ZEBRA ZD220 (01) PDF Document

The following graphic icons are used throughout the documentation for the ZEBRA ZD220 printer:

Caution: If the precaution is not heeded, the user could receive minor or moderate injury.

Eye Injury Caution: If the precaution is not taken, the user’s eyes could be damaged. For example, wear protective eyewear when installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons, as these are under tension and could fly off.

Electrical Shock Caution: If the precaution is not taken, the user could receive an electrical shock. For example, turn off (O) the printer and disconnect it from the power source before performing a procedure.

Hot Surface Caution: If the precaution is not taken, the user could be burned. For example, the printhead may be hot and could cause severe burns. Allow the printhead to cool.

Product Damage Caution: If the precaution is not taken, the product could be damaged. For example, unplugging the computer without properly shutting it down may corrupt the data on your hard drive.

ESD Caution: If the precaution is not taken, the product electronics could be damaged by an electrostatic discharge. For example, observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.

Important: This text indicates information that is important for the user to know.

Note: This text indicates information that is supplemental for the user to know and that is not required to complete a task.

The ZEBRA ZD220 series thermal transfer printers can support printing speeds up to 152.4 mm/s (6 ips) at 203 dpi print density and support ZPL and EPL programming languages.

Common Desktop Printer Features include:

• OpenAccess™ design for simplified media loading.

• Color-coded “touch points” for operator controls and media guides.

• Simple single control button and single multi-colored status indicator.

• Zebra’s printer operating system.

• Media roll support for Outer Diameter (O.D.) up to 127 mm (5 inch) and Inner Diameter (I.D.) roll cores of 12.7 mm (0.5 inch), 25.4 mm (1 inch), and an optional 1.5 inch (38.1 mm) media core adapter set.

• Half width Movable Media Sensor compatible with full or partial width black mark media, notched or slotted media, and a center position transmissivity sensor for label gap/web media.

• On-the-fly OpenType and TrueType font scaling and import, Unicode, a resident scalable font (Swiss 721 Latin 1 font), and a selection of resident bitmap fonts.

• Backwards compatibility with legacy Zebra desktop printers (accepts both EPL and ZPL).

• Universal Serial Bus (USB) 2.0 interface.

• XML-Enabled printing.

• Zebra Global Printing Solution.

• A minimum of 50 MB of internal (E:\) printer memory for storing forms, fonts, and graphics.

You can operate the ZEBRA ZD220 printer in many different modes and media configurations:

• Direct thermal printing: Uses heat-sensitive media to print.

• Thermal transfer printing: Uses ribbon rolls where heat and pressure transfer ink from the ribbon to the media.

• Standard Tear-Off mode: Allows you to tear off each label/receipt or batch print a strip of labels and tear them off after printing is complete.

• Label Dispense Mode: If a factory optional dispenser is installed, the backing material is peeled away from the label as it is printed. After the label is removed, the next one is printed.

• Media Cutting: If a factory optional media cutter is installed, the printer can cut the label liner between labels, receipt paper, or tag stock.

• Stand-alone: The printer can print without being directly connected to a computer using an auto-running label format/form.

• Shared network printing: Printers configured with factory-installed Ethernet (LAN) and Wi-Fi interface options include an internal print server.

After unpacking your ZEBRA ZD220 printer, ensure you have all the following parts:

Included in the Box:

• Printer

• USB Cable

• Printer Documentation

• Power Supply

• Power Cord (varies by locale or region)

• Empty 74 Meter Starter Ribbon Core

Included with ZD230 Thermal Transfer Printer models:

• Empty Starter 300 Meter Ribbon Core

• Non-Zebra 300 Meter Ribbon Adapters

Not Included in the Box:

• Print Media (Labels, Paper, etc.)

• Transfer Ribbon

When you receive your ZEBRA ZD220 printer, immediately unpack it and inspect for shipping damage.

1. Save all packing materials.

2. Check all exterior surfaces for damage.

3. Open the printer and inspect the media compartment for damage to components.

If you discover shipping damage upon inspection:

• Immediately notify the shipping company and file a damage report.

• Keep all packaging material for shipping company inspection.

• Notify your authorized Zebra® reseller.

To Open: To access the media compartment, pull the release latches towards you and lift the cover. Check the media compartment for any loose or damaged components.

