ties tha t were used in the media compartment (if any).
47 Printer Setup and Operation Handling the Print Engine 8/23/12 P1051584-002 T o Store the Print Engine If you are not placing th e print engine into immed iate operation, re package it using the original packing materials.
Printer Setup and Operation Print Engine Installation 48 P1051584-002 8/23/12 Print Engine Inst allation This section provid es basic information for mounting the p rint engine into an applica tor . The illustrations in th is section show the print engine from different a n gles and include dimensions and clearance needs.
49 Printer Setup and Operation Print Engine Installation 8/23/12 P1051584-002 Dimensions and Clearance Needs This section shows measurements rel evant wh en installing th e ZE500 print engine in an applicator . Front View (Right-Hand Print Engine Shown) 5 mounting screws - 0.
Printer Setup and Operation Print Engine Installation 50 P1051584-002 8/23/12 Rear View 9.648 in. (245 ± 0.1 mm) 0.445 in. (1 1.3 mm).
51 Printer Setup and Operation Print Engine Installation 8/23/12 P1051584-002 T op V iew 16.62 in. (422.1 mm).
Printer Setup and Operation Print Engine Installation 52 P1051584-002 8/23/12 Side V iew—ZE500-4 Print Engine 12.13 in (308.2 mm) 1.454 in. (37 mm) 15.89 in. (403.7 mm) 12.73 in. (323.2 mm) 7.34 in. (186.5 mm) 14.95 in. (379.73 mm) 19.87 in. (504.7 mm) 0.
53 Printer Setup and Operation Print Engine Installation 8/23/12 P1051584-002 Side V iew—ZE500-6 Print Engine 0.613 in. (15.6 mm) 0.52 in. (13.2 mm) Ribbon and media edge First print element Mainfra.
Printer Setup and Operation Print Engine Installation 54 P1051584-002 8/23/12 Inst all the Print Engi ne in an Applicator This section provid es the basic inst ructions for installing the print engine into an applicator . T o inst all the print engine into an applicator , complete these step s: 1.
55 Printer Setup and Operation Select a Data Communication Interface 8/23/12 P1051584-002 Select a Dat a Communication Interface Y ou may connect yo ur print engine to a compute r using one o r more of the ava ilable connection s. The standard connectio ns are shown in Figure 8 .
Printer Setup and Operation Select a Data Communication Interface 56 P1051584-002 8/23/12 Caution • Ensure that the print eng ine power is off ( O ) before connecting data communications cables. Co nnecting a data communications cable while the pow er is on ( I ) may damage the print engine.
57 Printer Setup and Operation Select a Data Communication Interface 8/23/12 P1051584-002 Applicator Option Limit ations and Requirements The applicato r interface is used to cont rol the print engine fro m an ext ernal device (usually a label app licator).
Printer Setup and Operation Select a Data Communication Interface 58 P1051584-002 8/23/12 Dat a Cables Y ou must supply al l data cables for your applica tion. Ethernet cables do not requ ire shielding, but all other da ta cables must be fully shielded and fitted with me tal or metallized connector shells.
59 Printer Setup and Operation Connect the Print Engi ne to a Power So urce 8/23/12 P1051584-002 Connect the Print Engine to a Power Source The AC power cord must ha ve a three-prong fema le connector on one end that plugs into the mating AC power conne ctor at the rear of the print engine.
Printer Setup and Operation Connect the Print Engine to a Power Source 60 P1051584-002 8/23/12 3. Tu r n o n ( I ) the print engine. The print engi ne boots up and performs a sel f-test. Power Cord Specifications Depending on how your p rint engine was ordered, a power cord may or may no t be included.
61 Printer Setup and Operation Connect the Print Engi ne to a Power So urce 8/23/12 P1051584-002 Figure 9 • Power Cord Specifications Figure 10 • International Safety Organization Certification Sy.
Printer Setup and Operation Load Ribbon and Media 62 P1051584-002 8/23/12 Load Ribbon and Media Use the instructions i n this section to load ri bbon (if used) and media in a ZE500 ™ print engine. Ribbon is used with thermal transfer labels. For d irect thermal labels, d o not load ribbon in the pr int engine.
63 Printer Setup and Operation Load Ribbon and Media 8/23/12 P1051584-002 2. Position the rib bon roll with th e loose end unrolling in the direction shown. 3. Place the roll of ri bbon on the r ibbon supply sp indle. Push th e roll back as far as it wi ll go.
