ZD411T

Desktop Printer

User Guide
Link-OS®

P1128298-02EN Rev A
 Copyright

2025/02/11
ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corporation, registered in many
jurisdictions worldwide. All other trademarks are the property of their respective owners. ©2025 Zebra
Technologies Corporation and/or its affiliates. All rights reserved.
Information in this document is subject to change without notice. The software described in this document
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only in accordance with the terms of those agreements.
For further information regarding legal and proprietary statements, please go to:
SOFTWARE: zebra.com/informationpolicy.
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WARRANTY: zebra.com/warranty.
END USER LICENSE AGREEMENT: zebra.com/eula.

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

Product Improvements
Continuous improvement of products is a policy of Zebra Technologies. All specifications and designs are
subject to change without notice.

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

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

About this Guide.............................................................................................................................................. 9

Finding ZD411T Printer References.................................................................................................... 9
Icon Conventions................................................................................................................................... 10

Introducing the ZD411T.................................................................................................................................. 11

Introduction to the Zebra ZD411T....................................................................................................... 11
Zebra Label Printing Solution..............................................................................................................11
Modes of Operation...................................................................................................................... 12
Common Link-OS Desktop Series Printer Features.....................................................................12
Link-OS Desktop Printer Options...................................................................................................... 14
What’s in the Zebra ZD411T Box?..................................................................................................... 15
Unpacking and Inspecting the Printer............................................................................................. 16
Opening the Printer...............................................................................................................................16
Closing the Printer.................................................................................................................................18

ZD411T Features............................................................................................................................................ 20
Label Dispenser Option...................................................................................................................... 23
Cutter Option......................................................................................................................................... 25
Attached Battery and Base Option.................................................................................................. 26
Zebra Print Touch.................................................................................................................................28

Controls and Indicators................................................................................................................................ 30

User Interface.........................................................................................................................................30
ZD411T Standard Interface Controls................................................................................................. 31

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Meaning of the Indicator Light Patterns................................................................................. 34

Battery Indicators and Controls................................................................................................ 36

Installing Hardware Options........................................................................................................................ 39

Field Installable ZD411T Accessories and Options...................................................................... 39
Printer Connectivity Modules............................................................................................................ 40
Power Failure Recovery Mode Jumper (OFF by Default)..........................................................40
Configuring Wired Connectivity Options and Power Failure Recovery Mode...................... 41
Installing the Wireless Connectivity Module..................................................................................47
Media Handling Options.....................................................................................................................50
Installing Dispense, Cut, and Tear Media Handling Options.....................................................51
Media Roll Core Size Adapters........................................................................................................ 55
Installing the Attached Battery Base Options...............................................................................58
Installing the Battery into the Attached Power Base..................................................................59

ZD411T Printer Setup..................................................................................................................................... 61

ZD411T Printer Setup Overview......................................................................................................... 61
Pre-installing the Window's Driver........................................................................................... 62
Select a Location for the Printer.............................................................................................. 64
Pre-Install Printer Options and Connectivity Modules........................................................ 65
Attaching Printer Power.............................................................................................................. 65
Getting Ready to Print................................................................................................................. 67
Preparing and Handling Labels and Media........................................................................... 67
Media Storage Tips...................................................................................................................... 67
Loading Roll Media in the ZD411T Printer..............................................................................68
How to Load Roll Media – ZD411T...........................................................................................69
Using the Movable Sensor......................................................................................................... 76
Adjusting the Movable Sensor for Black Marks or Notches..............................................77
Adjusting the Movable Sensor for Web/Gap Sensing........................................................ 78
How to Load Roll Media - Continued..................................................................................... 80
Using Thermal Transfer Ribbon in the Printer....................................................................... 81
Loading Zebra Transfer Ribbon – ZD411T............................................................................. 82
Run a SmartCal Media Calibration...........................................................................................85

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Print a Configuration Report to Test Printing........................................................................ 87

Detecting a Media Out Condition............................................................................................ 88
Detecting a Ribbon Out Condition.......................................................................................... 89
Connecting to the Printer............................................................................................................ 91
Pre-install Windows Printer Drivers...........................................................................................91
Interface Cable Requirements....................................................................................................91
USB Interface (Device)................................................................................................................. 93
Serial Interface............................................................................................................................... 94
Ethernet (LAN, RJ-45).................................................................................................................. 95
Running the Printer Installation Wizard.................................................................................. 96

Setup for Windows....................................................................................................................................... 101

Zebra Setup Utility: Pre-install Windows Printer Drivers........................................................... 101
Windows to Printer Communication Setup (Overview).............................................................102
Setting Up the Wi-Fi Print Server Option..................................................................................... 102
Using a Configuration Script............................................................................................................102
Saving a Configuration Script.......................................................................................................... 103
Bluetooth Option Configuration...................................................................................................... 103
Windows 10 (PC version)...........................................................................................................105
After the Printer is Connected........................................................................................................ 108
Testing Communications by Printing..................................................................................... 109

Print Operations............................................................................................................................................ 110

Thermal Printing Basic Setting and Operations...........................................................................110
Determining the Printer’s Configuration Settings................................................................110
Sending Files to the Printer...................................................................................................... 110
Select a Print Mode for Media Handling.................................................................................111
Adjusting the Print Quality.......................................................................................................... 111
Adjusting the Print Width............................................................................................................ 111
Replacing Supplies while Using the Printer..........................................................................112
Printing on Fan-Fold Media............................................................................................................... 112
Using the Label Dispenser Option..................................................................................................114
Printing with Externally Mounted Roll Media................................................................................ 117

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Printing with the Attached Battery Base and Battery Option...................................................118

Printer Fonts...........................................................................................................................................118
Zebra Keyboard Display Unit (ZKDU) – Printer Accessory......................................................120
Zebra Basic Interpreter (ZBI) 2.0.................................................................................................... 120
Setting the Power Failure Recovery Mode Jumper................................................................... 121

Maintaining the Printer............................................................................................................................... 122

Cleaning Supplies............................................................................................................................... 122
Recommended Cleaning Schedule................................................................................................123
Cleaning the ZD411T Printhead....................................................................................................... 124
Media Path Cleaning.......................................................................................................................... 125
Cleaning the Cutter Option.............................................................................................................. 126
Cleaning the Label Dispenser Option........................................................................................... 127
Sensor Cleaning.................................................................................................................................. 128
Platen Cleaning and Replacement.................................................................................................130
Replacing the ZD411T Printhead..................................................................................................... 134
Updating Printer Firmware................................................................................................................143
Other Printer Maintenance................................................................................................................144

Troubleshooting............................................................................................................................................145
Resolving Alerts and Errors..............................................................................................................145
Alert: Printhead/Cover Open.................................................................................................... 145
Alert: Media/Labels Out............................................................................................................. 145
Alert: Cut Error..............................................................................................................................147
Alert: Printhead Over Temperature........................................................................................ 147
Alert: Printhead Under Temperature......................................................................................148
Alert: PRINTHEAD SHUTDOWN.............................................................................................. 148
Alert: Out Of Memory.................................................................................................................149
Resolving Print Issues........................................................................................................................ 149
Issue: General Print Quality Issues.........................................................................................149
Issue: No Print on the Label..................................................................................................... 151
Issue: Print Image Moves or is Distorted...............................................................................151
Communication Issues....................................................................................................................... 152

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Issue: USB Printer Fails to Install after Connecting Printer (Before Installing the
Printer Driver)...........................................................................................................................152
Issue: Label Job Sent, No Data Transfer..............................................................................153
Issue: Label Job Sent, Skips Labels or Prints Bad Content.............................................153
Issue: Label Job Sent, Data Transfers, But No Print..........................................................154
Miscellaneous Issues..........................................................................................................................154
Issue: Settings are Lost or Ignored........................................................................................ 154
Issue: Non-continuous Labels act as Continuous Labels.................................................155
Issue: Printer Locks-Up.............................................................................................................. 155
Issue: Battery has a Red Indicator..........................................................................................156

Onboard Printer Tools................................................................................................................................. 157

Printer Diagnostics.............................................................................................................................. 157
SmartCal Media Calibration.............................................................................................................. 157
Printing a Configuration Report (CANCEL Self Test).................................................................158
Printer Network (and Bluetooth) Configuration Report.............................................................159
Resetting Printer Factory Defaults (PAUSE + FEED Self Test)................................................ 159
Resetting Network Factory Defaults (PAUSE + CANCEL Self Test).......................................159
Generating a Print Quality Report (FEED self-test).................................................................... 159
Activating Advanced Mode............................................................................................................... 161
Manual Media Calibration Mode............................................................................................. 162
Using the Manual Print Width Adjustment........................................................................... 162
Adjusting the Darkness with Manual Print Darkness........................................................ 163
Factory Test Modes............................................................................................................................165
Using the Reset Button..................................................................................................................... 165
Running a Communication Diagnostics Test...............................................................................166
Sensor Profile Report......................................................................................................................... 167

Interface Information................................................................................................................................... 169

Universal Serial Bus (USB) Interface..............................................................................................169
Serial Port Interface............................................................................................................................ 170

Types of Thermal Media............................................................................................................................. 173

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Determining Thermal Media Types................................................................................................ 173

General Media and Print Specifications........................................................................................174
Various Types of Roll and Fan-Fold Media..................................................................................176

ZD411T Printer Dimensions.........................................................................................................................179

ZD411T Thermal Transfer Printer Dimensions............................................................................. 180

ZPL Configuration........................................................................................................................................ 185

Managing the ZPL Printer Configuration...................................................................................... 185
ZPL Print Configuration File Format...............................................................................................185
Configuration Setting to Command Cross-Reference.............................................................. 186
Printer Memory Management and Related Status Reports.....................................................190
ZPL Programming for Memory Management....................................................................... 191

8
About this Guide
About this Guide

This guide is for operators and integrators of Zebra ZD411T Link-OS desktop thermal printers. Use this
guide to install, change the configuration, operate, and support these printers.

Finding ZD411T Printer References

Information, support, and additional resources are available online to support this printer:
• ZD411T Thermal Transfer printer – https//www.zebra.com/zd411t-info

Printer Resources
Zebra has a large suite of technical resources for your Zebra Link-OS printer, as well as free and fee-based
software and apps (applications), including:
• How-To videos
• Printer accessory, supplies, parts, and software links
• Label Design software
• Printer Drivers (Windows, Apple, OPOS, etc.)
• Printer Firmware
• Printer Management tools
• Virtual Devices for legacy languages normally associated with other printer brands
• Various setup and configuration guides
• Cloud-based Enterprise printer management and printing
• XML and PDF format file printing
• Programmer’s manuals
• Printer Fonts
• Utilities
• Knowledge base and support contacts
• Printer warranty and repair links

Zebra OneCare Printer Service and Support

For increased productivity, we can help your business ensure its Zebra printers are Online and ready for
business. Refer to the descriptions of the Zebra OneCare service and support options available for the
printer at zebra.com/zebraonecare.

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 About this Guide

Icon Conventions
The documentation set is designed to give the reader more visual clues. The following graphic icons are
used throughout the documentation set. These icons and their associated meanings are described below.

NOTE: The text here indicates information that is supplemental for the user to know and that is
not required to complete a task.

IMPORTANT: The text here indicates information that is important for the user to know.

CAUTION—EYE INJURY: Wear protective eyewear when performing certain tasks such as
cleaning the inside of a printer.

CAUTION—EYE INJURY: Wear protective eyewear when performing certain tasks such as
installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons. These parts are
under tension and could fly off.

CAUTION—PRODUCT DAMAGE: If the precaution is not taken, the product could be damaged.

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

CAUTION—HOT SURFACE: Touching this area could result in burns.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.

CAUTION—ELECTRIC SHOCK: Turn off (O) the device and disconnect it from the power source
before performing this task or task step to avoid the risk of electric shock.

WARNING: If danger is not avoided, the user CAN be seriously injured or killed.

DANGER: If danger is not avoided, the user WILL be seriously injured or killed.