To Close: Lower the top cover. Press down in the middle of the cover in the front until the cover snaps closed.

ESD Caution: The discharge of electrostatic energy that accumulates on surfaces can damage or destroy the printhead and other electronic components. You must observe static-safe procedures when working with the printhead or the electronic components under the top cover.

The user interface on the ZEBRA ZD220 consists of a Power button, a multi-function FEED button, and a tri-color STATUS indicator.

1. Power Button: Turns power ON and OFF.

• Power ON: Press the Power button once for less than two seconds. The STATUS indicator will turn Amber during self-diagnostics, then turn solid GREEN when ready.

• Power OFF / Shutdown: Press and hold the button for 4-9 seconds.

2. STATUS Indicator: Provides printer health and operational status.

• Solid Green: Printer is ready for print and data activity.

• Flashing Green: Normal operation. Printer may be communicating or processing data.

• Double Flashing Green (2 short flashes followed by a long green): Printer is Paused.

• Flashing Red: Media Alert. The printer is out of media (ribbon, paper, labels, etc.), there is a media sensing failure, the printer cover is open, or there is a cut error.

• Flashing Amber: Over Temp. The printhead is over temperature and must cool down to resume printing.

• Flashing Red, Red, Green: Critical Over Temp. The printhead or motor has failed.

3. FEED (Advance) Button: A multi-function button.

• Feed One Label: Press and release before two seconds when not printing to advance one blank label.

• Reprint Last Label: Allows reprinting of a failed media print (activated via SGD or ZPL command).

• Pause Printing: Pressing the FEED button while printing will stop print activities and put the printer in a ‘Pause’ state.

• Resume Printing: Pressing the FEED button while in a Pause state will return the printer to normal operation.

The Power ON advanced modes are used for printer configuration and setup. To enter this mode, press and hold the FEED button when the ZEBRA ZD220 printer is ON and the STATUS Indicator is green. The printer will enter Advanced mode after two seconds. Observe the STATUS Indicator light pattern to select the desired mode:

• Printing a Configuration Report (One Single Flash):

The STATUS Indicator flashes once. If you release the FEED button at this point, a Configuration Report will print, and the printer will exit Advanced mode.

• Media Calibration (Two Flashes):

Continue holding the FEED button, and the STATUS Indicator will flash twice. If you release the FEED button here, the printer begins the Smart Cal routine to measure media and set the label sensing parameters, then exits Advanced mode.

• Reset Factory Defaults (Three Flashes):

Continue holding the FEED button, and the STATUS Indicator will flash three times. If you release the FEED button here, the printer resets to factory default settings and exits Advanced mode.

• Return to normal operating mode:

Release the FEED Button two or more seconds after the third flash sequence to return to normal operation without selecting a mode.

The Power OFF advanced modes on the ZEBRA ZD220 are used to update and troubleshoot the printer. First, load a roll of media for printing. Then, press and hold the FEED button while turning the printer ON.

• Forced Download Mode:

The STATUS Indicator will alternate between Amber and Red. If you release the FEED button at this point, the printer will begin waiting for data to start a firmware download. After the download, the printer may be configured to calibrate media and print a Configuration Report.

• Begin Normal Printer Bootup:

Continue to hold the FEED Button for three seconds until the STATUS Indicator turns Amber. Releasing the FEED button here will allow the printer to boot-up normally.

• Enter Data Diagnostics Mode:

Continue holding the FEED Button for three or more seconds. The printer will boot-up into Diagnostic (Hex Data Dump) mode. The FEED Button can be released at any time after the three seconds. The printer will print:

***********************

* Entering Diag Mode *

***********************

• Return to normal operating mode:

To exit Diagnostic Mode, release the FEED Button two or more seconds after leaving the mode, or hold the FEED button down for five or more seconds after the STATUS indicator turns green.

The hardware setup for your ZEBRA ZD220 involves the following steps:

1. Place the printer in a safe location with access to power and where you can connect interface cables or wirelessly to the system.

2. Attach the printer and power supply to a grounded AC power source.

3. Select and prepare media for your printer.

4. Load the media.

5. Turn the printer ON. Calibrate the media with a SmartCal Media calibration.

6. Print a ‘Configuration Report’ to verify basic printer operation.

7. Turn the printer OFF.

8. Choose a method to communicate via a wired or wireless connection to your printer (e.g., USB port, factory-installed Ethernet).