Printer Setup and Operation Load Ribbon and Media 64 P1051584-002 8/23/12 5. 6. W ind the ri bbon around t he core on the ribbon take-u p spindle. Caution • The printhead may be ho t and could cause severe burns.
65 Printer Setup and Operation Load Ribbon and Media 8/23/12 P1051584-002 Loading Media 7. Load media on the media supply reel of t he applicator (refer to the applicator ’ s documentation for mo re information). 8. Press the release butto n on the pinch roller assemb ly .
Printer Setup and Operation Load Ribbon and Media 66 P1051584-002 8/23/12 10. Thread the medi a under the uppe r guide post (1) , below the pinc h roller assembly (2) , and under the printhead assembly (3) . 11 . Extend approximatel y 30 in. (75 cm) of media past th e peel bar .
67 Printer Setup and Operation Load Ribbon and Media 8/23/12 P1051584-002 12. Slide in the med ia guide unt il it just touc hes the edge of the med ia. 13. Press down on the pinch roller assembly until it locks close d. 14. Rotate the pri nthead-release latc h to the closed position.
Printer Setup and Operation Load Ribbon and Media 68 P1051584-002 8/23/12 15. Raise the peel roller latch so th at the peel roller assembly pivo ts downward . 16. Thread the liner around the peel bar , under th e platen roller , and throug h the peel roller assembly .
69 Printer Setup and Operation Load Ribbon and Media 8/23/12 P1051584-002 17. Rotate the pe el roller assembly up until it locks into the cl osed position. 18. Thread the liner around the ta ke-up spindle of the applicator (refer to the applicator’ s documentation for mo re information).
Printer Setup and Operation Load Ribbon and Media 70 P1051584-002 8/23/12 Notes • ___________ ____________________ _____________________ _______________ ___________ _____________________ ___________.
8/23/12 P1051584-002 3 Printer Configuration and Adjustment This section assists yo u with configuration of and a d justments to the p r int engine. Content s Changing Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Configuration and Adjustment Changing Printer Settings 72 P1051584-002 8/23/12 Changing Printer Settings This section p resents the pr inter setti ngs that you c an change a nd identifies t he tools for changing them.
73 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Print Settings T able 5 • Print Settings Print Darkness Set the darkn ess to the lowest setting th at provides good print quality .
Printer Configuration and Adjustment Changing Printer Settings 74 P1051584-002 8/23/12 Backfeed Speed Backfeed refers to the backward motion of t he me dia from the tear-of f or peel-of f position to the print posit ion. This motion occu rs so that more of the lea d edge of each label can be used for printing .
75 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Print Mode Select a print mo de that is compa tible with your print engine opti ons. Accepted values: • APPLICA TOR—The print engine prin ts a label when it receives a signal from the appli cator .
Printer Configuration and Adjustment Changing Printer Settings 76 P1051584-002 8/23/12 St a r t P r i n t Signal This parameter d etermines how th e print engine reacts to the Start Prin t Signal input on pin 3 of the applicator interfa ce connecto r at th e rear of the print engine.
77 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Print Width Specify the width of th e labels being used. Note • Setting the width too narro w can result in portions of a label forma t not being printed on the media.
Printer Configuration and Adjustment Changing Printer Settings 78 P1051584-002 8/23/12 Maximum Label Length Set the maxi mum label length to a va lue that is at least 1.
79 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Ribbon Te n s i o n Select the ri bbon tension setting that is appropriate for the widt h or type of me dia being printed.
Printer Configuration and Adjustment Changing Printer Settings 80 P1051584-002 8/23/12 Label T op Position This parameter adjusts the print position ve rtically on the label. Po sitive numbers adjust the label top posi tion farther d own the label (away from the printhead) by the specified n umber of dots.
81 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Ribbon Lo w Mode The Ribbon Low feature determines if the prin t engine will generate a warning when the amount of ribbo n left on the ro ll gets low .
Printer Configuration and Adjustment Changing Printer Settings 82 P1051584-002 8/23/12 Maintenance and Diagnostic T ools T able 7 • Maintenance and Diagnostic T ools Early W arning for Media a nd Ribbon When this feature is e n abled, the p rint engine prov ides warnings when the media or ribbon is reaching near the end of the roll.
83 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Non-Resettable Counter The non-resettab le counter gives th e total length of media that t he printer has printed. Y ou can use firmware co mmands to change the unit of measure for this co unter .