10
Introducing the ZD411T
Introducing the ZD411T

This section introduces the Zebra ZD411T Link-OS 2-inch desktop thermal label printer. It has an overview
of the Link-OS printer’s features and options, and what ships with your new printer.
https://www.zebra.com/zd411t-info

Introduction to the Zebra ZD411T

This Zebra Link-OS 2-inch Desktop printer offerings include:
• Direct thermal and thermal transfer printing
• Standard Print Resolution – 8 dots per millimeter (203 dots per inch)
• Prints at speeds up to 203 millimeters per second (8 inches per second)
• Print width is 56 mm (2.20 in.)
• Higher Resolution Option – 12 dots per millimeter (300 dots per inch)
• Prints at speeds up to 152.4 millimeters per second (6 inches per second)
• Print width is 56 mm (2.20 in.)
• Thermal Transfer Printing – Includes a 74 m ribbon roll system
• Non-Zebra 300 m Ribbon Roll Adapters

NOTE: Maximum print speeds vary by model, print resolution, and the type of media in use.

Zebra Label Printing Solution

The large set of Zebra printer capabilities and resources provide the ability to print unconnected or as a
part of a larger print system.
The printer is just one of three parts of a printing solution. To print; you need your Zebra printer, compatible
labels (and ribbon if used with thermal transfer labels), and software (such as the driver, mobile apps,
programming, and more) to tell the printer what to do and print.
Use Zebra's free label and form design software, ZebraDesigner, to make professionally looking label
designs and print them.
Zebra provides a complete suite of free Link-OS software: mobile and personal computer applications,
drivers, set up utilities, monitor and control printing, import graphics and fonts, send programming

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 Introducing the ZD411T

commands, update firmware, and download files. The Link-OS suite has emulation for a wide variety of
other printer control languages via Link-OS Virtual Devices and includes a free PDF Direct emulation app.
The Zebra website or your reseller will be able to help you identify media for your desired use case.

Modes of Operation
The printer has many operating configurations and hardware options. Here is a partial list of some of the
operating modes that this versatile printer can do.
• Direct thermal printing (which uses heat-sensitive media to print).
• Standard Tear-Off mode allows you to tear off each label/receipt or batch print a strip of labels and tear
them off after it is printed.
• Label Dispense Mode: If an optional dispenser is installed, the backing material can be peeled away
from the label as it is printed. After this label is removed, the next one is printed.
• Media Cutting: If an optional media cutter is installed, the printer can cut the label liner between labels,
receipt paper, or tag stock.
• Linerless media printing with Cut or Tear-Off label options for easy pick and place label applications.
• Internet of Things (IoT) data tools (Savanna)
• Stand-alone: The printer can print without being directly connected to a computer.
• A printer with the Color Touch Display option can use menus to access and print a label format/form.
• A Link-OS App connecting via Bluetooth (Wireless option).
• An auto-running label format/form (programming based).
• A data input device connected to the printer's USB Host port or serial port. This accommodates data
input devices, such as scanners, weigh scales, keyboards, etc.
• Use the printer with an Attached Battery option and wireless communication via mobile
configuration apps or the desktop computer (apps, drivers, and programs).
• Shared network printing: Printers configured with Ethernet (LAN) and Wi-Fi interface options include an
internal print server.

Common Link-OS Desktop Series Printer Features

Zebra Link-OS Desktop printers share a common feature set. Here are some common platform features:
• OpenAccess design for simplified media loading.
• Zebra’s Link-OS Software, Apps, and SDK's–an open platform that connects operating systems for
smart Link-OS Zebra devices with powerful software apps (applications), making the devices easy to
integrate, manage, and maintain from any location.
• The Link-OS suite has emulation for a wide variety of other printer control languages via Link-OS
Virtual Devices and includes a free PDF Direct emulation app.
• Color-coded touchpoints for operator controls and media guides.
• Enhanced user interface featuring three buttons and five status indicators.
• Easy, field-installable media handling options.

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 Introducing the ZD411T

• Media roll support:

• Outer Diameter: Up to 127 mm (5 in.)
• Inner Diameter: 12.7 mm (0.5 in.), 25.4 mm (1 in.), and additional core sizes with optional media core
adapters.
• Moveable Sensor provides compatibility with the widest range of media types:
• Outer Diameter: Up to 127 mm (5 in.)
• Compatible with notched or slotted media.
• Multi-center position transmissivity sensor for use with label gap/web media.
• USB Host Port that can be used for easy firmware updates.
• USB 2.0 interface
• Modular Connectivity Slot for field installable 10/100 Ethernet (802.3 RJ-45) and Serial (RS-232 DB-9)
interface options.
• On-the-fly OpenType and TrueType font scaling and import, Unicode, resident scalable font (Swiss 721
Latin 1 font), and a selection of resident bitmap fonts.
• Backward compatibility focused technology eases printer replacement:
• Drop-in replacement of legacy Zebra desktop printers. The printer accepts both EPL and ZPL
programming languages.
• Supports Link-OS virtual devices to interpret non-Zebra printer programming languages.
• XML-Enabled printing – allows XML communications for barcode label printing, eliminating license fees
and print server hardware, and lowering customization and programming costs.
• Zebra Global Printing Solution supports:
• Microsoft Windows keyboard encoding (and ANSI)
• Unicode UTF-8 and UTF 16 (Unicode Transformation Formats)
• XML
• ASCII (7- and 8-bit used by legacy programs and systems)
• Basic single and double-byte font encoding
• JIS and Shift-JIS (Japanese International Standards)
• Hexadecimal encoding
• Custom character mapping (DAT table creation, font linking, and character remapping)
• The printer supports configuration via a setup utility running on mobile devices.
• Use the printer’s optional Bluetooth Low Energy (LE) feature for short-range communication to a
variety of mobile devices. Bluetooth LE works with Zebra mobile setup utility applications to assist in
the printer setup, perform media calibration, and maximize print quality.
• Zebra’s Print Touch (Near Field Communication - NFC) tap to pair devices, access printer
information, and access mobile applications.
• An On-board Real-Time Clock (RTC).
• Printhead maintenance reporting is enabled and customizable by the user.
• Easy tool-less replacement of printhead and platen (driver) roller.
• A minimum of 64 MB of internal printer memory for storing forms, fonts, and graphics.

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 Introducing the ZD411T

See Also
zebra.com/linkos

Link-OS Desktop Printer Options

The printer can be ordered with a wide variety of factory-installed options. Other options are field upgrade
kits.
• Wired and Wireless options (factory installed or field upgrade-able):
• Bluetooth Low Energy (LE) wireless connectivity.
• Wi-Fi (802.11ac – includes a/b/g/n), Bluetooth 4.2 (4.1 compatible), and Bluetooth Low Energy (LE) 5.0
wireless connectivity.
• Wi-Fi (802.11ax – includes a/b/g/n), Bluetooth 5.3, and Bluetooth Low Energy (LE) 5.3 wireless
connectivity.
• Internal Ethernet Print Server (LAN, RJ-45 connector) – supports 10Base-T, 100Base-TX, and fast
Ethernet 10/100 auto-switching networks for wired connectivity.
• Modular Connectivity Slot for field installable 10/100 Ethernet (802.3 RJ-45) and Serial (RS-232 DB-9)
interface options.
• Internal Ethernet Print Server (LAN, RJ-45 connector) – supports 10Base-T, 100Base-TX, and fast
Ethernet 10/100 auto-switching networks.
• Serial (RS-232 DB-9) Port
• Media handling options (field-installable):
• Label Dispenser (Peel-Off liner and present the label to the operator)
• General-purpose media cutter
• Media Core Adapter kits include adapters for media rolls with outer diameters up to 127 mm (5 in.):
• 38.1 mm (1.5 in.) inner diameter media cores
• 50.8 mm (2.0 in.) inner diameter media cores
• 76.2 (3.0 in.) inner diameter media cores
• Attached Battery Base with a removable battery
• The Attached Battery Base and battery are sold separately
• The battery is designed to provide constant regulated power for consistent print quality (darkness-
contrast).
• Includes a Shutdown Mode for shipping and storage
• Includes battery charge and status indicators built into the battery
• USB Host Port that can be used for easy firmware updates.
• USB 2.0 interface
• Asian language support with printer configuration options for the large Simplified and Traditional
Chinese, Japanese, or Korean character sets.
• Zebra ZBI 2.0 (Zebra BASIC Interpreter) programming language. ZBI allows you to create custom printer
operations that can automate processes and use peripherals (for example, scanners, scales, keyboards,
Zebra ZKDU, etc.) all without being attached to a PC or network.

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 Introducing the ZD411T

What’s in the Zebra ZD411T Box?

The printer typically ships with the following items.

Included

Printer USB Cable

Printer Documentation Power Supply

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 Introducing the ZD411T

Power Cord Ribbon Roll Core

Not Included
Desktop Media - Labels, Ribbons, etc.

Unpacking and Inspecting the Printer

Tips for inspecting and verifying the printer items.
When you receive the printer, immediately unpack it and inspect it for shipping damage.
• Save all packing materials.
• Check all exterior surfaces for damage.
• Open the printer and inspect the media compartment for damage to components.
If you discover shipping damage upon inspection:
• Immediately notify the shipping company and file a damage report. Zebra Technologies Corporation is
not responsible for any damage to the printer incurred during shipment, and will not cover the repair of
this damage under its warranty policy.
• Keep all packaging material for shipping company inspection.
• Notify your authorized Zebra reseller.

Opening the Printer

Accessing the printer's media compartment.

CAUTION—ESD: The discharge of electrostatic energy that accumulates on the surface of

the human body or other surfaces can damage or destroy the printhead and other electronic
components used in this device. You must observe static-safe procedures when working with the
printhead or the electronic components under the top cover.
Open the printer to view and access the label compartment.

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 Introducing the ZD411T

1. Open the printer by pulling the two printer release latches on both sides of the printer.

2. Lift up the cover when the latch releases. Remove any loose test labels in the label compartment.

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 Introducing the ZD411T

3. Inspect for any loose or damaged parts within the printer.

Closing the Printer

Close the printer after accessing the label compartment to protect the printer.
1. If labels are loaded in the printer, verify that the labels completely cover the platen roller at the front of
the printer.

NOTE: If the printer is not in use, it is recommended that a label (1) be placed over the whole
platen roller and closed to prevent the printhead from sticking to the platen roller. Do this for
shipping and storage.

2. Gently lower the cover.

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 Introducing the ZD411T

3. Push down on the front of the printer to close. Push the center or both corners of the printer firmly until
both sides of the latches lock.

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ZD411T Features
ZD411T Features

This section identifies features of the Zebra ZD411T Link-OS 2-inch desktop thermal label printer. There is
also a How-To Features video on the Zebra Web site.
The printer Support page and videos are found here:
https://www.zebra.com/zd411t-info

Figure 1 External Features - Front View

1 Release latch (one on each side)

2 User Interface

For more details on printer controls, see Controls and Indicators on page 30.

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 ZD411T Features

Figure 2 External Printer Features - Rear View

1 Release latch
2 DC power receptacle
3 Interface and connectivity module slot access
4 Fanfold media entry slot
5 Power button

Figure 3 Features Inside the Printer

4
5

4
7

1 Printhead
2 Upper web (gap) array sensor (on the other side)
3 Roll holders
4 Media guides
5 Media guide/roll stop adjustment
6 Movable sensor (black mark and lower web/gap)

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 ZD411T Features

7 Platen Drive Roller

8 Head-Up Sensor (inside)
9 Ribbon Drive Carriage

Figure 4 Ribbon Chassis–Ribbon Roll Holders

1 1

2
2

1 Take-up spindle (starts with empty roll)

2 Supply spindles (starts with full roll)

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 ZD411T Features

Label Dispenser Option

The Label Dispenser option is a common 2-inch Link-OS printer upgrade kit for the printer family.

Figure 5 Label Dispenser Closed

2
1

1 Door Latch
2 Label Taken Sensor

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 ZD411T Features

Figure 6 Label Dispenser Open

1 4

2
3

1 Label Peel Bar

2 Peel Roller
3 Dispenser Door
4 Label liner exit path

See Also
Installing Dispense, Cut, and Tear Media Handling Options

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 ZD411T Features

Cutter Option
The Cutter option is a common 2-inch Link-OS printer upgrade kit for the printer family.

Figure 7 Cutter

2
1

1 Media Exit Slot

2 Cutter Module

See Also
Installing Dispense, Cut, and Tear Media Handling Options

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 ZD411T Features

Attached Battery and Base Option

The Attached Battery and Base option is a common Link-OS printer upgrade kit for the printer family.