9. Attach the printer cable to the network or host system while the printer is OFF.

10. Begin the second phase of printer setup, which typically involves software and driver installation for your operating system.

To ensure optimal print operations, select a location for your ZEBRA ZD220 printer that meets these conditions:

• Surface: The surface must be solid, level, and of sufficient size and strength to hold the printer with media.

• Space: The area must provide enough space for opening the printer (for media access and cleaning) and for access to connectivity and power cords. Leave open space on all sides of the printer for proper ventilation and cooling. Do not place any padding or cushioning material under or around the base of the printer, as this restricts airflow and could cause overheating.

• Power: Place the printer close to an easily accessible power outlet.

• Data Communication Interfaces: Ensure that cabling and radio signals do not exceed the maximum distance specified by the communication protocol. Radio signal strength can be reduced by physical barriers like walls.

• Data Cables: Cables should not be routed with or near power cords, fluorescent lighting, transformers, microwave ovens, or other sources of electrical noise and interference.

• Operating Conditions:

– Operational Temperature: 40° to 105°F (5° to 41°C)

– Operational Humidity: 10 to 90% non-condensing

– Non-Operational Temperature: -40° to 140°F (-40° to 60°C)

– Non-Operational Humidity: 5 to 85% non-condensing

Follow these steps to safely attach power to your ZEBRA ZD220 printer. Never operate the printer and power supply in an area where they can get wet.

1. Plug the power supply into the printer’s DC power receptacle.

2. Insert the AC power cord into the power supply.

3. Plug the other end of the AC power cord into an appropriate AC electrical outlet. Note that the plug type may vary by region.

4. The active power light on the power supply will turn on green if power is on at the AC outlet.

Important: Ensure the appropriate power cord with a three (3) prong plug and an IEC 60320-C13 connector are used at all times. These power cords must bear the relevant certification mark of the country in which the product is being used.

Careful handling and storage of your media are important for maximizing print quality. If media becomes contaminated, it can damage the printer and cause defects in the printed image.

Preparing and Handling Media:

During manufacturing, packaging, handling, and storage, the outside length of a media roll may become dirty. It is recommended to remove the outside layer of the media roll or stack to prevent contaminants from being transferred to the printhead.

Media Storage Tips:

• Store media in a clean, dry, cool, dark area. Direct thermal media is heat-sensitive, so direct sunlight or heat sources may expose it.

• Do not store media with chemicals or cleaning products.

• Leave media in its protective packaging until it is ready to be put in the printer.

• Many media types and adhesives have a ‘shelf life’ or expiration date. Always use the oldest, viable media first.

This procedure works for Tear-Off, Label Dispense, and Media Cutting printer options on the ZEBRA ZD220. The printer supports continuous, marked, and label media types.

1. Open the printer. Pull the release latch levers toward the front of the printer.

2. Open the media roll holders. Orient the media roll so that its printing surface will face up as it passes over the platen (drive) roller. Pull the media guides open with your free hand, place the media roll on the roll holders, and release the guides. Verify the roll turns freely and does not sit in the bottom of the media compartment.

3. Pull the media so that it extends out of the front of the printer.

4. Push the media under both of the media guides.

5. Align the movable media sensor for your media type:

• For continuous roll receipt media or label media without black marks, align the media to the default center position.

• For black mark media, adjust the sensor position so it aligns with the center of the black mark. Avoid the center area of the media to use only black mark sensing.

6. For printers with the optional cutter, thread the media through the cutter’s media slot and pull it out the front of the printer.

7. Close the printer. Press down until the cover snaps closed.

You may need to calibrate your printer for the media. When reloading the same media, you can just press the FEED (Advance) button once to prepare the media for printing.

The ZEBRA ZD220 supports 74-meter and 300-meter genuine Zebra® ribbons. Always use a ribbon that is wider than the media to protect the printhead.

1. With the printer open, place an empty ribbon core on the printer’s take-up spindles (the top set). Push the right side of the empty core onto the spring-loaded spindle. Align the core with the center of the left side spindle’s hub and rotate it until the notches align and lock.

