ZEBRA ZD230 (01) PDF Document

You can operate the ZEBRA ZD230 printer in several 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.

• Label Dispense Mode: If a factory optional dispenser is installed, the backing material is peeled away from the label as it is printed. After a 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 (programming based).

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

If you discover shipping damage upon inspection of your ZEBRA ZD230 printer, you should take the following steps:

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

2. Keep all packaging material for the shipping company’s inspection.

3. Notify your authorized Zebra reseller.

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.

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

The Power Button on your ZEBRA ZD230 turns the power ON and OFF.

• Power ON: Press the Power button once for less than two (2) seconds. The printer will turn on, and the STATUS Indicator light will turn on Amber while the printer performs self-diagnostics. The STATUS Indicator will then turn solid GREEN (or Flashing Green) when the printer is ready for normal operation.

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

The STATUS Indicator on the ZEBRA ZD230 printer provides information on the printer’s operational status:

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

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

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

The FEED button on the ZEBRA ZD230 is a multi-function button. When the printer is ON:

• Feed One Label: Pressing and releasing the FEED button before two (2) seconds will advance the media by one blank form/label length.

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

• Enter Advanced Modes: Pressing and holding the FEED button for more than two (2) seconds when the printer is ready (solid green STATUS light) initializes the Power ON FEED Button modes. You can then select a mode by observing the STATUS Indicator light flashes:

• One Flash – Printing a Configuration Report: Release the button after the first flash. A Configuration Report will print.

• Two Flashes – Media Calibration: Release the button after the second flash. The printer will calibrate for the installed media (Smart Cal routine).

• Three Flashes – Reset Factory Defaults: Release the button after the third flash. The printer will reset to its factory default settings.

The Power OFF advanced modes are used to update and troubleshoot the ZEBRA ZD230 printer. To enter these modes, 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 here, the printer will wait for data to begin a firmware download. After a successful download, the printer may calibrate and print a Configuration Report.

• Begin Normal Printer Bootup: Continue holding the FEED Button for three (3) seconds until the STATUS Indicator turns Amber. Releasing the FEED button here allows the printer to boot up normally.

• Enter Data Diagnostics Mode: Continue holding the FEED Button for three (3) or more seconds. The printer will boot up into Diagnostic (Hex Data Dump) mode and print “* Entering Diag Mode *”. You can release the button at any time after the three seconds.

To return to normal operating mode, release the FEED Button two (2) or more seconds after leaving the Data Diagnostic Mode, or simply hold the FEED button down for five (5) or more seconds after the STATUS indicator turns green.

The physical hardware setup for your ZEBRA ZD230 involves the following steps:

1. Place the printer in a safe location with access to power and connectivity.

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

3. Select and prepare the media for your printer.

4. Load the media.

5. Turn the printer ON and 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 your communication method (e.g., USB, Ethernet) and attach the appropriate cable to the network or host system while the printer is OFF.

9. Proceed to the software/driver setup phase for your operating system.

Select a location for your ZEBRA ZD230 printer that meets these conditions:

• Surface: The surface must be solid, level, and strong enough to hold the printer and media.

• Space: Allow enough space for opening the printer for media access and cleaning, and for access to power and data cords. Leave open space on all sides for proper ventilation and cooling.

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

• 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 attach power to your ZEBRA ZD230 printer:

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.

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

Careful handling and storage of your media is important to maximize print quality.

• Handling: During manufacturing, packaging, and storage, the outside layer of media can 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.

• Storage Tips:

• Store media in a clean, dry, cool, and 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.

• Use the oldest, non-expired media first, as many media types have a ‘shelf life’.

Follow these steps to load roll media into your ZEBRA ZD230:

1. Open the printer by pulling the release latch levers toward the front.

2. Open the media roll holders. Orient the media roll so its printing surface will face up as it passes over the platen (drive) roller. Place the media roll on the roll holders and release the guides. Ensure 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 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, avoiding the center area of the media.

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

After loading, you may need to calibrate the printer for the media.

Follow these steps to load a genuine Zebra thermal transfer ribbon:

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, then align and lock the notched left side onto the hub.

2. Place a new ribbon roll on the printer’s lower ribbon supply spindle in the same manner.

3. Attach the leader of the new ribbon to the empty take-up core using the adhesive strip or a thin piece of tape. Align the ribbon so it will be taken up straight onto the core.

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

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

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

7. Change the print mode setting from direct thermal to thermal transfer using your printer driver, application software, or programming commands.