Printer Configuration and Adjustment Changing Printer Settings 84 P1051584-002 8/23/12 Print Informat ion Print the specified i n formation on on e or more labels. • FONTS—Prints the availabl e fonts in the print engine, in cluding standard print engine fonts plus any op tional fonts.
85 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Power -Up Action Set the Power -Up Action Set the action for the printer to take during the power -up sequence. • CALIBRA TE adjusts sensor levels and thresho lds, determines the label length, and feeds the media to the next web.
Printer Configuration and Adjustment Changing Printer Settings 86 P1051584-002 8/23/12 Load Defaults Load Printer or Pr int Server Defaults • F ACTO R Y—Restores all printer settings other th an the network settings bac k to the factory defaults.
87 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Media and Ribbon Sensor Calibration Calibrate the printer to adjust th e sensitivity of the media and rib bon sensors. For comple te instruction s on how to perform a calibratio n procedure, see Cali brate the Ribbon and Med ia Sensors on page 99 .
Printer Configuration and Adjustment Changing Printer Settings 88 P1051584-002 8/23/12 Idle Disp lay Select the info rmation sho wn on the prin ter ’ s display when the printer is idle .
89 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Network Settings T able 8 • Network Settings Primary Network Select the Primary Network Device This parameter determines wh ich device should be considered primary i n the active device selection.
Printer Configuration and Adjustment Changing Printer Settings 90 P1051584-002 8/23/12 IP Protocol Set the IP Resolution Method This parameter tells if t h e user (permanent) or the server (dynamic) se lects the IP address.
91 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Subnet Mask V iew or Set the Subnet Mask V iew and, if necessary , change the subnet mask. This menu item appears only if a wired or wireless print server i s installed on your printer .
Printer Configuration and Adjustment Changing Printer Settings 92 P1051584-002 8/23/12 ESSID V iew the ESSID V alue The Extended Service Set Ident ification (ESSID) is an identifier for your wireless network. This setting, whic h cannot be modified fro m the control panel, gives t he ESSID for the current wireless configuration.
93 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Language Settings T able 9 • Language Settings Language If necessary , change the lang uage that the printer di splays.
Printer Configuration and Adjustment Changing Printer Settings 94 P1051584-002 8/23/12 Command Character Set the Format Command Pr efix V alue The format command prefix is a two-digit hex value used as a parameter place marker in ZPL/ZPL II format instructions .
95 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Sensor Settings T able 10 • Sensor Settings Sensor T ype Select the Media Sensor Select the medi a sensor that is approp riate for the media that you are using.
Printer Configuration and Adjustment Changing Printer Settings 96 P1051584-002 8/23/12 Port Settings T able 1 1 • Port Settings Parallel Communications Set Parallel Communications Select the commu nications port tha t matches the one b eing used by the host computer .
97 Printer Configuration and Adju stment Changing Printer Settings 8/23/12 P1051584-002 Baud Rate Set the Baud Rate Select the baud value that matc hes the one being used by the host comp uter .
Printer Configuration and Adjustment Changing Printer Settings 98 P1051584-002 8/23/12 Host Handshake Set the Host Handshake Pr otocol V alue Select the handshake protocol that mat ches the o ne being us ed by the ho st computer .
99 Printer Configuration and Adju stment Calibrate the Ribbon and Media Sensors 8/23/12 P1051584-002 Calibrate the Ribbon and Media Sensors Use the procedure in this section to calibrate the printer , which adj usts the sensitivi ty of the media and ribbon sensors.
Printer Configuration and Adjustment Calibrate the Ribbon and Media Senso rs 100 P1051584-002 8/23/12 2. 3. Extend approximat ely 8 in. (203 mm) of media past th e peel bar . Remove and disc ard the labels from the liner o n this exposed media. Caution • The printhead may be ho t and could cause severe burns.
101 Printer Configuration and Adju stment Calibrate the Ribbon and Media Sensors 8/23/12 P1051584-002 4. Pull the med ia back into th e print engi ne so that only the liner is betw een the media sensors. 5. Press PLUS (+) to continue . The control panel di splays: REMOVE RIBBON 6.
Printer Configuration and Adjustment Calibrate the Ribbon and Media Senso rs 102 P1051584-002 8/23/12 11 . Rotate the printh ead-release latch t o the closed p o sition.