2. Place a new ribbon roll on the printer’s lower ribbon supply spindle. Push it onto the right spindle and lock the left side the same way as the take-up core.

3. Attach the ribbon to the take-up core. Use the adhesive strip on new rolls, or a thin strip of tape. Align the ribbon so it will be taken straight onto the core.

4. Turn the ribbon take-up hub (top moving toward the rear) to remove slack from the ribbon and align it with the supply roll.

5. Verify that the media is loaded and ready to print, then close the printer cover.

6. If the printer power is on, press the FEED button to advance about 20 cm (8 inches) of media to remove slack and ribbon wrinkle. Otherwise, wait to turn on the printer.

7. Change the print mode setting from direct thermal to thermal transfer using your printer driver, software, or programming commands. To verify the change, print a configuration label and check that ‘PRINT METHOD’ reads ‘THERMAL-TRANS’.

The ZEBRA ZD220 printer needs to set media parameters before printing for optimal operation. The printer will automatically determine the media type and measure its characteristics. After the initial calibration for a specific media, it is not required to perform additional calibrations each time the media is replaced, as the printer adjusts for small changes while printing.

SmartCal Procedure:

1. Make sure the media and ribbon (if applicable) are loaded properly in the printer and the top cover is closed.

2. Press the POWER button to turn the printer on.

3. Once the printer is in the Ready state (STATUS Indicator is solid green), press and hold the FEED button for two (2) seconds. The STATUS Indicator will flash once.

4. Continue to hold the FEED button until it has flashed a second time, then immediately release the FEED button.

5. The printer will measure a few labels and adjust media sensing levels.

6. When the printer stops, the STATUS indicator will turn solid green, indicating it is ready.

Before connecting the ZEBRA ZD220 printer to a computer, you should print a configuration report to ensure it is in proper working order. The information on this report is helpful for installation and troubleshooting.

1. Make sure the media and ribbon (if you are thermal transfer printing) are loaded properly in the printer and the top cover of the printer is closed.

2. Turn the printer ON.

3. Once the printer is in the ready state (STATUS indicator is solid green), press and hold the FEED button for approximately two (2) seconds. The STATUS Indicator will blink off once.

4. Release the FEED button.

5. The Printer and Network Configuration Reports will be printed.

6. When the printer stops, the STATUS Indicator will turn solid green.

If you cannot get these reports to print, refer to the troubleshooting section of the user guide.

When the ZEBRA ZD220 printer runs out of media, the STATUS Indicator will flash red to report a ‘Media Out’ condition. This is part of the normal media usage cycle.

To recover from a Media Out condition:

1. Open the printer.

2. Observe that the media is at the end of the roll, possibly with a label missing from the liner.

3. Remove the remaining media and the empty roll core.

4. Insert a new roll of media.

• If you are installing more of the same media, load the new roll and press the FEED (Advance) button once to resume printing.

• If you are loading different media (different size, vendor, or batch), you will need to reload the media and then perform a SmartCal calibration for optimal operation.

Important: If a label is missing from the middle of a roll, it will also cause a ‘Media Out’ condition. To recover, pull the media past the missing label until the next label is over the platen roller. Close the printer and press the FEED button once. The printer will resynchronize the label position and be ready to print.

When the ZEBRA ZD220 printer runs out of ribbon, it will report a ‘Ribbon Out’ condition with the STATUS Indicator flashing red. The printer detects the silvery reflector on the end of a Zebra brand ribbon roll.

To recover from a Ribbon Out condition:

1. Open the printer.

2. Observe that the reflective end-of-ribbon trailer is exposed on the underside of the supply roll and the take-up roll is full.

3. Remove the full take-up roll of used ribbon and dispose of it. Keep the now empty supply ribbon core.

4. Load a new ribbon roll onto the supply spindles and use the empty core from the previous roll on the take-up spindles.

5. Press the FEED (Advance) button once to resume printing.

The Ethernet connector on the ZEBRA ZD220 printer has two status/activity indicators that are partially visible at the connector. They indicate the following:

Use a print mode on your ZEBRA ZD220 that matches the media being used and the printer options available. The media path is the same for roll and fanfold media. The available print modes are:

• TEAR OFF: This is the default mode and can be used with any printer options and most media types. The printer prints label formats as it receives them, and the operator can tear off the printed labels at any time.