Table 1 Printer with Battery Base and Battery

1
2

1 – Battery Power Base 3 – Battery

2 – Battery Status and Charge Indicators 4 – Power Interface

Table 2 Inserting the Battery

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 ZD411T Features

Table 2 Inserting the Battery (Continued)

1 – Battery Latch 2 – Battery Control Button

NOTE: The battery can be charged, checked, and configured for storage without the printer. A
printer power supply or other approved Zebra power source is needed to charge the battery.

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 ZD411T Features

Zebra Print Touch

With the Zebra Print Touch feature, you can use a Near Field Communication (NFC)-enabled device such
as a smartphone or tablet to scan the Print Touch logo and pair the device to the printer.
Print Touch is available on models with a factory-installed low-power Bluetooth. This capability enables
you to use your device to provide information for which you are prompted and then print a label using that
information.

NOTE: Some mobile devices may not support NFC communication with the printer until you
configure the required NFC settings in your device. If you encounter difficulties, consult your
service provider or your smart device manufacturer for more information.

Figure 8 Zebra Print Touch NFC Reader Activation Location

Data Included in the Encoded NFC Tag

• A URL for a Zebra QuickHelp style support web page
• The printer's Bluetooth Low Energy MAC address
• The printer's Bluetooth Classic MAC address (if present)
• The printer's Wi-Fi (WLAN) MAC address (if present)
• The printer's Ethernet (LAN) MAC address (if present)
• The printer SKU – example ZD42122-D01W01EZ

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 ZD411T Features

• The printer's serial number

Uses for the Print Touch feature (NFC tag)

• Facilitate Bluetooth pairing with a compatible mobile device
• Launch an application
• Launch a mobile browser to a web page

29
Controls and Indicators
Controls and Indicators

This section discusses user controls and their functionality.

User Interface
The primary user controls are found on the front of the printer.

Standard User Interface

• This interface provides the basic control and status needed by an operator. The printer operating
status is reported by five icon status indicator lights. The icons represent several functional areas of
operation. The indicator lights, as a group, provide a wide range of printer status notifications when
used in combination. They are visible from a greater distance than you can read on a printer with a
display. See the Meaning of the Indicator Light Patterns on page 34.
• This interface supports operator tasks of replacing printing supplies (labels, receipt paper, transfer
ribbon, etc.) when prompted by two indicators.
• Status indicator icons represent a functional area of printer operation.
• Status indicator lights typically use color to show the operator the functional status of the printer.
The status indicator lights may be off (not lit), red, green, or amber (orange/yellow). Red is Needs
Attention or Not Ready. Green is for Ready or Functioning. Amber (orange/yellow) is for a busy
or active process (data downloading, over-temperature cooling cycle, etc.). An off or un-lit status
indicator does not require the operator's attention.
• A status indicator can flash (blink), fade (bright to off), alternate between colors, or remain on in a
variety of patterns that denote various printer activities, and operational status as a group.
• Control buttons are used in various combinations to access internal utilities that calibrate the printer
to your media and make limited print settings.

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 Controls and Indicators

ZD411T Standard Interface Controls

The ZD411T printer interface provides the basic control and status of common printer operations.

Figure 9 Identifying Standard Interface Controls and Indicators

9 8 7 6 5

2 3 4

1
Power button
2
Pause button
3
Feed (Advance) button
4
Cancel button
5
Network indicator
6
Supplies indicator
7
Data indicator
8
Pause indicator

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 Controls and Indicators

9
Status indicator

Power Button – Turns power ON and OFF in the printer. It is also used to initiate low-power sleep and
wake states.
• Initial Power ON – Press Power until the printer’s indicator lights flash on. The indicator lights will flash
on and off in various combinations while the printer does self-diagnostics, configuration checks, and
integrate optional components which will take several seconds to complete. The Status indicator will
turn solid green indicating the printer is ready for normal print operations.
• Energy Star (Low Power Mode) – Press and release Power to enter Energy Star low power mode.
The printer will minimize power use. All the indicators will be off except the Status Indicator will slowly
change between On and Off to indicate Energy Star Mode.
• Power OFF with Energy Star Delayed – Press and hold Power for 4-9 seconds. The operator can start
a batch print job and put the printer into the low power consumption state of Sleep mode – after the job
has finished.
• Power OFF / Shutdown – Press and hold Power for 4-9 seconds. The printer turns OFF.
• Power Failure Recovery Mode – This printer feature is activated by a hardware jumper setting on
one of the optional Printer Connectivity Modules installed in the printer. See Setting the Power Failure
Recovery Mode Jumper on page 121.
• The printer will automatically Power ON when plugged into an active (ON) AC power source.
• Supports Sleep Mode and Power OFF with Sleep mode Delayed.
• A Power OFF/Shutdown resets the printer and then runs the Initial Power ON sequence.

NOTE: The Power Failure Recovery Mode is only available on printers with a Printer Connectivity
Module installed in the printer.

Pause Button – Pauses print and media movement actions.

• Pressing Pause to stop print activities and place the printer into a pause state. The printer will complete
printing a label that is printing before it pauses.
• The Pause indicator displays Amber (orange/yellow) to indicate the pause state.
• Pressing Pause while in the pause state to return the printer to normal operation. If printing a multi-label
(form/format) job or another print job is waiting to print in the print queue, then the printer will resume
printing.

Feed (Advance) Button – Advance a label (print form/format).

• Feed One Label – Press and release Feed when the printer is not printing to advance media one (1)
blank form/format length (label, receipt, tag, ticket, etc.).
• Advance Multiple Labels – Press and hold Feed to advance labels until released. It finishes advancing
to the beginning position of the next label.
• Reprint Last Label (activated via an SGD command: ezpl.reprint_mode) – The intended purpose
of this feature is to allow reprint of a failed media print. If the printer runs out of media (paper, labels,
transfer ribbon, etc.), then the printer can re-print the last label (print form/format). The print buffer that
stores the print image available for reprint is cleared when the printer gets turned off or is reset.

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 Controls and Indicators

Cancel Button – Cancels print jobs.

• Cancel is only functional when the printer is in the Pause state.
• Press Cancel once to cancel printing the next format in the print buffer.
• Press and hold Cancel for two seconds to cancel the printing of ALL pending formats.

Status Indicator – Primary status indicator for overall printer health and operational status. This
indicator is also known as the power indicator.
• Green: Ready for print and data activity.
• Green, Slowly Changing between ON and OFF: The printer is in Sleep Mode.
• Red: Media out, media detection error, head (cover/printhead) open, cut error, printhead authentication
failure.
• Amber: Printhead Over Temp (temperature), printhead element failure, out of memory while storing
content (formats, graphics, fonts, etc.), and interface power fault for USB Host or Serial ports.
• Blinking Amber: Printhead Under Temp (temperature).
• Blinking Red: Printhead Over Temp (temperature) – this status is coupled with a blinking red Pause
indicator. Requires cooling and printer restart.

Pause Indicator – The printer is in pause mode when the Pause indicator light is on. A label (print form)
or all labels (print forms) in the print buffer’s queue can be canceled when the Pause indicator is on using
the Cancel button.
• Amber: The printer is paused. Print, label feed (advance), and other label routines are suspended until
the pause state is removed by pressing Pause .
• Blinking Red: Printhead Over Temp (temperature) – this status is coupled with a blinking red Status
indicator. Requires cooling and printer restart.

Data Indicator – Indicates the status of data transfer activity.

• Off: Data is not being transferred.
• Green: A data communication operation has not finished but is not actively being transferred.
• Blinking Green: Data communications are in process.
• Blinking Amber: Out of memory while storing content (formats, graphics, fonts, etc.).

Supplies Indicator – Indicates media (label, receipt, tags, transfer ribbon, ribbon cartridge, etc.) status.
• Red: There is a media out condition.
• Blinking Red: Ribbon Out.

Network Indicator – Indicates network activity and status.

• Amber: 10 base Ethernet (LAN) connection detected.
• Green: 10/100 Ethernet (LAN) connection detected or when Wi-Fi (WLAN) has a strong signal and is
connected.
• Red: when an Ethernet (LAN) or Wi-Fi (WLAN) fault occurs.
• Blinking Red: during Wi-Fi (WLAN) association.

33
 Controls and Indicators

• Blinking Amber: during Wi-Fi (WLAN) authentication.

• Blinking Green: when Wi-Fi (WLAN) has completed but has a weak signal.

Meaning of the Indicator Light Patterns

All of the Link-OS Desktop printers have five common status indicators.
These five indicators help you identify issues. The individual indicators tell you the general area of
interest. The indicators may be off or on in a variety of lighting patterns of red, green, or amber (orange/
yellow). The status indicators can flash (blink), fade (bright to off), alternate between colors, or just remain
on. The status information that these lighting patterns represent is detailed in this section.

Status - Typical Operating Conditions

Printer Ready

The printer is powered on and ready to print.

Pause

The printer is paused. The operator must press the Pause button to resume print operations.
Media Out

The media (labels, receipts, tags, tickets, etc.) supply is out. The printer needs attention and cannot
continue without user intervention.
Transferring Data

Data communications are in process.

Data Transfers Paused

A data communication operation has not finished but is not actively being transferred.
Out of Memory

Out of memory while storing content (formats, graphics, fonts, etc.).

Cover Open/Printhead (PH) Open

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

The cutter blade is bound and is not moving properly.

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 Controls and Indicators

Status - Printhead Operation

CAUTION: Hot Surface — The printhead becomes hot while printing. To protect from damaging
the printhead and risk of personal injury, avoid touching the printhead. Only use the cleaning pen
to perform printhead maintenance.
Printhead Over Temp

Out of memory while storing content (formats, graphics, fonts, etc.).

Printhead Under Temp

The printhead is under temperature. Typically, the operating environment is below the printer’s
minimum operational temperature.
Printhead Shutdown

The printhead is over-temperature. Turn the printer OFF. After several minutes to allow the printer
to completely cool, turn the printer ON.
Printhead Resolution Error

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

The printhead was replaced with one that is not a genuine Zebra printhead. Install a genuine Zebra
printhead to continue.

Status - Bluetooth Low Energy (BTLE) Option

Bluetooth LE Paired

Bluetooth Low Energy has paired.

Bluetooth LE Failed to Pair

Bluetooth Low Energy has failed to pair.

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 Controls and Indicators

Status - Ethernet (LAN) Option

Ethernet (LAN) No Link

No Ethernet link is available. NETWORK status is light off

Ethernet (LAN) 100base Link

A 100 Base link was found.

Ethernet (LAN) 10base Link

A 10 Base link was found.

Ethernet (LAN) Link Error

An error condition exists. The printer is not connected to your network.

Status - Wi-Fi (WLAN) Option

Wi-Fi Connecting to WLAN

The light flashes red while the printer associates with the network.
The printer switches to authentication mode with a change to flashing amber.

The light then flashes yellow while the printer is authenticating with the network.
Wi-Fi (WLAN) 100base Strong Link

The printer is connected to your network and the Wi-Fi signal is strong.
Wi-Fi (WLAN) 100base Weak Link

The printer is connected to your network and the Wi-Fi signal is weak.

Battery Indicators and Controls

The battery uses the printer's power supply and its single control button.
The optional printer battery accessory has a simple, one-button, four LED indicator light user interface to
control and display battery status and health. The battery acts as a UPS (uninterruptible power supply) for
the printer. For more information on using the battery with the printer and power-saving modes (such as
sleep or shutdown), see Printing with the Attached Battery Base and Battery Option on page 118.

36
 Controls and Indicators

Figure 10 Battery Controls

4
1

1 Rear view of the battery

2 Battery Health indicator
3 Charge Level indicators
4 Battery Control button

Battery Control Button

The button helps you control the battery, both inside and outside of the printer.
• Battery On - Press and release.
• Wakes up (activates power) the battery from Sleep or Shutdown Modes. The battery health and
charge status are checked. The battery indicators all flash on and off together 3 times. The operator

37
 Controls and Indicators

now has one minute to turn the printer on before the battery reverts back to the previous Sleep or
Shutdown Mode.
• Battery displays the battery level charge during the first 10 seconds after internal battery health
checks are complete
• Shutdown Mode - Press and hold the button for 10–11 seconds and release. The battery begins
shutdown and approximately 3 seconds later all of the battery LEDs will flash three times to let you
know the battery has shut down.