A SmartCal calibration sets the media parameters for optimal operation. It is recommended after loading a new type of media.

1. Make sure the media (and ribbon, if used) are loaded properly and the top cover of the printer is closed.

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

3. Once the printer is in the Ready state (STATUS Indicator is solid green), press and hold the FEED button.

4. The STATUS indicator will flash. Continue to hold the FEED button until it has flashed a total of two times, then immediately release the FEED button.

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

6. When the printer stops, the STATUS indicator will turn solid green, indicating the calibration is complete.

Printing a configuration report helps verify that the printer is in proper working order before connecting it to a computer.

1. Make sure the media (and ribbon, if applicable) are loaded correctly and the printer cover 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 until the STATUS Indicator blinks once, then release it.

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

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

When the STATUS Indicator is flashing red for a ‘Media Out’ condition, follow these steps to recover:

1. Open the printer.

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

3. Insert a new roll of media.

• If you are using the same type of media, simply load the new media and press the FEED button once to resume printing.

• If you are loading a different type of media (different size, vendor, or batch), you must perform a SmartCal calibration after loading to ensure optimal operation.

If the ‘Media Out’ condition is caused by a missing label in the middle of a roll, 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 and be ready to print.

When the printer reports a ‘Ribbon Out’ condition (STATUS indicator flashing red), follow these steps:

1. Open the printer.

2. You will see a reflective trailer on the ribbon and the take-up roll will be full.

3. Remove the full take-up roll of used ribbon and dispose of it. Keep the now empty supply 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. Close the printer and press the FEED button once to resume printing.

For a local (wired) connection to a computer with a supported Windows Operating System, follow these general steps:

1. Download the Zebra Setup Utilities (ZSU) from the Zebra website.

2. Run the Zebra Setup Utilities from your Download directory.

3. Click on ‘Install New Printer’ and follow the install wizard.

4. Select ‘Install Printer’ and choose your ZD200 series model number from the list.

5. Select the USB port and connect the printer to the PC.

6. Turn the printer ON and configure printer communications for your interface type as prompted by the wizard.

7. Use the Windows driver to print a ‘Test Print’ to verify the operation.

You can verify the print system’s operation in several ways:

Test Printing with Zebra Setup Utility:

1. Open the Zebra Setup Utility.

2. Click on the newly installed printer’s icon to select it.

3. Click the ‘Open Printer Tools’ button.

4. In the ‘Print’ tab window, click on the ‘Print configuration label’ line and click the ‘Send’ button. The printer should print a configuration report.

Test Printing with Windows ‘Printers and Faxes’ menu:

1. Access the ‘Printers and Faxes’ or ‘Devices and Printers’ menu from the Windows Start menu or Control Panel.

2. Right-click on the newly installed printer’s icon and select ‘Printer Properties’.

3. From the printer’s ‘General’ tab, click the ‘Print Test Page’ button. The printer should print a Windows test print page.

If media (labels, ribbon, etc.) runs out while printing, leave the printer power on while reloading to avoid data loss. After you load a new roll of media or ribbon, press the FEED button to restart the print operation.

Print quality on the ZEBRA ZD230 is affected by the heat (darkness/density) setting, the print speed, and the media in use. The darkness (or density) setting can be controlled by:

• The Set Darkness (~SD) ZPL command.

• The Windows printer driver or an application software like ZebraDesigner.

• For the ZD230 model, you can also use the Print Rate (^PR) command to lower the print speed to 101.6 mm/sec (4 ips – default) for better quality on certain media.

Experiment with these settings to find the optimal mix for your application. You can verify the settings by printing a Printer Configuration label.

Printing on fan-fold media requires adjusting the media guides stop position.

1. Open the top cover of the printer.

2. Adjust the media guide stop position using the gray Slide Lock. Push the 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 fan-fold 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.

If the media does not track down the center, you may need further adjustment of the media guide stop position. For thin media, you can route it over the two roll holding pins on the media guide for better stability.

The label dispenser option (Peel-Off mode) automatically removes the backing material from your labels as they print.

1. Ensure your printer is configured for Peel-Off mode via the printer driver, Zebra Setup Utility, or by sending the appropriate ZPL commands (^XA ^MMP ^XZ or ^XA ^JUS ^XZ).

2. Load your labels into the printer. Close the printer and press the FEED button until a minimum of 4 inches (100 mm) of exposed labels exit the printer.