• PEEL: This mode is for the Label Dispenser Option only. The printer peels the label from the liner during printing and then pauses until the label is removed.

• CUTTER: This mode is for the Cutter Option only. The printer cuts between labels after each one is printed.

To set the printer to use an available print mode, you can use the ZPL Programmer’s manual for the ^MM command.

Adjusting the Print Quality

Print quality on the ZEBRA ZD220 is affected by the heat (density) setting of the printhead, the print speed, and the media in use. Experiment with these settings to find the optimal mix for your application.

The darkness (or density) setting can be controlled by:

• The Set Darkness (~SD) ZPL command.

• The Windows printer driver or application software.

• ZD230 only: Use the Print Rate (^PR) command to lower the print speed to 101.6 mm/sec (4 ips – default).

Adjusting the Print Width

The print width must be set before you use the printer for the first time and any time you change the width of the media in use.

Print width may be set by:

• The Windows printer driver or application software.

• Controlling printer operations with ZPL programming; refer to the Print Width (^PW) command.

Printing on fan-fold media with the ZEBRA ZD220 requires you to adjust the media guides stop position.

1. Open the top cover of the printer.

2. Adjust the media guide stop position with the Slide Lock (gray). Push the gray locking slide on the left-hand roll holder towards the back of the printer to lock the roll holder position. Pull it forward to release the lock.

3. Insert the media through the slot at the rear of the printer and place the media between the media guide and roll holders.

4. Close the top cover.

After printing or using the FEED button to advance several labels, if the media does not track down the center or the sides of the media are frayed, the media guide stop position may need further adjustment.

The label dispenser option on the ZEBRA ZD220 allows you to print a label and have the backing material automatically removed. When printing multiple labels, removing the dispensed label triggers the printer to print the next one.

1. Load your labels into the printer. Close the printer and press the FEED button until a minimum of 100 millimeters or 4 inches of exposed labels exit the printer. You can leave the labels on the liner.

2. Lift the liner over the top of the printer. Pull the gold latch in the center of the dispenser door away from the printer, and the door will open.

3. Insert the label liner between the dispenser door and the printer body.

4. Close the dispenser door while pulling the end of the label liner tight.

5. Press and release the FEED (Advance) button one or more times until a label is presented for removal.

6. During the print job, the printer will peel off the backing and present a single label. Take the label from the printer to allow the printer to print the next label.

Note: If you do not activate the label taken sensor with software commands, the printed labels will stack and may bind the mechanism.

To keep your ZEBRA ZD220 printer functional and printing high-quality labels, periodic maintenance is required. Use recommended cleaning supplies like printhead cleaning pens, 90% minimum pure Isopropyl Alcohol, fiber-free cleaning swabs, and a can of compressed air.

• Printhead:

– Interval: Clean after every 5 rolls of media printed.

• Platen (Drive) Roller:

– Interval: As needed to improve print quality. Platen rollers can slip, causing print image distortion.

• Media Path:

– Interval: Clean as needed.

– Method: Clean thoroughly with fiber-free cleaning swabs and cloths moistened with 90% isopropyl alcohol. Let alcohol evaporate completely.

• Interior:

– Interval: Clean as needed.

– Method: Use a soft cloth, brush, or compressed air to wipe or blow out dust. Use 90% isopropyl alcohol and a fiber-free cloth to dissolve contaminants like oils and grime.

• Exterior:

– Interval: Clean as needed.

– Method: Use a soft cloth, brush, or compressed air. The exterior can be cleaned with a cloth moistened with plain soap and water solutions. Use a minimum amount of solution to avoid getting it inside the printer.

• Label Dispenser Option:

– Interval: As needed to improve label dispensing operations.

• Cutter Option:

– Interval: This is not an operator-serviceable component. Do not clean inside the cutter opening or blade mechanism. Call a service technician.

Always use a new cleaning pen on the printhead, as an old pen can carry contaminants. The printhead becomes hot while printing; allow it to cool before cleaning.

1. If transfer ribbon is installed, remove it before proceeding.

2. Rub the cleaning pen across the dark area of the printhead. Clean from the middle to the outside. This will move adhesive transferred from the media edges to the outside of the media path.