103 Printer Configuration and Adju stment Remove Used Ribbon 8/23/12 P1051584-002 Remove Used Ribbon Remove used ribbon from the ribbon take -up spindle each time you ch ange the roll of ribbon. T o remove used ribbon, complete the se steps: 1. Has the ribb on run out? 2.
Printer Configuration and Adjustment Adjust the Sensors 104 P1051584-002 8/23/12 Adjust the Sensors This section describes ho w to adjust the sensors. T ransmissive Media Sensor The transmissive medi a sensor finds “start of la be l” indicators, such as notc hes or holes in the media or interlabel gaps.
105 Printer Configuration and Adju stment Adjust the Sensors 8/23/12 P1051584-002 Reflective Me dia Sens or Some types of med ia have black marks printed on the underside of the media lin er , which act as “start of label” indicators. The reflectiv e media sensor senses these black marks.
Printer Configuration and Adjustment T ogg le Positioning 106 P1051584-002 8/23/12 T oggle Positioning Proper toggle positi oning is important for proper print q u ality . T o adjust the toggles, complete these s teps: 1. Print some labels at 2 in. (51 mm) per second by running th e P AU SE Self T est (see PA U S E Self T est on page 132 ).
107 Printer Configuration and Adju stment T oggl e Positioning 8/23/12 P1051584-002 6. Print addition al labels at 2 in. (51 mm) per second by again running the P AUSE Self T est.
Printer Configuration and Adjustment Printhead Pressure Adjustment 108 P1051584-002 8/23/12 Printhead Pressure Adjustment Before adj usting the pri nthead pre ssure, check that the tog gles are po sitioned co rrectly . See T oggle Positioning on page 10 6 .
109 Printer Configuration and Adju stment Printhead Pressure Adjustment 8/23/12 P1051584-002 4. 5. Move the adjust ing nut until the print qualit y is acceptable. Use the lowe st pressure that provides the desired pr int quality . • T o increase p rinthead pressure, move the ad justing nut d ownward.
Printer Configuration and Adjustment Printhead Pressure Adjustment 110 P1051584-002 8/23/12 Notes • ___________ ____________________ _____________________ _______________ ___________ _______________.
8/23/12 P1051584-002 4 Routine Maintenance This section provid es routine cl eaning and maintenance p rocedures. Content s Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 12 Clean the Exterior .
Routine Maintenance Cleaning Schedule 112 P1051584-002 8/23/12 Cleaning Schedule Cleaning yo ur print engine regularly maintains print quali t y and may ext end the life of t h e print engine. The recommended cl eaning sche dule is shown in Ta b l e 12 .
113 Routine Maintena nce Clean the Me dia Comp artment 8/23/12 P1051584-002 Clean the Media Comp artment Remove any acc umulated dirt and lint from the interior of the print engine using a soft bri stle brush and/or vacu um cleaner . This area should be inspected every time a new ribbon is loaded .
Routine Maintenance Clean the Printhead and Rol lers 114 P1051584-002 8/23/12 4. Using Preventative Mainte nance kit (part number 47362 ) or a solution of 90% isopropyl alcohol and 10% deionize d water on a co tton swab, wipe the print elements from end to end.
115 Routine Maintena nce Replacing Print Engine Componen ts 8/23/12 P1051584-002 Replacing Print Engine Component s Some print engine components, su ch as the print head and plate n roller , may wear out over time and can be replaced easily . Regular cleaning may extend the life of some of these compo nents.
Routine Maintenance Lubrication 116 P1051584-002 8/23/12 Notes • ___________ ____________________ _____________________ _______________ ___________ _____________________ ____________________ _______.
8/23/12 P1051584-002 5 Troubleshooting This section provides information about errors that you mig ht need to troubl eshoot. Assorted diagnostic test s are includ ed. Content s Printing Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T roubleshooting Printing Issues 118 P1051584-002 8/23/12 Printing Issues Ta b l e 13 identi fies possib le issues with printing or pr int qualit y , the possible cau ses, and the recommended solution s.
119 T roublesh ooting Printing Issues 8/23/12 P1051584-002 Long tracks of missing print on several la bels Print element da maged. Call a servic e technician. W rinkled ribbon. See wrinkled ribbon cau ses and solutions in Ribbon Pr oblems on page 12 1 .
T roubleshooting Printing Issues 120 P1051584-002 8/23/12 V ertical image or label drift The print engin e is using non-continuous l abels but is configured in contin uous mode.