Battery Health Indicator

Displays the battery’s charging status and health of the battery.
• Green - Good health, charge complete, and ready to operate.
• Amber - Charging (printer is OFF).
• Red - Battery has an internal error. Remove the battery and see Troubleshooting on page 145.
• Flashing Red - Charging error, over or under temperature, internal monitoring error, etc.

Battery Charge Level Indicator

Displays the battery’s charging status and health of the battery.
• Three green bars on, no flashing - Battery is fully charged. The battery stopped charging.
• Two green bars on with the top bar flashing. Less than a full charge.
• One green bar flash - Time to charge your battery.
• No bars illuminated - Battery needs charging, but the Battery Health indicator flashes when the Battery
Control button is pressed. The printer can not be turned on.
• Amber - Charging.

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Installing Hardware Options
Installing Hardware Options

This section assists you in installing common printer connectivity modules and media handling options.

IMPORTANT:
To simplify and speed up the setup process, install all connectivity modules and media handling
options before setting up and using the printer for the first time.
It is strongly recommended that you update the printer’s firmware after the printer has completed
the setup process. Many of these options have internal firmware that requires an update to
operate properly with the printer’s Main Logic Board’s installed firmware version.

Field Installable ZD411T Accessories and Options

The printer supports a wide variety of user upgrade kits for connectivity, media handling, and power
options.

Printer Connectivity Modules

The connectivity module access door must be removed prior to installing the following options – Accessing
the Connectivity Module Slot.
• Wireless Connectivity Module - Installing the Wireless Connectivity Module
• Wi-Fi 802.11ac, Bluetooth 4.2, BTLE 5.0, and MFi 3.0
• Wi-Fi 802.11ax, Bluetooth 5.3, BTLE 5.3, and MFi 3.0

Media Handling Options

The printer standard bezel must be removed prior to installing the following options – Removing the
Standard Bezel.
• Label Dispenser (Peel-Off Liner and Present Label for Operator) - Installing the Label Dispenser
• General Purpose Media Cutter – Installing the Standard Media Cutter
• Media Roll Adapters for 38.1 mm (1.5 in.), 50.8 mm (2.0 in.), or 76.2 mm (3.0 in.) inner diameter media
cores - Media Roll Core Size Adapters

Power Base Options

The printer supports a power base field upgrade kit for the printers.
• Battery Power Base (battery pack sold separately) – Installing the Attached Battery Base Options
• Battery Pack (battery power base sold separately) – Installing the Battery into the Attached Power Base

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 Installing Hardware Options

Printer Connectivity Modules

The connectivity modules can be easily installed without tools.

CAUTION—ESD: The discharge of electrostatic energy that accumulates on the surface of

the human body or other surfaces can damage or destroy the printhead and other electronic
components used in this device. You must observe static-safe procedures when working with the
printhead or the electronic components under the top cover.

Power Failure Recovery Mode Jumper (OFF by Default)

All of the Printer Connectivity Modules have a Power Failure Recovery jumper. It is set to the OFF position
by default. With the jumper set to ON, the printer will automatically Power ON when plugged into an active
(ON) AC power source (and not powered off).
• See ZD411T Standard Interface Controls on page 31 – Power Button - Power Failure Recovery Mode for
power ON/OFF behaviors.
• See Setting the Power Failure Recovery Mode Jumper on page 121 for instructions on activating the
mode

NOTE: The Power Failure Recovery Mode is only available on printers with a Printer Connectivity
Module installed in the printer.

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 Installing Hardware Options

Configuring Wired Connectivity Options and Power Failure Recovery

Mode
Use this reference to assist in upgrading, reconfiguring, troubleshooting the printer; and setting the Power
Failure Recovery Mode on the connectivity option cards.

Accessing the Connectivity Module Card or Empty Slot

CAUTION—HOT SURFACE: The printhead becomes hot while printing. To protect from
damaging the printhead and risk of personal injury, avoid touching the printhead. Only use the
cleaning pen to perform printhead maintenance.
Installation Preparation – No tools are needed for this procedure.
• Disconnect the DC power plug from the rear of the printer.
• Remove any interface cables and USB devices from the printer to protect you and the printer.
• This will help avoid accidents and damage to the printer and you.
Open the module access door by pushing down on the top of the door with your fingertip. This releases
the latch. Pull the door down and away from the printer.

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 Installing Hardware Options

Removing a Connectivity Module Card

The module cards have a hole punched into the edge of the module card to pull the card out. Use your
fingers, a connected cable connector body, or a pointy-tipped object to pry the card out.

The Serial Port Module requires the use of fingers, a scribe, or a small flat-bladed screwdriver to pry the
card out.

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 Installing Hardware Options

Setting the Power Failure Recovery Mode Jumper

NOTE:
The Power Failure Recovery Mode is only available on printers with a Printer Connectivity Module
installed in the printer.
The Printer Connectivity Modules have a Power Failure Recovery jumper set to OFF. With the
jumper set to ON, the printer will automatically Power ON when plugged into an active (ON) AC
power source.
Move the AUTO (Power Failure Recovery Mode) jumper from the OFF position to the ON.

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 Installing Hardware Options

1 2 1 2

1 – Default: Power Failure Recovery Mode is OFF 2 – Power Failure Recovery Mode is ON

Installing a Connectivity Module Card

Push the circuit card in slowly but firmly until the card is just past the inside lip of the access door.

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 Installing Hardware Options

Installing a Connectivity Module Door

Align the bottom of the door to the bottom lip of the module access opening. Swing the door up and snap
the cover closed. The locking tabs hook to the base under the inserted module card.

45
Installing Hardware Options

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 Installing Hardware Options

Installing the Wireless Connectivity Module

The wireless connectivity module provides Wi-Fi connectivity for the printer. Install it to allow your printer to
connect to Wi-Fi networks.

CAUTION—ESD: The discharge of electrostatic energy that accumulates on the surface of

the human body or other surfaces can damage or destroy the printhead and other electronic
components used in this device. You must observe static-safe procedures when working with the
printhead or the electronic components under the top cover.
1. Remove the media roll from the Media Roll Holder.
2. Disconnect the DC power plug from the rear of the printer.
3. Remove any interface cables and USB devices.
4. Turn the printer over to access the wireless connectivity door located at the bottom of the printer.
5. Open the module access door by pushing the latch at the top of the door. The printer base has a
recessed area for your fingertip.
The latch releases.
6. Lift and swing the door up to remove it.

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 Installing Hardware Options

7. Align the antenna arm and lower the module into the printer body.

NOTE: Ensure the printer's Wi-Fi connector aligns with the module's connectors.

8. Align the shortest side of the wireless connectivity door to the shortest side of the opening.
9. Swing the door closed and push down to lock the latch.

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 Installing Hardware Options

10. Place the three labels included on the bottom of the printer (1). These labels (2 and 3) assist with
the printer configuration (and later reconfiguration) of the printer. Mobile apps, use of scanners, and
printer support are aided by these printer configuration labels.

1
2

Re-connect the printer's power and interface cables after all hardware upgrade kits have been added to
the printer.

NOTE: It is recommended that you update the printer firmware to verify that the printer and
wireless module are at the same and latest version. See Updating Printer Firmware on page
143.

IMPORTANT:
The Wireless Connectivity Module needs to have Wi-Fi and Bluetooth configured to communicate
with the printer.
The network automatically provides a new IP address when the printer is turned on. The
Windows printer driver uses a static IP address to connect to the printer, usually used in
controlled networking environments. See Setting Up the Wi-Fi Print Server Option on page 102.
See the following manuals on the Zebra website at zebra.com/manuals.
• Wired and Wireless Print Server User Guide
• Bluetooth Wireless Guide

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 Installing Hardware Options

Media Handling Options

Use these easy-to-add media options to modify the printer to your media needs.
The printer will verify any hardware changes and configure the printer as needed during restart.
• The printer will not detect Media Roll Core Size Adapter addition or changes.
• These media options do not require removal for normal operation and cleaning.
• ZD Series Cutters are self-cleaning by design and do not require internal cleaning with the use of Zebra
media and supplies.

NOTE: You should not remove and replace Media Handling Options as a general practice. Only
remove for repairs.

CAUTION—ESD: The discharge of electrostatic energy that accumulates on the surface of

the human body or other surfaces can damage or destroy the printhead and other electronic
components used in this device. You must observe static-safe procedures when working with the
printhead or the electronic components under the top cover.

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 Installing Hardware Options

Installing Dispense, Cut, and Tear Media Handling Options

The printer uses a common installation and mounting method for the label dispensers, cutter, and label
tear-off printer option kits.

Removing Media Handling Options

To protect you and the printer, before installing, reconfiguring, or troubleshooting media handling options
in your print please do the following.
• Remove the media roll from the Media Roll Holder.
• Disconnect the DC power plug from the rear of the printer.
• Remove any interface cables and USB devices.
Tools Required:
Upgrade kits come with a common T10 hexolobular Allen-style wrench.

IMPORTANT: You should not remove and replace connectivity modules as a general practice.

IMPORTANT: The printer will verify any hardware changes and configure the printer as needed
during restart. For optimal printer performance, update the printer’s firmware immediately after
the printer’s initial setup is done or after upgrading the printer is completed. See Updating Printer
Firmware on page 143.
The standard Tear option bezel is removed the same as other media handling printer options.
1. Turn the printer upside down. Remove the two mounting screws.
2. Slide the bezel along the front of the printer about 12.5 mm (0.5 in.) towards the printer base. Pull the
loose bezel straight out the front of the printer.

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 Installing Hardware Options

Installing Media Handling Options

See the illustrations for attaching media option bezels to the printer.
1. Center and push the module onto the front of the printer and slide it into the front of the printer.
2. Attach the option module to the printer with the two screws.

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 Installing Hardware Options

Installing a Label Dispenser

53
 Installing Hardware Options

Installing a Media Cutter

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 Installing Hardware Options

Media Roll Core Size Adapters

This option kit modifies the printer to use media rolls with larger inner roll core diameters.
The media roll adapters option kit includes the screws to attach them. The kits are for the following inner
diameter media cores:
• 38.1 mm (1.5 in.)
• 50.8 mm (2.0 in.)
• 76.2 (3.0 in.)
Adapter Usage
• The adapters are intended to be permanently installed in the printer.
• Adapters may be changed to support other media roll sizes.
• The adapters may loosen if they are changed too many times.
• Remove any debris from the media roll bay before placing a new media roll.
Installing Media Roll Adapters
1. Each roll holder gets one adapter.

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 Installing Hardware Options

2. Place the adapter onto the roll holder.

3. Attach the adapter to the roll holder using a screw.

4. Tighten the screw until there is no gap between the adapter and the roll holder. Do not tighten beyond
this point. Over-tightening will strip the thread.
5. Repeat for the other adapter and roll holder.

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 Installing Hardware Options

Example of a label roll (1) placed on the adapters.

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 Installing Hardware Options

Installing the Attached Battery Base Options

Easily attach the printer battery base to the printer. The battery is sold separately.
• Remove any media rolls from the printer.
• Remove the DC power cable from the back of the printer.
• Remove any attached printer interface cables.

1. Turn the printer over and align the battery base to the bottom of the printer with the printer power plug
oriented toward the rear of the printer. The printer’s rubber feet align with recesses at the top of the
battery base.

2. Use the two screws provided to attach the battery base to the printer. Tighten the screws using the T10
hexolobular wrench.
The battery is now ready to be installed in the printed battery base.

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 Installing Hardware Options

Installing the Battery into the Attached Power Base

Describes how to add the battery to the battery base attached to the printer.

IMPORTANT: The printer must have an Attached Battery Base securely installed to the printer to
keep it from damaging the printer or battery.

IMPORTANT: Batteries are shipped in Shutdown Mode for safety and to keep the battery from
discharging during storage and shipping. The battery requires charging prior to initial use with
the printer.
1. Disconnect the printer’s external power supply from the DC Power Input located in the rear of the
printer.
2. Slide the battery into the battery base’s battery slot. Push the battery into the base until the battery pack
is flush with the rear of the battery base, and the connectors on the battery pack are engaged with the
ports on the back of the printer. The battery latch (1) locks the battery in place.