3. Lift the liner over the top of the printer. Pull the gold latch in the center of the dispenser door away from the printer to open the door.

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

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

6. Press the FEED button one or more times until a single label is presented for removal.

7. During a print job, the printer will peel and present a single label. Take the label from the printer to trigger the printing of the next label.

Printhead:

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

• Procedure: See “Cleaning the Printhead” instructions.

Platen (Drive) Roller:

• Interval: As needed to improve print quality.

• Procedure: See “Platen Cleaning and Replacement” instructions.

Media Path:

• Interval: Clean as needed.

• Method: Clean thoroughly with fiber-free cleaning swabs and cloths moistened with 90% isopropyl alcohol.

Interior:

• Interval: Clean the printer as needed.

• Method: Use a soft cloth, brush, or compressed air to remove dust. Use 90% isopropyl alcohol and a fiber-free cloth to dissolve oils and grime.

Exterior:

• Interval: Clean as needed.

• Method: Use a soft cloth moistened with a plain soap and water solution.

Label Dispenser Option:

• Interval: As needed to improve label dispensing operations.

Always use a new cleaning pen to avoid transferring contaminants. The printhead becomes hot during printing, so allow it to cool before cleaning.

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

2. Using a cleaning pen, rub the pen across the dark area of the printhead.

3. Clean from the middle to the outside. This moves any adhesive from the media edges away from the media path.

4. Wait one minute for the cleaning solvent to dry before closing the printer or loading a ribbon.

Media Path Cleaning:

1. Use a cleaning swab or lint-free cloth lightly moistened with 90% isopropyl alcohol.

2. Wipe the inside surfaces of the roll holders and the underside of the media guides.

3. Wipe the movable sensor slide channel (but not the sensor window itself). Move the sensor to access all areas of the channel.

4. Wait one minute before closing the printer.

Sensor Cleaning:

1. Gently brush away dust from the Movable Sensor’s window or use a can of compressed air. Do not use an air compressor.

2. If adhesive or other contaminants remain, use a swab moistened with alcohol to break them up.

3. Use a dry swab to remove any residue left from the first cleaning.

4. Repeat as needed until all residue is removed from the sensor.

Removing the Platen Roller:

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

2. Pull the platen bearing latch release tabs (on the right and left sides of the platen) toward 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 bearings off the shaft of the platen roller.

Cleaning and Reinstalling:

5. Clean the platen with a fiber-free swab moistened with 90% isopropyl alcohol. Clean from the center out. Repeat with a new swab if there is heavy adhesive buildup.

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

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

8. Rotate the platen bearing latch release tabs down and towards the rear of the printer to snap them into place.

9. Allow the printer to dry for one minute before closing the cover or loading media.

Use the Zebra Setup Utilities (ZSU) to load new firmware:

1. Open Zebra Setup Utilities.

2. Select your installed printer.

3. Click on the ‘Open Printer Tools’ button.

4. Click on the ‘Action’ tab.

5. Ensure the printer is loaded with media.

6. Click on the text line ‘Send file’. Use the Browse (…) button to select the latest firmware file you have downloaded.

7. Wait while the firmware downloads to the printer. The STATUS Indicator will flash green. The printer will then restart to install the firmware. When the update is complete, the STATUS Indicator will display solid Green, and a printer Configuration Report will automatically print.

A ‘Printhead Open’ alert means a print command was sent or the FEED button was pressed, but the printer has detected that 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 to lock the cover for printing.

A ‘Media Out’ alert occurs when the printer cannot detect media in the print path. Here are the common causes and solutions:

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

• Solution: Load media into the printer and close it. You may need to press the FEED button to resume.

• Cause 2: A label is missing from the liner at the end of the roll.

• Solution: This indicates the end of the roll. Replace the empty media roll with a new one to continue printing.

• Cause 3: The movable media sensor is misaligned.

• Solution: Check and adjust the position of the movable media sensor for your media type. You may need to run a SmartCal Media Calibration after adjusting it.

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

• Solution: Check that the media sensor is in the center default position and recalibrate the printer for the media.

• Cause 5: The media sensor is dirty.

• Solution: Clean the Upper Web (Gap) Sensor and the lower Movable Media sensor.

This alert means the printhead is over its normal operating temperature and has paused printing to allow it to cool down.

• Possible Cause 1: The printer is printing a large batch job with a high amount of print.

• Resolution: The print operation will resume automatically after the printhead has cooled.