121 T roublesh ooting Ribbon Problems 8/23/12 P1051584-002 Ribbon Problems Ta b l e 14 identifies problems that may occur w ith ribbon, the possible causes, and th e recommended solution s. T able 14 • Ribbon Problems Problem Possible Cause Recommended Soluti on Broken or mel ted ribbon Darkness sett ing too high .
T roubleshooting Error Messages 122 P1051584-002 8/23/12 Error Messages The control p anel displays me ssages when th ere is an err or . See Ta b l e 15 for LCD er rors, the possible causes, and the recommend ed solutions. T able 15 • Error Message s Displa y/ Print Engine Condition Possible Cause Recommended Solution The ERROR light flashes.
123 T roublesh ooting Error Messages 8/23/12 P1051584-002 The print engine stops; t he RIBBON light is on; the ERROR light flashes. In thermal transfer mode, ri bbon is not loaded or incorrectly load ed. Load ribbon correctly . See Load Ribbon and Media on page 62 .
T roubleshooting Error Messages 124 P1051584-002 8/23/12 The ERROR light flashes. The printhead has a faul ty thermistor . Call a service tec hnician. The print engine pri nts while the ERROR ligh t flashes. Caution • An improperly connected printhead data or power cable can cause this error message.
125 T roublesh ooting Error Messages 8/23/12 P1051584-002 The print engine stops; t he ERROR light is on; th e print engine cycles throug h these three messages. Caution • An improperly connected printhead data or power cable can cause these error messag es.
T roubleshooting Error Messages 126 P1051584-002 8/23/12 There is not enough memory to perform the functi on specified on the second line of the error message. Free up some of the print eng ine’ s memory by adjusting the label format or print eng ine paramete rs.
127 T roublesh ooting Communicat ions Problems 8/23/12 P1051584-002 Communications Problems Ta b l e 16 identifies problems with communications , the possible causes, and the recommended solutions. T able 16 • Communications Problems Problem Possible Cause Recommended Solution A label format was sent to the print engi ne but was not r ecognized.
T roubleshooting Miscellaneous Issues 128 P1051584-002 8/23/12 Miscellaneous Issues Ta b l e 17 identifies miscellaneous issues with th e print engine, the possible causes, and the recommended solution s.
129 T roublesh ooting Miscellaneous Issues 8/23/12 P1051584-002 All indica tor lights are o n , nothing is on the display (if the printer has a disp lay), and the print engine locks up. Internal electronic or firmware failure. Call a servic e technician.
T roubleshooting Print Engine Diagnosti cs 130 P1051584-002 8/23/12 Print Engine Diagnostics Self tests and other diagnostic s provide specific informatio n about the condition of the print engine. The self tests produce samp le printouts and p rovide specific inform ation that helps determine th e operating con d itions for th e print engi ne.
131 T roublesh ooting Print Engine Diagnostics 8/23/12 P1051584-002 CANCEL Self T est The CANCEL self test pr ints a printer c o nfiguration label and a n etwork configura tion label. For other ways to print these labels, see Print Informat ion on page 84 .
T roubleshooting Print Engine Diagnosti cs 132 P1051584-002 8/23/12 PA U S E S e l f Te s t This self test can be used to prov ide the test labels required when making adjustment s to the print engine’ s mechanical assemblies or to determi ne if any printh ead elements are not working.
133 T roublesh ooting Print Engine Diagnostics 8/23/12 P1051584-002 FEED Self T est Different types of media may require differen t darkness settings. This sect ion contains a simple but ef fective method for determi ning the ideal darkness for printi ng bar codes t h at are within specifications.
T roubleshooting Print Engine Diagnosti cs 134 P1051584-002 8/23/12 Figure 16 • Bar Code Darkness Comp arison T able 18 • Judging Bar Code Quality Print Quality Description To o d a r k Labels that are too dark are fai rly obvious. They may be readable but not “in-spec.
135 T roublesh ooting Print Engine Diagnostics 8/23/12 P1051584-002 5. Note the relat ive darkness value a nd the print sp eed printed on the best test la bel. 6. Add or subtract th e relative darkness value from the darkness value specified on th e configuration la bel.
T roubleshooting Print Engine Diagnosti cs 136 P1051584-002 8/23/12 FEED + P AUSE Self T est Performing this self test temporarily resets the prin t engine confi guration to th e factory d efault values. These v alues are active only until po wer is turned off un less you sa ve them permanently in memory .