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 Installing Hardware Options

3. Attach the printer’s power supply to the battery to wake up the battery from Shutdown Mode and begin
its initial charge.

4. Charge the battery. The battery must be fully charged before its first use.
See Battery Indicators and Controls on page 36 to learn how to:
• Turn the battery on.
• Discover battery charge-saving features and behaviors.
• Check the battery’s charge level and health.
5. The printer will take approximately two hours to reach a full charge. The battery status (health) indicator
(lightning bolt) will go from Amber (Charging) to Green (Charged)

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ZD411T Printer Setup
ZD411T Printer Setup

This section assists you in setting up and operating your ZD411T printer. The setup process is broken down
into two phases: hardware setup and host system (software/driver) setup. This section covers the physical
hardware setup needed to print your first label.

ZD411T Printer Setup Overview

This list highlights important steps and warnings for the basic printer setup process.
Go to the Zebra Support page and look in the Drivers section to download the recommended Windows
Printer Driver v8.
• ZD411T Thermal Transfer printer – https//www.zebra.com/zd411t-info

IMPORTANT: Do not connect your printer to a computer yet!

• If you connected your printer to a computer via USB before driver installation, the printer
might appear as an unknown (unspecified) device in “Devices and Printers.”
• If necessary, follow these recovery steps before proceeding to Step 1.

NOTE: You will need a roll of media (labels, receipt paper, or tags) to set up your printer for the
first test print. See the Zebra Web site or contact your reseller to help you select the right media
for your use. Find media at http:www.zebra.com/supplies.
This is a simplified instruction list to assist you in planning a basic printer setup.
1. Run the downloaded Windows Printer Driver v8 file from your Windows computer. The driver
executable file (such as zd86423827-certified.exe) is added to your Download folder.
See Pre-installing the Window's Driver.
2. Place the printer in a safe location with access to power and where you can connect with interface
cables or wirelessly to the system.
• See Select a Location for the Printer.
• See Attaching the Printer Power.
• See Interface Cable Requirements.
3. Remove the outside layer of your media roll to keep grit, adhesive, and other handling contaminants
from damaging the printhead.

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 ZD411T Printer Setup

4. Load media. Typically this is a roll of labels, receipt paper, or tags. See How to Load Roll Media.
• For label and receipt (continuous) media roll, see Adjusting the Movable Sensor for Web/Gap
Sensing.
• For label and receipt (continuous) media roll, see Adjusting the Movable Sensor for Black Marks or
Notches .
5. Load ribbon if you are printing on thermal transfer media. See Using Thermal Transfer Ribbon in the
Printer and Loading Zebra Transfer Ribbon.
The media settings must match the actual media that you are using. See How to identify media type
on the Zebra website.
6. Turn the printer ON. The USB cable should not be connected to the computer!
7. Calibrate media properties and label positioning. See Run a SmartCal Media Calibration.
8. Print a Configuration Report as a test print. See Print a Configuration Report to Test Printing. The
information needed to identify and select the printer driver is at the top of the report. Use it to connect
to printer communications ports.
9. Turn the printer OFF.
10. For USB printer communication ports, connect the supplied USB cable to the printer. The printer can
connect to multiple uniquely named ports.

IMPORTANT: You must have the Windows Printer Drivers v8 installed prior to powering the
printer ON with the USB cable connected to the computer.
• See Pre-installing the Window's Driver to pre-load the drivers before continuing.
• If you connected your printer to a computer via USB before driver installation, the printer
might appear as an unknown (unspecified) device in “Devices and Printers.”
• If necessary, follow these recovery steps before proceeding to Step 1.
11. For non-USB printer communication ports, run the Windows Printer Driver v8 previously used to
preload the drivers. The driver executable file (such as zd86423827-certified.exe) was added to your
Download folder. See Running the Printer Installation Wizard on page 96.
12. Turn the printer ON when instructed.
• Windows should automatically detect and configure your printer for USB port operations.
• Network (Ethernet and Wi-Fi), Bluetooth, and Other (serial port) will require additional setup. Follow
the on-screen instructions and prompts to complete the wizard.
• The printer can connect to multiple uniquely named ports.

Pre-installing the Window's Driver

Pre-installing the printer driver is an important first step in setting up your printer.
The Windows Printer Driver v8 has been preloaded
1. Navigate to www.zebra.com/drivers.
2. Click Printers.
3. Select your printer model.
4. On the printer product page, click Drivers.

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 ZD411T Printer Setup

5. Download the appropriate driver for Windows.

The driver executable file (such as zd86423827-certified.exe) is added to your Download folder.
6. Run the executable file and follow the prompts.

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 ZD411T Printer Setup

7. Review the settings before continuing and the drivers will finish pre-loading after setting the
checkboxes.
a) To pre-install the drivers only: Unselect Run the printer installation wizard to disable running the
print wizard until the printer is operating without a computer.
b) Click Finish.

8. The drivers will be pre-installed and the window will close automatically went finished.

Select a Location for the Printer

The printer and media need a clean safe area with moderate temperatures to have optimal print
operations.
Select a location for the printer that meets these conditions:
• Surface: The surface where the printer will be located must be solid, level, and of sufficient size and
strength to hold the printer with media.
• Space: The area where the printer will be located must include enough space for opening the printer
(media access and cleaning), and for printer access to connectivity and power cords. To allow for
proper ventilation and cooling, leave open space on all sides of the printer.

IMPORTANT: Do not place any padding or cushioning material under or around the base of the
printer because this restricts airflow and could cause the printer to overheat.
• Power: Place the printer close to an easily accessible power outlet.
• Data Communication Interfaces: Ensure that cabling and Wi-Fi or Bluetooth radios do not exceed the
maximum distance specified by the communication protocol standard or product data sheet for this
printer. Radio signal strength can be reduced by physical barriers (objects, walls, etc.).

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 ZD411T Printer Setup

• Data Cables: Cables should not be routed with or near power cords or conduits, fluorescent lighting,
transformers, microwave ovens, motors, or other sources of electrical noise and interference. These
interference sources may cause problems with communications, host system operation, and printer
functionality.
• Operating Conditions: The printer is designed to function in a wide range of environments.
• Operational Temperature: 0–40°C (32–104°F)
• Operational Humidity: 20–85% non-condensing
• Non-Operational Temperature: -40–60°C (0–140°F)
• Non-Operational Humidity: 5–85% non-condensing

Pre-Install Printer Options and Connectivity Modules

Pre-Install the following printer options before proceeding with the printer’s setup. The printer auto-detects
and updates the option hardware and the printer's hardware configuration. The media roll size adapters
are not detected. These may be needed for your chosen media.
•
• Internal Wireless connectivity:
• Wi-Fi (802.11 ac – includes a/b/g/n), Bluetooth 4.2 (4.1 compatible), and BLE 5.0.
• Wi-Fi (802.11ax – includes a/b/g/n), Bluetooth 5.3, and BLE 5.3.
• Label Dispenser (Peel-Off Liner and Present Label for Operator) - Installing the Label Dispenser
• Cutter - Installing the Cutter
• Media Roll Core Size Adapters for 38.1 mm (1.5 in.), 50.8 mm (2.0 in.), or 76.2 (3.0 in.) inner diameter
media cores

Attaching Printer Power

This procedure guides you through attaching the power supply to a grounded power source and the
printer.

CAUTION: Never operate the printer and power supply in an area where they can get wet.
Serious personal injury could result!

NOTE: Set up the printer so that you can handle the power cord easily if needed. Some
processes for setup or troubleshooting issues may ask you to remove power. Separate the
power cord from the power supply receptacle or AC electrical outlet to ensure that the printer
cannot carry electrical current.
Connect power in this order.
1. Plug the power supply into the printer’s DC power receptacle.
2. Insert the AC power cord into the power supply.

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 country's
relevant certification mark in which the product is being used.

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3. Plug the other end of the AC power cord into an appropriate AC electrical outlet. the AC outlet end of
the power cord’s plug type can vary by region.

NOTE: The AC outlet end of the power cord’s plug type can vary by region.

The active power light will turn on (green) if power is ON at the AC outlet.

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Getting Ready to Print

Get labels ready following a few easy practices and can help maximize print quality and printer life.

IMPORTANT: The printer does not come with labels or other media. The media may be labels,
tags, tickets, receipt paper, fan-fold stacks, tamper-proof labels, etc. Ideally, choose the same
labels or other media needed for your planned use of the printer. The printer setup cannot be
completed without media.
The Zebra Web site or your reseller may be able to help you select the right media for your intended
printing application. Find all your labels and other media type designed for use in your printer at
zebra.com/supplies.

Preparing and Handling Labels and Media

Careful handling and storage of your media are important in order to maximize print quality.
The media comes in protective packaging. Once the labels or other media have been removed from its
packaging, it will typically pick up dust and particles from work and storage surfaces.
If the media becomes contaminated or dirty, it can damage the printer and cause defects in the printed
image (voids, streaks, discoloration, compromise the adhesion of the adhesive, etc.).

IMPORTANT: During manufacturing, packaging, handling, and storage, the outside length of
media may become dirty or contaminated. This will remove any contaminants which might be
transferred onto the printhead during normal operation.
Remove the outside layer of the media roll or the top label of the stack.

Media Storage Tips

Storing media safely and managing your supplies will keep your media ready to use.
• Store media in a clean, dry, cool, dark area. Direct thermal media is chemically treated to be heat
sensitive. Direct sunlight or heat sources may expose the media.
• Do not store media with chemicals or cleaning products.
• Leave media in its protective packaging until it is going to be put in the printer.
• Many media types and label adhesives have a shelf life or expiration date. Always use the oldest, viable
(non-expired) media first.

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Loading Roll Media in the ZD411T Printer

All of the Link-OS printers load print labels and media rolls the same.
• Label media uses the sensor to look through the media backing (liner) to see the beginning and end of
labels on the roll
• Marked media (black lines, black marks, notches, or holes) to define the print length
• Continuous (receipt, etc.) with no marks to define the print length

Setting Media Sensing by Media type

• For web/gap label media, the printer senses the differences between the label and the liner
to determine the print format length.
• For continuous roll media, the printer only senses the media’s characteristics. The print format’s length
is set by programming (driver or software) or the last stored form’s length.
• For black mark media, the printer senses the beginning of the mark and the distance to the start of the
next black mark to measure the print format length.
• For other common media and setting variations
• Setup printing with the Label Dispenser Option after you have loaded media using this procedure.
• For loading fan-fold media, see Printing on Fan-Fold Media. Those instructions replace steps 1-4 for
loading roll media.

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How to Load Roll Media – ZD411T

This procedure works for Tear-Off (standard bezel), Label Dispense, and Media Cutting printer options.
1. Slide the release latches to the front to unlock the cover.

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2. Spread the roll holders open and place the roll into the printer.

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3. Verify the roll turns freely. The roll must not sit in the bottom of the media compartment.
4. Pull the end of the roll past the front edge of the printer.

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

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6. Flip the media up to access the sensor and the backside of the media.

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7. Align the movable media sensor for your media type.

1 – Default Sensor Position 2 – Standard Labels 3 – Standard Receipt

(transmissive web/gap sensing) (continuous roll shown in the
printer)

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1 – Off-Center Positions 3a – Blackline Label 4a – Black Mark Label (shown

(Reflective) in the printer)
2 – Notched or Hole (label or 3b – Blackline Tear-Off 4b – Black Mark Tear-Off
tear-off) (continuous)4b – Black Mark (continuous)
Tear-Off (continuous)

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Using the Movable Sensor

This adjustable sensor allows you to use a wide variety of media and media tracking/positioning methods.
The movable sensor is a dual function sensor. It provides transmissive (sees through media) and reflective
media sensing. The printer can use either sensing method, but not both at the same time.
The movable sensor has a center array of sensors. This provides an adjustable transmissive web/gap
sensing to positions that match legacy Zebra desktop printer sensor locations and positions in between.
This also provides for use of some atypical media variations or irregularly shaped media.
The movable sensor allows the printer to use media with black marks or notches (holes through the media)
on the backside of the media (or media liner). Align the sensor to the middle of black marks or notches not
in the center of the media roll to avoid web/gap sensing array.