3. Wait one minute before closing the printer or loading a ribbon to allow all components to dry.

The platen (drive roller) normally does not require cleaning, but if you experience poor performance, print quality, or media handling issues, it may need to be cleaned or replaced. Contaminants on the platen can damage the printhead or cause media to slip.

Removing the Platen Roller:

1. Open the cover and remove any media from the platen area.

2. Pull the platen bearing latch release tabs on the right and left sides towards the front of the printer and rotate them up.

3. Lift the platen out of the printer’s bottom frame.

4. Slide the gear and the two (2) bearings off the shaft of the platen roller.

Cleaning and Replacing the Platen Roller:

5. Cleaning Only: Clean the platen with a fiber-free swab lightly moistened with medical-grade alcohol (90% pure or better). Clean from the center out. Repeat if necessary to remove heavy adhesive build-up.

6. Discard the cleaning swabs after use; do not reuse.

7. Make sure the bearings and drive gear are back on the shaft of the platen roller.

8. Align the platen with the gear to the left and lower it into the printer’s bottom frame.

9. Rotate the platen bearing latch release tabs down on the right and left sides towards the rear of the printer and snap them into place.

10. Allow the printer to dry for one minute before closing the cover or loading labels.

The printer’s firmware may need to be updated periodically for new features and improvements. Use Zebra Setup Utilities (ZSU) to load new firmware.

1. Open Zebra Setup Utilities.

2. Select your installed ZEBRA ZD220 printer.

3. Click on the ‘Open Printer Tools’ button, and a ‘Tools’ window will open.

4. Click on the ‘Action’ tab.

5. Load the printer with media.

6. Click on the text line – ‘Send file’. The lower half of the window will show a filename and path with a Browse (…) button to select the latest firmware file you have downloaded.

7. Observe the user interface and wait. If the firmware version is different from the one installed on the printer, the firmware will download. The STATUS Indicator will flash green during the download. The printer will then restart and begin installing the firmware. When the update is complete, the STATUS Indicator will display solid Green. A printer Configuration Report is automatically printed, and the firmware update is complete.

A “Media Path” alert can indicate several issues on the ZEBRA ZD220 printer.

Printhead Open

This occurs when a print command or FEED button press happens while the printhead (cover) is not closed.

• Possible Cause: The cover is open or not closed properly.

• Resolution: Close the cover/printhead. Push down on the front top corners of the printer’s cover. You should hear and feel the cover latches snap into place.

Media Out

This occurs when the printer cannot detect media in the print path during a print job.

• Possible Cause 1: There is no media in the printer.

• Resolution: Load media into the printer and close the cover. You may need to press the FEED button to resume operation.

• Possible Cause 2: A missing label on the roll, used by manufacturers to identify the end of the roll.

• Resolution: Replace the empty media roll and continue printing. Do not power the printer off, or you will lose your print job.

• Possible Cause 3: The movable media sensor is misaligned.

• Resolution: Check the position of the movable media sensor. You may need to calibrate the media after adjusting it.

• Possible Cause 4: The printer is set for non-continuous media (labels), but continuous media is loaded.

• Resolution: Check that the media sensor is in the center default location. Recalibrate for the media if needed.

• Possible Cause 5: The media sensor is dirty.

• Resolution: Clean the Upper Web (Gap) Sensor Array and the lower Movable Media sensors. Reload media, adjust the sensor, and recalibrate.

Here is how to resolve “Ribbon Out” and “CUT ERROR” alerts on your ZEBRA ZD220 printer.

Ribbon Out

• Condition: The printer stops printing because it has detected the end of the ribbon, which has a reflective trailer.

• Resolution: Remove the used ribbon and replace the ribbon rolls in the printer without turning the printer OFF. Close the printer. You may need to press the FEED button or the PAUSE button to resume your print operation.

CUT ERROR

• Condition: The cutter blade is bound and not moving properly.

• Cause: Media, adhesive, or an external object has stopped the cutter blade from operating.

• Resolution: Turn the printer off by holding the POWER button down for 5 seconds. Wait for the printer to shut down completely, then turn it back on.

Cut Warning: There are no operator-serviceable parts in the cutter unit. Never remove the cutter cover (bezel) or attempt to insert objects or fingers into the cutter mechanism.