137 T roublesh ooting Print Engine Diagnostics 8/23/12 P1051584-002 Communication Diagnostics T est The communicat ion diagnostic s test is a troublesho oting tool fo r checking the int erconnection between the print engine an d the host computer .
T roubleshooting Print Engine Diagnosti cs 138 P1051584-002 8/23/12 Sensor Profile Use the sensor profile image (which will extend across several actual labels or tags) to troubleshoot the foll owing sit uations: • The printer ex periences diffic ulty in determin ing gaps (web) b etween labels.
139 T roublesh ooting Print Engine Diagnostics 8/23/12 P1051584-002 Figure 18 • Sensor Profile (Ribbon Section) Media Sensor Profile ( Figure 19 ) The media sensor readings ar e shown as bars an d flat areas on the sensor profile ( Figure 19 ).
T roubleshooting Print Engine Diagnosti cs 140 P1051584-002 8/23/12 Notes • ___________ ____________________ _____________________ _______________ ___________ _____________________ _________________.
8/23/12 P1051584-002 6 Specifications This section lists g eneral printer specificatio ns, printing spec ifications, ribbon specificatio ns, and media specifications. Content s General S pecifications . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications General S pecifications 142 P1051584-002 8/23/12 General Specifications Model ZE500-4 ZE500-6 Height 1 1.8 in. (300 mm) 1 1.8 in. (300 mm) Wi d t h 9.6 in. (245 mm) 9.6 in. (245 mm) Depth 14.95 in. (380 mm) 17.23 in (438 mm) We i g h t 34 lb (15.
143 Specifications Printing S pecificatio ns 8/23/12 P1051584-002 Printing S pecifications Ribbon S p ecifications Print resoluti on 203 dpi (dots per inch) (8 dots/mm) 300 dpi (12 dot s/mm) Dot size (nominal) (width x lengt h) 203 dpi 0.0049 in. x 0.
Specifications Media S pecifi cations 144 P1051584-002 8/23/12 Media S p ecifications Model ZE500-4 ZE50 0-6 Minimum l abel lengt h Applicator mode , backfeed on 0.50 in. (12.7 mm) 3.0 in. (76.2 mm) Applicator mode , backfeed off 0.25 in. (6.4 mm) 1.0 in.
8/23/12 P1051584-002 A Applicator Interface Board Reconfiguration The print engi ne ships with the following caution label over the op tional applic ator port: • For +5V non-isolated mode (internal power), no configuration is necessary .
Applicator Interface Board Reconfiguration Changing Jumper Settings for Isolated Mode 146 P1051584-002 8/23/12 Changing Jumper Settings for Isolated Mode T o change from non-isolated mode (internal power) to is olated mode (external power), complete these step s: Remove Power and Dat a Cables 1.
147 Applicator Interface Board Reconfigura tion Changing Jumper Settings for Isolated Mode 8/23/12 P1051584-002 4. Remove the fo ur long moun ting screws ( 1 ) that secure the electronics cove r , and then slide the electron ics cover ( 2 ) off of the print engine.
Applicator Interface Board Reconfiguration Changing Jumper Settings for Isolated Mode 148 P1051584-002 8/23/12 5. On the back of t he applicator interface board, remove the two mounting screw s ( 1 ) that secure the applicator interfa ce board ( 2 ) to the back plane of the print engin e.
149 Applicator Interface Board Reconfigura tion Changing Jumper Settings for Isolated Mode 8/23/12 P1051584-002 8. Inside the print engine, locate the applicator interface board. 9. Disconnect the connectors ( 1 ) along the accessible edge of the applicator interface board.
Applicator Interface Board Reconfiguration Changing Jumper Settings for Isolated Mode 150 P1051584-002 8/23/12 11 . Disconnect the re maining connecto rs on the applicator interfac e board and the attached voltage regulator board. 12. Remove the applicator i nterface board from the print engine.
151 Applicator Interface Board Reconfigura tion Changing Jumper Settings for Isolated Mode 8/23/12 P1051584-002 Adjust Jumper Placement for +5V to +28V Is olated Mode 13. Locate the areas ma rked J4 and J5. 14. Caution • Do not apply external power until after the board is reco nfigured for Isolated Mode.
Applicator Interface Board Reconfiguration Changing Jumper Settings for Isolated Mode 152 P1051584-002 8/23/12 Reinsert and Reconnect the App licator Interface Board 15. Gently insert the applicator interface board into the print en gine, and slide it toward the back plane.