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Adjusting the Movable Sensor for Black Marks or Notches

The printer sensing for black marks and notches uses reflective sensing. Reflective (area) sensing does not
work in the default sensing position.
The black mark sensing looks for non-reflective surfaces such as black marks, black lines, notches, or holes
on the back of the media which do not reflect the sensor’s near-infrared light beam back to the sensor’s
detector. The sensor light and its black mark detector are next to each other under the sensor cover.
• Position the sensor alignment arrow to the middle of the black mark or notch in the underside of the
media.
• Sensor alignment should be set as far as possible from the edge of media but where 100% of the sensor
window is covered by the mark.
• When printing, the media can move from side to side ±1mm (due to media variations and edge damage
due to handling). Notches cut into the side of the media can also become damaged by handling.

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Adjusting the Movable Sensor for Web/Gap Sensing

The printer sensing for standard media uses transmissive (see-through) sensing. Transmissive (area)
sensing does not work out of the default sensing position.
The movable sensor for web/gap sensing supports multiple positions.
• The movable sensor’s Default position is ideal for most label types.
• The adjustment range is from the center to maximum right positions which are ideal for printing two
labels side by side on a roll.
• The movable sensor adjustment range covers sensor positions used by legacy Zebra printers.
• Web/gap sensing with the movable sensor only functions when the movable sensor’s alignment arrow
points to any position on the alignment key.

Figure 11 Web/Gap Sensing Positions

4
2
1 CL

5 6 7

CL CL CL

1 – Center Line 2 – Default Gap Sensing Position 3 – Alignment Key

4 – Alignment Arrow (Default 5 – Center Aligned 6 – Default
7 – Maximum Right

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Zebra Printer Models Fixed Sensor Position Relative to a ZD-Series Printer

• Default – Zebra Models: G-Series fixed position sensors, LP/TLP 2842, LP/TLP 2844, LP/TLP 2042
• Center Aligned – Zebra Model: LP/TLP 2742

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How to Load Roll Media - Continued

This procedure works for Tear-Off (standard bezel), Label Dispense, and Media Cutting printer options.
1. Cutter Models — For printers with the optional cutter module installed, thread the media through the
cutter’s media slot and pull it out the front of the printer.

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

Calibrate the printer for the new media. The printer’s sensors need to adjust to sense the label, the
liner, and the distance between labels to operate properly.
When reloading the same media (size, vendor, and batch), you can just press the FEED (Advance)
button once to prepare the media for printing.

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Using Thermal Transfer Ribbon in the Printer

The printer has the ability to use a wide variety of Zebra and non-Zebra thermal transfer ribbons.
The printer supports a 74-meter thermal transfer ribbon.

Transfer ribbons come in several varieties and in some cases colors to match your application needs.
Genuine Zebra transfer ribbons are specifically designed for the printer and Zebra brand media. Using non-
Zebra media or ribbons not approved for use in your Zebra printer may damage the printer or printhead.
• The media and ribbon types should be matched to provide you with optimal print results.
• Always use a ribbon that is wider than the media to protect the printhead from wear.
• For direct thermal printing, do not load ribbon in the printer.
• Always use an empty ribbon core that matches your transfer ribbon roll’s inner diameter. Ribbon
wrinkling and other print problems can occur.
Genuine Zebra ribbons for this printer include:
• Performance Wax
• Premium Wax/Resin
• Performance Resin for synthetics (6 ips max. speed) and coated paper (4 ips max. speed)
• Premium Resin for synthetics (4 ips max. speed)

IMPORTANT: – Do not use early model desktop printer ribbon cores. The older style ribbon
cores (and some Non-Zebra ribbons) can be identified by notches on only one side of the ribbon
core. These older cores are too large.

IMPORTANT: Do not use ribbon cores with damaged notches that may be rounded, frayed,
smashed, etc. The core notches should be square to lock the core on the spindle or the core may
slip causing ribbon wrinkle, poor end of ribbon sensing, or other intermittent failures.

See Also
Go to the Zebra website for thermal transfer ribbons and other printing supplies.

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Loading Zebra Transfer Ribbon – ZD411T

The printer has a 74-meter ribbon system.
Before following these steps, prepare the ribbon by removing its wrapping and pulling its adhesive strip
free.

3
2

1 - Notch (Required on the left 2 - Adhesive Strip 3 - Right Notch (not usable by
side of Zebra thermal transfer ribbon drive system)
ribbon)

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

NOTE: You can find your first ribbon take-up core in the packing box. Subsequently, use the
empty supply core from the supply spindle for the next roll of ribbon.

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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 as the take-up mounting the take-up core.

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

4. Turn the ribbon take-up hub with the top moving toward the rear to remove slack from the ribbon.
Rotating the hub helps to finish aligning the take-up ribbon position to the supply ribbon roll. The ribbon
leader should be completely covered by the ribbon.
5. Verify that the media is loaded and ready to print and then close the printer cover.
6. If printer power is on, press the FEED button to have the printer advance a minimum of 20 cm (8 in.)
of media to remove slack and ribbon wrinkle (straightens the ribbon), and to align the ribbon on the
spindles. Otherwise, wait to turn on the printer and complete the printer instructions in this chapter.
7. Change the print mode setting from direct thermal printing to thermal transfer to set the printer’s
temperature profiles for thermal transfer media. This can be done with the printer driver, ZebraDesigner
label design software, or printer programming commands.
• When controlling printer operations with ZPL programming, refer to the Media Type (^MT) ZPL II
command (follow the instructions in the ZPL Programming Guide).
• When controlling printer operations with EPL Page Mode, refer to the Options (O) EPL command
(follow the instructions in the EPL Page Mode Programmer’s Guide).
To verify the mode change from direct thermal printing to thermal transfer printing, use the Test Printing
with the Configuration Report to print a configuration label. The PRINT METHOD should read THERMAL-
TRANS on the printer configuration status label.

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Run a SmartCal Media Calibration

The printer needs to set the media detection parameters prior to printing for optimal operation. After the
printer has media correctly loaded for your selected media, then use SmartCal to automatically determine
media type (web/gap, black mark/notch, or continuous) and measure media characteristics to calibrate the
printer.
The printer needs the media loaded and the movable media sensor properly adjust for your media type
chosen.
1. Make sure the media and ribbon cartridge (if you are thermal transfer printing) are loaded properly in
the printer and the top cover of the printer is closed.
2. Press the POWER button to turn the printer ON.
3. Once the printer is in the ready state (Status indicator is solid green), press and hold the PAUSE and
CANCEL button for two seconds and release.

The printer will measure a few labels and adjust media sensing levels.
When the printer stops, the Status indicator will turn solid green.

IMPORTANT:

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After the initial calibration to a specific media is completed, it is not required to perform additional
calibrations each time the media is replaced. The printer automatically measures the media to
adjust for small changes in the media characteristics while printing.
Pressing the FEED (Advance) once or twice after a new roll of media (same batch) has been
installed will synchronize the labels. It is then ready to continue printing.

See Also
Loading Roll Media in the Printer
How to Load Roll Media
Adjusting the Movable Sensor for Web/Gap Sensing
Adjusting the Movable Sensor for Black Marks or Notches

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Print a Configuration Report to Test Printing

Printing a Configuration Report is a great way to test and verify the printer's basic operation and settings.
Before you connect the printer to a computer, make sure that the printer is in proper working
order. You can do this by printing a Configuration Report using this procedure. The information on the
Configuration Report's printout may be helpful with printer installation and troubleshooting the printer.
1. Make sure the media and ribbon cartridge (if you are thermal transfer printing) are loaded properly in
the printer and the top cover of the printer is closed.
2. Turn the printer ON.
3. Once the printer is in the ready state (Status indicator is solid green), press and hold the FEED and
CANCEL buttons for two seconds and release.

If you cannot get these reports to print, then see Troubleshooting.

IMPORTANT:
Use the Configuration Report to find your printer's model, print resolution (for example XXX
dpi), programming language (typically ZPL, CPCL, and EPL), and alpha-numeric serial number
at the top of the printout. They are used to set and configure the printer for various printer
communication options (USB, Wi-Fi, Ethernet, and Bluetooth) and supported operating systems
(Windows, Android, Apple, and more).

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Detecting a Media Out Condition

When you run out of media, the printer will report a Media Out condition with the Status and Media
indicators both solid red. This is part of the normal media usage cycle.

Figure 12 Media Out Detected

Recovering from a Media Out condition

1. Open the printer.
2. Observe that the media is at the end or nearly at the end of the roll with a label missing from the liner.

IMPORTANT:
Sometimes a label may be missing somewhere in the middle of your roll of labels (not at the
end of media). This will also cause a Media Out condition.
To recover, just pull the media past the missing label until the next label is over the platen
roller. Close the printer. Press the FEED (Advance) button once. The printer will resynchronize
the label position and will be ready to resume printing.
3. Remove the remaining media and roll core.

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4. Insert a new roll of media.

See Loading Roll Media.
• If you are installing more of the same media, just load the new media and press the FEED (Advance)
button once to resume printing.
• If you are loading different media (size, vendor, or even batch is different), then reloading media
followed by a SmartCal is needed to ensure optimal operation.

NOTE: Changing media size (length or width) usually requires you to change the programmed
media dimensions or the active label format in the printer.

Detecting a Ribbon Out Condition

When you run out of printable ribbon, your printer will report a Ribbon Out condition with the Status and
Media indicators. This is part of the normal media usage cycle.
The printer's Status indicator will turn solid red and the Media indicator will be flashing red when the
printer detects the ribbon is out.

1. Open the printer. Do not turn the printer OFF.

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2. Observe a reflective ribbon (used to detect the end of the ribbon) is exposed on the underside of the
ribbon cartridge or ribbon roll. The front ribbon/top roll is also full.

1 – Take-Up Ribbon Roll is Full 2 – End of Ribbon at the Reflective Ribbon Trailer

3. Remove the used Take-Up roll of ribbon and dispose of it properly. Keep the now empty lower Supply
Ribbon core located towards the bottom/back of the ribbon carriage.
4. Load a new ribbon roll.
See Loading Thermal Transfer Roll Ribbon for more details.
5. Press the FEED (Advance) once to resume printing.

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Connecting to the Printer

The printer supports a wide offering of communication options to use the printer.
The printer supports a variety of interface options and configurations. These include:
• Universal Serial Bus (USB 2.0) interface - Standard.
• RS232 Serial – Installed or as a Field Upgrade Option
• Ethernet (LAN) – Installed or as a Field Upgrade Option
• Factory Installed Option or as a Field Upgrade Wireless Connectivity with Wi-Fi:
• 802.11ac and Bluetooth 4.2 (4.1 compatible).
• 802.11ax and Bluetooth 5.3.
• Wi-Fi models include Bluetooth Low Energy (low-speed connection) for printer configuration using
software running on an Android or iOS device.

Pre-install Windows Printer Drivers

The Printer Setup Utility installs the driver on your computer to simplify the setup.
Install the Printer Setup Utility before applying power to the printer connected to the PC. The utility installs
the Zebra Windows drivers first. The installation wizard will then prompt you to turn on the printer. Follow
the instructions to complete the printer installation.
The Printer Setup Utility is designed to assist you in setting up printer operations in Windows. Make
configuration setup choices prior to and immediately following applying power using the utility's
wizards. The cabling and parameters for each of these physical printer communication interfaces are
discussed in the following pages to assist you. The Printer Setup Utility configuration wizards will instruct
you when to turn the printer’s power on at the appropriate time to complete the installation of the printer.
For more details on configuring network (Ethernet or Wi-Fi) and Bluetooth communication, see the
following guides:
• Wired and Wireless Print Server User Guide
• Bluetooth Wireless Guide

Interface Cable Requirements

Interface cabling needs to comply with requirements for shielding and routing to keep noise and
interference from printer communications.
Data cables must be of fully shielded construction and fitted with metal or metalized connector shells.
Shielded cables and connectors are required to prevent radiation and reception of electrical noise.
To minimize electrical noise pickup in the cable:
• Keep data cables as short as possible. 1.83 m (6 ft.) is the maximum recommended length)
• Do not tightly bundle the data cables with power cords.
• Do not tie the data cables to power wire conduits.
• To minimize electrical noise pickup in the cable:

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IMPORTANT: This printer complies with FCC Rules and Regulations, Part 15, for Class B
Equipment, using fully shielded data cables. The use of unshielded cables may increase radiated
emissions above the Class B limits.