If the printed image on your ZEBRA ZD220 does not look right, consider the following causes and solutions:

• Possible Cause 1: Incorrect darkness level and/or print speed.

• Resolution: Adjust the printer’s Darkness setting.

• Possible Cause 2: The printhead is dirty.

• Resolution: Clean the printhead.

• Possible Cause 3: The platen roller is dirty or damaged.

• Resolution: Clean or replace the platen. Platens can wear out or get damaged.

• Possible Cause 4: For Thermal Transfer printing, the image looks fuzzy, has smudge marks, or has voids.

• Resolution: The print material (wax, wax-resin, or resin) may not match the media (paper, synthetic). Do not set the print speed higher than the maximum rated speed for your media/ribbon combination.

• Possible Cause 5: You may be using the wrong power supply.

• Resolution: Verify you are using the power supply that came with the printer.

• Possible Cause 6: The printhead has worn out.

• Resolution: Contact your Zebra partner or Zebra Tech Support for assistance.

Issue: Non-continuous labels act as Continuous labels.

This occurs when a non-continuous label format is sent to the printer, but it prints as if it were on continuous media.

• Possible Cause 1: The printer was not calibrated for the media being used.

• Possible Cause 2: The printer is configured for continuous media.

• Resolution: Set the printer for the correct media type (gap/notch, continuous, or mark) and calibrate the printer using the SmartCal Media Calibration procedure.

Issue: Printer Locks-Up

This occurs when all indicator lights are on and the printer locks up, either during operation or while restarting.

• Possible Cause: The printer memory has been corrupted by an unknown event.

• Resolution:

1. Reset the printer to factory defaults. You can do this via the FEED Button Modes – Power ON procedure or using the Zebra Setup Utility (Open Printer Tools > Action > Load printer defaults).

2. Reload the printer firmware.

3. If the printer does not recover, contact your Zebra partner or Zebra Tech Support for assistance.

Manual calibration is recommended whenever you are using pre-printed media or if the printer will not correctly auto-calibrate.

1. Make sure media is loaded. A common label size like 4 by 6 inches is good for this procedure.

2. Turn on the printer power.

3. Send the following command to the printer: ! U1 do “ezpl.manual_calibration” “”

4. The printer will set the media sensor for the label backing being used. After making this adjustment, the roll will automatically feed until a label is positioned at the printhead. A profile of the media sensor settings will then print. Upon completion, the printer will save the new settings in memory and will be ready for normal operation.

Thermal transfer media requires a ribbon for printing, while direct thermal media does not. To determine which type of media you have, perform a media scratch test.

1. Scratch the print surface of the media with a fingernail or a pen cap. Press firmly and quickly while dragging it across the media surface. This test uses friction heat to expose the chemically treated surface of direct thermal media.

2. Observe the result:

The general media and print specifications for the ZEBRA ZD220 are as follows:

• Media Width:

– Direct Thermal: Max. 108mm (4.25 inches)

– Thermal Transfer: Max. 112mm (4.41 inches)

– All Printers: Min. 15mm (0.59 inches)

• Media Length:

– Max: 990mm (39 inches)

– Min: 25.4mm (1.0 inch) for Tear Off, Peel, or Cutter

• Media Thickness:

– Min: 0.06mm (0.0024 inches)

– Max: 0.1905mm (0.0075 inches)

• Media Roll Outer Diameter (O.D.) max.: 127mm (5.0 inches)

• Media Roll Core Inner Diameter (I.D.):

– 12.7mm (0.5 inch) – Standard roll configuration

– 25.4mm (1 inch) – Standard roll configuration

– 38.1mm (1.5 inches) – with optional media roll adapter

• Ribbon Rolls – 74 meter:

– Length: 74 m (243 feet)

– Width Max: 110 mm (4.33 inches)

– Width Min: 33 mm (1.3 inches)

– Core I.D.: 12.7mm (0.5 inches)

• Ribbon Rolls – 300 meter:

– Length: 300 m (984 feet)

– Width Max: 110 mm (4.33 inches)

– Width Min: 33 mm (1.3 inches)

• Dot Pitch (203 dpi): 0.125mm (0.0049 inches)

• Barcode modulus x-dim (203 dpi): 0.005-0.050 inches