153 Applicator Interface Board Reconfigura tion Changing Jumper Settings for Isolated Mode 8/23/12 P1051584-002 Figure 20 • Applicator Interface Board Connections 1 2 3 4 5 7 8 9 6 1 J3: Applicator .
Applicator Interface Board Reconfiguration Changing Jumper Settings for Isolated Mode 154 P1051584-002 8/23/12 17. Align the mounting holes in th e applicator int e rface board with the holes in the back plane of the print engine .
155 Applicator Interface Board Reconfigura tion Changing Jumper Settings for Isolated Mode 8/23/12 P1051584-002 Reinst all the Print Engine in the Applicator (If Applicable) 22. T o reinstall the pri nt engine in to the applic ator, carefully place t h e keyhole on the center mounting bolt.
Applicator Interface Board Reconfiguration Changing Jumper Settings for Isolated Mode 156 P1051584-002 8/23/12 Notes • ___________ ____________________ _____________________ _______________ ________.
8/23/12 P1051584-002 Glossary alphanumeric Indicating lette rs, numerals, and c haracters such as punct uation mark s. backfeed When the print en gine pulls the media and ribbon (i f used) backward into the prin t engine so th at the begi nning of the l abel to be printed is properly positioned behind the printhead.
Glossary 158 P1051584-002 8/23/12 die-cut media A type of l abel stock that has individual labels stuck to a media liner . The labels may be either lined up against each othe r or separa ted by a small distance. T ypically the material surrounding the l abels has been removed.
159 Glossary 8/23/12 P1051584-002 media Material onto which data is printed by the print engine. T ypes of media include: tag stock, die-cut labe ls, continuous label s (with and without medi a liner), non-contin uous media, fanfold media, and roll media.
Glossary 160 P1051584-002 8/23/12 symbology The term generally used when referring to a bar code. ta g A type of media having no adhesive backing but featuring a hole or notch by which the tag can be hung on something. T ags are usuall y made of cardboa rd or other durable material.
8/23/12 P1051584-002 Index A active print server how to interpre t, 89 user menu item, 36 adhesive test for ribbon coating, 42 adjustments label left posi tion, 80 label top po sition, 80 maximum labe.
Index 162 P1051584-002 8/23/12 C CALIBRA TE button, 16 calibra tion Auto Calibrate failed, 120 how to set as hea d-close action, 85 how to set as power -up action, 85 media/ribbon cal procedure, 99 us.
163 Index 8/23/12 P1051584-002 disposal of printer parts, 1 15 door-open sensor when to cl ean, 112 E early war ning maintenan ce how to enable or disable, 82 printhead life menu item, 25 reset new pr.
Index 164 P1051584-002 8/23/12 IP address user menu item, 36 ways to view or set, 90 IP protocol how to change, 90 user menu item, 36 IP resolution IP protocol how to change, 90 user menu item, 36 L l.
165 Index 8/23/12 P1051584-002 N navigation, 17 network configur ation label user menu item, 27 ways to print, 84 network ID how to change, 98 user menu item, 30 network settings load defaults ways to.
Index 166 P1051584-002 8/23/12 print qua lity bar code does not scan, 120 running FEED self test , 133 troubleshoot ing, 118 print server active print server how to interpret, 89 user menu item, 36 ch.
167 Index 8/23/12 P1051584-002 reprint mode how to set and use, 81 user menu item, 33 requirements for installation, 48 reset network settings user menu item, 37 ways to reset, 92 reset printe r to de.
Index 168 P1051584-002 8/23/12 T tag stock, 39 T ear-Of f mode how to select, 75 select print mode throug h user menu, 22 tear -of f bar cleaning, 1 12 tear -of f position how to adjust , 74 user menu.
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Zebra T echnologies Corporation Zebra Technolo gies Corporation 475 Half Day Road, Suite 500 Lincolnshire, IL 6006 9 USA T: +1 847 63 4 6700 Toll-free +1 866 230 9494 F: +1 847 913 8766 Zebra T echnol.
An important point after buying a device Zebra ZE500 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Zebra ZE500 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Zebra ZE500 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Zebra ZE500 you will learn all the available features of the product, as well as information on its operation. The information that you get Zebra ZE500 will certainly help you make a decision on the purchase.
If you already are a holder of Zebra ZE500, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Zebra ZE500.
However, one of the most important roles played by the user manual is to help in solving problems with Zebra ZE500. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Zebra ZE500 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