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USB Interface (Device)

Connect to the printer with USB 2.0 cables.

IMPORTANT:
Turn the print power off. Keep the printer power OFF until instructed to turn it ON by the printer
installation wizard. You must pre-load the Windows Printer Driver v8 driver set before the printer
can be turned ON! The Windows system will detect and load the wrong printer driver otherwise.
To recover from incorrect driver installation, see Troubleshooting, USB Printer Fails to Install after
Connecting Printer.
Run the Windows Printer Driver v8 and select run the Printer Installation Wizard.
USB (version 2.0 compliant) provides a fast interface that is compatible with your existing PC hardware.
Multiple printers can share a single USB port/hub.
When using a USB cable, verify that the cable or cable packaging bears the Certified USB mark (see below)
to guarantee USB 2.0 compliance.

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Serial Interface
The printer supports Serial Port as a factory configuration or as a field upgrade kit.

IMPORTANT: Do not use RS-232 cable adapter dongles for data terminal equipment (DTE) and
data communication equipment (DCE) with this printer. Some dongles can interfere with the
operation of USB Host port devices at printer power-up.
The printer uses a Null Modem (cross-over) cable for DTE communications. The required cable must have a
nine-pin D-type (DB-9P) male connector on one end which plugs into the mating (DB-9S) serial port located
on the back of the printer. The other end of this signal interface cable connects to a serial port on the host
computer. For pin-out information, refer to Interface Connector Wiring Diagram.
The serial port communication settings between the printer and host (typically a PC) must match for reliable
communication. The Bits per second (or Baud rate) and Flow control are the most common settings that get
changed.
Serial communications between the printer and the host computer can be set by:
• ZPL programming ^SC command.
• Resetting the printer to its default printer configuration.
Factory defaults for serial communication settings are 9600 baud, 8-bit word length, NO parity, 1 stop bit,
and XON/XOFF (Software data flow control in the Windows-based host system).

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Ethernet (LAN, RJ-45)

Connect to the printer with a wired Ethernet cable.
The printer requires a UTP RJ45 Ethernet cable (1) with a CAT 5 rating or higher.
The printer has a built-in network print server. For more information on configuring the printer to run on a
compatible Ethernet-based network, see the Wired and Wireless Print Server users guide. The printer must
be configured to run on your network. The print server onboard the printer can be accessed through the
printer’s print server Web pages.

Ethernet Status/Activity Indicators

The Ethernet connector on the printer has two status/activity indicators that are partially visible to provide
interface status at the connector. The printer also has the user interface indicator lights for printer network
operation status. See the Meaning of the Indicator Light Patterns on page 34 for more details.

LED Status Description

Both OFF No Ethernet link detected
Green 100 Mbps link detected
Green with the Amber flashing 100 Mbps link and Ethernet activity detected
Amber 10 Mbps link detected
Amber with the Green flashing 10 Mbps link and Ethernet activity detected

Assigning an IP Address for Network Access

All devices on an Ethernet network (LAN and WLAN) require a network IP (Internet Protocol) address. The
printer’s IP address is needed to access the printer for printing and printer configuration. The five different
ways to assign an IP address are:
• DHCP (Dynamic Host Connection Protocol) - Default setting
• Zebra Setup Utilities (includes the ZebraDesigner Windows printer driver)
• Telnet
• Mobile Apps
• ZebraNet Bridge

DHCP for Personal Networks

The printer by default is set to operate on an Ethernet LAN or Wi-Fi network with DHCP. This setting is
intended primarily for personal networks. The network automatically provides a new network IP address
each time the printer is turned on. The Windows printer driver uses a Static IP address to connect to the
printer. The IP address set in the printer driver will need to be changed to access the printer if its assigned
IP address has changed after the printer’s initial installation.

Managed Networks
Using the printer in a structured network (LAN or Wi-Fi) requires a network administrator to assign the
printer a Static IP address and other settings needed to operate on the network properly.

• User ID: admin

• Password: 1234

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Running the Printer Installation Wizard

Running the printer installation wizard will complete the printer setup.
The Windows Printer Drive v8 has been pre-installed.
1. Run the Windows Printer Driver v8 previously used to preload the drivers. The driver executable file
(such as zd86423827-certified.exe) was added to your Download folder.
a) Follow the screens and answer the prompts. The drivers are ready to be preloaded after Finish is
pressed.

2. Review the checkbox settings before continuing.

a) Verify that the checkbox for Run the printer installation wizard to Select and enable the wizard.
b) Click Finish to close the window and run the wizard.

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3. The Printer Installation Wizard displays after the preloaded drivers are loaded or have finished loading
(if this is the first time using the Windows Printer Driver v8 file).

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

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5. Click Install Printer.

The license agreement displays. Read the important information and agree to the terms by selecting the
I Accept the Terms in the License Agreement button. Click Next.

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6. You are prompted to select the printer port.

Complete the installation by following the instructions in the wizard.

The model of the printer is located on the top front of the printer. You can use a Configuration Report
(see Print a Configuration Report to Test Printing on page 87) to identify the model number, print
resolution (203 dpi, 300 dpi, and 600 dpi), primary printer programming language (ZPL, EPL, CPCL), and
the printer serial number. Installing some of the communication port selections will use some of

NOTE:
Each port selection other than USB requires you to select, recognize, or use the information
on the Configuration Report (see Print a Configuration Report to Test Printing on page 87).
You can use a Configuration Report to identify the model number, print resolution (203 dpi,
300 dpi, and 600 dpi), primary printer programming language (ZPL, EPL, CPCL), and the
printer serial number.
Installing Network ports require IT assistance or knowledge of your network and networking
principles and equipment.
Bluetooth uses the printer’s serial number to identify the printer for pairing.
See Serial Interface for information needed to configure the optional serial port
communication for the printer.
The Parallel Port option is not available for this printer.
7. The wizard automatically closes the window when the installation process has been completed.

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Setup for Windows

The section helps setting up communications between your printer and the Windows operating system
environment.

Zebra Setup Utility: Pre-install Windows Printer Drivers

IMPORTANT:
Go to the Zebra Support page:
https://www.zebra.com/zd411t-info
Look in the Drivers section to download the recommended Windows Printer Driver v8.
Do not connect your printer to a computer yet!
• If you connected your printer to a computer via USB before driver installation, the printer
might appear as an unknown (unspecified) device in “Devices and Printers.”
• If necessary, follow these recovery steps before proceeding to Step 1.
You will need a roll of media (labels, receipt paper, or tags) to set up your printer for the first test
print. See the Zebra Web site or contact your reseller to help you select the right media for your
use. Find media at http:www.zebra.com/supplies.
Install the Zebra Setup Utility before applying power to the printer connected to the PC (running a Zebra
driver-supported Windows operating system). The utility installs the driver first. The installation wizard will
then prompt you to apply the printer power. Continue to follow the instructions to complete the printer
installation.
The setup utility is designed to assist you in setting up printer communication on a PC running the
Windows operating system. The cabling and parameters for each of these physical printer communication
interfaces are discussed in the following pages to assist you with making configuration setup choices prior
to and immediately following applying power. The configuration wizard will instruct you to turn the printer’s
power on at the appropriate time to complete the installation of the printer.
For more details on installing Ethernet (network) and Bluetooth interfaces:
• Wired and Wireless Print Servers User Guide
• Bluetooth User Guide

See Also
zebra.com/manuals

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 Setup for Windows

Windows to Printer Communication Setup (Overview)

For supported Windows Operating systems (most common) with a Local (wired) connection:
1. Download the Zebra Setup Utilities from the Zebra Web site. See zebra.com/setup.
2. Run the Zebra Setup Utilities from your Download directory.
3. Select Install New Printer and run the install wizard.
4. Select Install Printer.
5. Select the printer’s model number from the list of ZDesigner printers.
6. Select the USB port to connect to the PC. Use the interface to assist the Wizard-guided installation of
networked or Bluetooth Classic.
7. Turn the printer ON and configure printer communications for your interface type.
8. Use the Windows driver to print a test page to verify operation with Windows. From the printer
properties of the printer's driver, select the General window tab, and then click the Print Test Page
button.

Setting Up the Wi-Fi Print Server Option

This section covers the basic configuration of your internal Wi-Fi Print Server option. For more detailed
information, refer to the Wired and Wireless Print Servers User Guide. See zebra.com/manuals.
You may configure the printer for wireless operation in the following ways. This basic guide covers only the
first option, the Connectivity Wizard.
• Through the Connectivity Wizard, which writes a ZPL script for you. On the last screen of the utility,
you may choose to send the command directly to the printer, or you may choose to save the ZPL script
to a file. The saved ZPL file has several purposes:
• The file can be sent to the printer through any available connection (USB, or wired print server).
• The file can be resent to the printer after the network settings have been restored to factory
defaults.
• The file can be sent to multiple printers that will use the same network settings.
• Through ZPL a script that you write yourself. Use the ^WX command to set the basic parameters for
security type. You can send the command through any available connection (USB, or wired print server).
Refer to the ZPL Programming Guide for more information on this option.
• Through Set/Get/Do (SGD) commands that you send to the printer. Begin with WLAN.security to
set the wireless security type. Depending on which security type that you select, other SGD commands
will be necessary to specify other parameters. You can send the commands through any available
connection (USB, or wired print server). Refer to the ZPL Programming Guide for more information on
this option.

Using a Configuration Script

Complete the setup by sending the ZPL script to the printer through the port selected at the beginning of
this procedure.
1. Verify that the printer is connected to the computer through the wired cable connection to USB port.
2. If you have not already done so, turn ON the printer.

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3. On the Review and Send ZPL for Wireless window, click Finish.
4. The printer sends the ZPL script to the printer through the selected port. The Wireless Setup Wizard
screen closes.
5. Turn the printer OFF and then back ON.

Saving a Configuration Script

Save the ZPL script to a file for use later or for use with other printers.

NOTE: You can send the ZPL script file to multiple printers that use the same configuration, or
you can send the file to a printer that had the network settings restored to the factory defaults.
This saves you from having to go through the Wireless Setup Wizard more than once.
1. On the Review and Send ZPL for Wireless window, highlight the script, right-click, and select Copy.
2. Open a text editor, such as Notepad, and paste the script into the application.
3. Save the script.
4. In the Connectivity Wizard, click Cancel to exit without sending the script at this time.
5. If you have not already done so, turn ON the printer.
6. Send the ZPL file to the printer through the connection of your choice. If you have not already done so,
turn ON the printer.
7. Observe the wireless status on the printer’s indicator lights, and confirm you have set up the printer for
wireless connectivity.

Bluetooth Option Configuration

The Zebra Setup Utilities provides a quick and easy way to configure a Bluetooth wireless connection with
the printer.
1. Double-click the Zebra Setup Utilities icon on your desktop.
2. Connect a USB cable from your printer to the computer.
3. On the first ZSU screen, highlight the printer displayed in the window and click the Configure Printer
Connectivity where shown.

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4. Select Bluetooth on the Connectivity Type screen and click Next.

5. On the Bluetooth Settings screen, check Enabled to enable Bluetooth functionality.

6. In the Friendly Name text field, set the Bluetooth name of the device. This name appears during
device discovery and the central device will label the printer with this name.
7. Set Discoverable to On or Off to set whether the device will appear when central devices are looking
for new devices to pair with.
8. Set Authentication to On.

NOTE: This setting does not exist in Link-OS, but you need to turn it on if you want to enter
a PIN in ZSU. The actual authentication setting on the printer is set in the Security Mode on
the Advanced Settings menu.
9. The values set in the Authentication PIN field will vary depending on the Bluetooth version of
the central device. If the central uses BT v2.0 or older, enter a numeric value in this field. You are
prompted to enter this same value on the central device to verify the pairing. Security Mode 2 or 3

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in Advanced Settings should also be selected for PIN paring. In Advanced Settings, select Security
Mode 2 or 3 for PIN paring.