• Possible Cause 2: The ambient temperature at the printer’s location is too high or it is in direct sunlight.

• Resolution: Move the printer to a cooler location or reduce the ambient temperature where it is operating.

If the printed image does not look right, consider these possible causes and solutions:

• Cause 1: The printer is set at an incorrect darkness level or print speed.

• Solution: Adjust the printer’s Darkness setting.

• Cause 2: The printhead is dirty.

• Solution: Clean the printhead.

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

• Solution: Clean or replace the platen roller.

• Cause 4 (Thermal Transfer only): The ribbon and media are mismatched, or the print speed is too high.

• Solution: Ensure the ribbon material (wax, wax-resin, resin) matches the media type (paper, synthetic). Do not set the print speed higher than the maximum rated speed for your media/ribbon combination.

• Cause 5: You are using the wrong power supply.

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

• Cause 6: The printhead is worn out.

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

If your labels are blank, check the following:

• Cause 1: If you are not using a ribbon (Direct Thermal printing), the media may not be direct thermal media. It might be thermal transfer media.

• Solution: Perform a media scratch test to determine the media type. If it is thermal transfer media, you must use a ribbon.

• Cause 2: Media has been loaded incorrectly.

• Solution: The printable surface of the media must face up towards the printhead. Reload the media correctly.

This issue (mis-registration) can be caused by several factors:

• Cause 1: Media has been loaded incorrectly or the movable media sensor is not set properly.

• Solution: Verify that the media is loaded correctly and that the movable sensor is positioned properly for your media type.

• Cause 2: The printer’s media sensors are not calibrated for your media’s length or physical properties.

• Solution: Run a SmartCal Media Calibration.

• Cause 3: The platen (drive) roller is slipping or damaged.

• Solution: Clean or replace the platen.

If data was transferred but no printing occurs, check these possibilities:

• Cause 1: The prefix and delimiter characters set in the printer do not match those in the label format.

• Solution: Verify the ZPL programming’s prefix (COMMAND CHAR) and delimiter (DELIM./CHAR) characters. You can check the printer’s current settings on a Configuration Report.

• Cause 2: Incorrect data is being sent to the printer.

• Solution: Check the label format for correct syntax and commands. Refer to the ZPL Programmer’s Manual for details on printer programming.

If printer parameters are set incorrectly or seem to be ignored, consider these causes:

• Cause 1: Printer settings were changed without being saved.

• Solution: The ZPL `^JU` command was not used to save your configuration before turning the printer off. Send the `^JU` command to save settings permanently.

• Cause 2: The label format contains commands with syntax errors or that have been used incorrectly.

• Solution: Review the ZPL programmer’s guide to verify command usage and syntax in your label format.

• Cause 3: The prefix and delimiter characters set in the printer do not match the ones in the label format.

• Solution: Verify the ZPL programming settings for Control, Command, and Delimiter characters are correct for your software environment by printing a Configuration Report.

• Cause 4: The main logic board may be failing or firmware is corrupted.

• Solution: First, try resetting the printer to factory defaults. If that fails, try reloading the printer firmware.

If all indicator lights are on and the printer locks up (either during operation or while restarting), the printer memory has likely been corrupted.

Resolution:

1. Reset the printer to factory defaults. You can do this using the FEED Button Mode (three flash sequence) or via the Zebra Setup Utility.

2. If the issue persists, 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 when using pre-printed media or if the printer does not auto-calibrate correctly.

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

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. After this adjustment, the media roll will automatically feed until a label is positioned at the printhead. A profile of the media sensor settings will then print. The new settings are saved, and the printer is ready for normal operation.

If you are having trouble transferring data, you can put the printer in communications diagnostics mode to print the ASCII characters and their hexadecimal values for any data it receives.

To enter the mode:

Press and hold the FEED button while turning the printer ON. Continue holding the button for three or more seconds until the printer boots up into Diagnostic Mode and prints “* Entering Diag Mode *”.

To exit the mode:

Turn the printer OFF and then back ON. Alternatively, press the FEED button repeatedly to clear the command buffer until the printer prints ‘Out of Diagnostic mode’ on the label.

You can perform a simple media scratch test to determine if a ribbon is required for printing.

1. Scratch the print surface of the media with your fingernail or a pen cap. Press firmly and drag it quickly across the surface.

2. Observe the result:

• If a black mark appears on the media, it is Direct Thermal. No ribbon is required.

• If a black mark does not appear, it is Thermal Transfer. A ribbon is required.