If the central device uses BT v2.1 or newer, this setting has no effect. BT v2.1 and newer uses Secure
Simple Pairing (SSP) which does not require the use of a PIN.
Clicking the Advanced Settings button will display the Advanced Bluetooth Settings window. For
more information on Advanced Settings, refer to the Wired and Wireless Print Server Guide.
10. Click Next to continue configuring the printer.
11. The SGD commands to properly configure the printer are displayed. Click Next to continue to the
Send Data screen.
12. On the Send Data screen, click the Printer icon that you want to send the commands to, or click the
File button to save the commands to a file for reuse later.
13. To send the commands to the printer, click the Finish button. The printer will update and then reboot.
You may disconnect the USB interface from the printer now.
14. To complete the Bluetooth pairing process, enable Bluetooth device discovery on your central device
and follow the directions provided with the master device.

Windows 10 (PC version)

Before pairing or adding a Bluetooth-enabled device, make sure it is turned on and discoverable. Your
Windows device may need a Bluetooth adapter to connect to Bluetooth devices. Check with your device
manufacturer’s User Manual for further information.

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1. Open the Windows Start Menu by clicking on the Windows Start button and select Settings.

2. Click on the Devices category in the Settings window.

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3. Click on Bluetooth. If your PC doesn’t have Bluetooth installed, the Bluetooth category will not be
displayed in the list of device categories. The printer is identified by the serial number.

4. Click the printer icon and then click the Pair button for the printer.

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5. The printer prints a passcode. Compare that with the passcode showing on the screen. Click Yes if they
match.

6. The printer status changes to connected when the pairing is complete.

After the Printer is Connected

Now that you have basic communication to the printer, test printer communications, and then install other
printer-related applications, drivers, or utilities.

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Testing Communications by Printing

Verifying the print system’s operation is a relatively simple process. For Windows operating systems, use
the Zebra Setup Utility or the Windows Printers and Faxes or Devices and Printers to access and print a
test label. For non-Windows operation systems, copy a basic ASCII text file with a single command (~WC) to
print a configuration status label.

Test Printing with Zebra Setup Utility:

1. Open the Zebra Setup Utility.
2. Click on the newly installed printer’s icon to select the printer and activate the printer configuration
buttons below it in the window.
3. Click the Open Printer Tools button.
4. In the Print tab window, click the Print configuration label line.
5. Click the Send button. The printer should print a configuration report.

Test Printing with Windows Printer and Devices menu:

1. Click the Windows Start menu button, to access the Printers and Faxes or Devices and Printers menu.
You may also use the Control Panel to access the menus. Open the menu.
2. Select the newly installed printer’s icon to select the printer and right-click the mouse to access the
printer Properties menu.
3. From the printer’s General tab window, click the Print Test Page button. The printer should print a
Windows test print page.

Test Print with an Ethernet printer connected to a network:

Test Print on an Ethernet printer connected to a network (LAN or WLAN) with an (MS-DOS) Command
Prompt (or Run from the Windows XP Start menu):
1. Create a text file with the following ASCII three characters: ~WC
2. Save the file as: TEST.ZPL (an arbitrary file name and extension name).
3. Read the IP address from the printer’s configuration report’s Network Status printout. On a system that
is connected to the same LAN or WAN as the printer, type the following in the Web browser window’s
address bar and enter:

ftp (IP address)

(for IP address 123.45.67.01 it would be: ftp 123.45.67.01)

4. Type the word put followed by the file name and Enter. For this test print file, it would be:

put TEST.ZPL

The printer should print a new configuration report.

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Print Operations

This section provides general information on media and print handling, font and language support, and the
setup of less common printer configurations.

Thermal Printing Basic Setting and Operations

Extra care should be taken to avoid touching the printhead which gets hot and is sensitive to electrostatic
discharges.

CAUTION—HOT SURFACE: The printhead becomes hot while printing. To protect from
damaging the printhead and risk of personal injury, avoid touching the printhead. Only use the
cleaning pen to perform printhead maintenance.

CAUTION—ESD: The discharge of electrostatic energy that accumulates on the surface of

the human body or other surfaces can damage or destroy the printhead and other electronic
components used in this device. You must observe static-safe procedures when working with the
printhead or the electronic components under the top cover.

Determining the Printer’s Configuration Settings

Use the printer's Configuration Report to verify option installation, media handling, and print settings.
The printer provides a configuration report of the settings and hardware configuration. Operational status
(darkness, speed, media type, etc.), installed printer options (network, interface settings, cutter, etc.) and
printer description information (serial number, model name, firmware version, etc.) are all included in the
configuration report.

See Also
Test Printing with the Configuration Report to print this label
ZPL Configuration

Sending Files to the Printer

Use a wide variety of Zebra methods to transfer files for printing and updates for the printer.
Send graphics, fonts, and programming files to the printer from the Microsoft Windows operating
systems using the Link-OS Profile Manager, Zebra Setup Utilities (and driver), ZebraNet Bridge, or Zebra
ZDownloader found on the Zebra Web site: zebra.com/software.

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Select a Print Mode for Media Handling

Use a print mode that matches the media being used and the printer options available.

Print Modes
• TEAR OFF – This mode (default) can be used with any printer options and most media types. The
printer prints label formats as it receives them. The printer operator can tear off the printed labels any
time after they print.
• PEEL – Label Dispenser Option only. The printer peels the label from the liner during printing and then
pauses until the label is removed.
• CUTTER – Cutter Option only. The printer cuts between labels after each one is printed.
Related ZPL command(s):
^MM
SGD command used:
media.printmode
Printer web page:
View and Modify Printer Settings > General Setup > Print Mode

Adjusting the Print Quality

Print quality is affected by the heat (density) setting of the printhead, the print speed, and the media in use.
The printer's default darkness and speed settings work for most applications that use Zebra labels and
media. Set the printer to the maximum recommended speed of the media in use. Experiment with the
darkness setting first, then lower the speed setting to find the optimal mix for your application. Print quality
can be configured with the Zebra Setup Utility’s Configure Print Quality routine.

NOTE: Media (labels, receipt paper, tags, etc.) have maximum speed settings for your chosen
media. Start with these setting
The darkness (or density) setting can be controlled by:
• The Set Darkness (~SD) ZPL command (consult your ZPL Programming Guide).
• See the Adjusting the Darkness with Manual Print Darkness on page 163 routine.
Accepted values:
0.0 to 30.0
Related ZPL command(s):
^MD, ~SD
SGD command used:
print.tone
Printer web page:
View and Modify Printer Settings > General Setup > Darkness

Adjusting the Print Width

Adjust the print width to place your image on the media.
Print width must be set:
• Before you use the printer for the first time.
• Any time you change the width of the media in use.

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Print width may be set by:

• The Windows printer driver or application software such as ZebraDesigner™.
• Controlling printer operations with ZPL programming; refer to the Print Width (^PW) command (consult
your ZPL Programming Guide).
• See Using the Manual Print Width Adjustment on page 162.
Related ZPL command(s):
^PW
SGD command used:
ezpl.print_width
Printer web page:
View and Modify Printer Settings > Media Setup > Print Width

Replacing Supplies while Using the Printer

If media (ribbon, labels, receipts, tags, tickets, etc.) run out while printing, leave the printer power on while
reloading media. After you load a new roll of media or ribbon, press the FEED button to resync and restart
printing.

NOTE: Do not turn the printer off to replace the printer media. Data loss results if you turn off
the printer while printing. By maintaining printer power, print jobs in progress can resume and
complete if a single printout or a batch print job.
Press the FEED button once after reloading media initiates a media resync to the beginning of label.
Pressing the PAUSE will resume the print job in most cases.
Press the FEED button after the media has been resynced or calibrated and the printer's default setting is
to reprint the last label image in the printer.

Printing on Fan-Fold Media

The printer can use fan-fold media via a media access slot in the rear of the printer.

1. Remove any roll media from the printer.

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2. Open the top cover.

3. Adjust the media guide stop position with the gray slide-lock. It is located on the outside of the left
media roll holder. Use a piece of your fan-fold media to set the stop position's width Push the gray
slide-lock towards the rear of the print to lock its position.

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

5. Close the top cover.

After printing or using the FEED button to advance several labels: If the media does not track down the
center (moves the stack from side to side) or the sides of the media (liner, tag, paper, etc.) are frayed or
damaged when exiting the printer, then the media guide stop position may need further adjustment.
If this does not correct the problem, then the media can be routed over the two roll-holding pins on the
media guide depending upon your media.
An empty roll core of the same width as the stack of the fan-fold media can be placed between the roll
holders to provide additional support for thin media.

Using the Label Dispenser Option

Use the label dispenser option to print a label and have the backing material (liner/web) automatically
removed. When printing multiple labels, removing the dispensed (peeled) label can trigger the printer to
print and dispense the next label.
• For printers with the display option, use the Print > Label Position > Collection Method
• Set Media Handling to Peel-Off in the printer driver
• Use the Zebra Setup Utility Configure Printer Settings wizard
• Send the ZPL programming commands to the printer.
When programming in ZPL, you can use the command sequences shown below to configure the printer to
use the dispenser option:

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^XA ^MMP ^XZ

^XA ^JUS ^XZ

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

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 opens.

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

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

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

6. During the print job, the printer peels off the backing and presents a single label. Take the label from
the printer to allow the printer to print the next label.

IMPORTANT: If you did not activate the label taken sensor to detect the removal of the
dispensed (peeled and presented for removal) label with software commands, the printed labels
will stack and may bind the mechanism.

Printing with Externally Mounted Roll Media

The printer accommodates externally mounted roll media similar to the printer’s support of fan-fold media.

Externally Mounted Roll Media Considerations:

IMPORTANT: The printer requires the media roll and stand combination to have low initial inertia
to pull the media off the roll.
• The media enters the printer directly behind the printer through the fan-fold media slot in the rear of the
printer. See Printing on Fan-Fold Media on page 112.
• Lower the print speed to decrease the chance of motor stalls. The roll typically has the highest inertia
when trying to start the roll moving. Larger media roll diameters require the printer to have more torque
applied to get the roll moving.
• The media should move smoothly and freely. The media should not slip, skip, jerk, bind, and then move,
etc. when mounted on your media stand.
• The printer should not touch the media roll.
• The printer should not slip or lift up off the operating surface.

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Printing with the Attached Battery Base and Battery Option

Printer operating procedures change slightly when using the battery.
The battery is designed to maximize battery life, maintain print quality, and have a simple operation. Power
connections and power loss scenarios necessitate the differences in operation.
• Connecting the printer’s external power supply to the battery will wake up the battery. The battery
determines if charging is needed.
• The battery will not start charging until the battery’s charge level is below 90% charge. This extends
your battery’s life.
• Once charging has begun, the battery will charge to 100% capacity and then go into Sleep Mode.
• The printer is receiving the external power passed through by the battery circuitry into the printer. The
battery does not charge while printing or moving media.
• The battery uses a very small amount of power during Sleep Mode to maximize the available charge
stored in the battery.
• It takes about 2 hours to charge a fully discharged battery.

UPS Mode
The printer is receiving the external power passed through by the battery circuitry into the printer.
1. Press the Battery Control button to activate the battery and check the battery's charge level. After 60
seconds the battery goes to sleep.
2. The battery is in Sleep Mode awaiting the loss of external power to the battery (and attached printer).
The printer can be turned OFF and ON normally and does not require the battery to be ON to operate.

Battery Mode
The printer is powered by a battery only.
1. Press the Battery Control button to activate the battery and check the battery's charge level. After 60
seconds the battery goes to sleep if the printer has not been turned on yet.
2. Turn the printer ON.
3. Use the printer normally.
4. Check the battery charge status at any time by pressing the Battery Control button.
5. Change or charge your battery when the last battery charge level indicator is flashing. Your print
operation may be interrupted if the battery charge is used up and the printer turns off.

Printer Fonts
The ZD-Series printer supports your language and font requirements.
The ZPL programming language provides advanced font mapping and scaling technology to support
outline fonts (TrueType or OpenType) and Unicode character mapping as well as basic bitmapped fonts
and character code pages.
The printer’s font capabilities are programming language-dependent. The ZPL and the legacy EPL
programming guides describe and document the fonts, code pages, character access, listing fonts, and
limitations for their respective printer programming languages. See the printer programming guides for
information on Text, Fonts, and Character support.

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Zebra has a variety of utilities and application software that support font download to the printer for ZPL
and EPL printer programming languages.

IMPORTANT: Some factory-installed ZPL fonts in the printer cannot be copied, cloned, or
restored to the printer by reloading or updating firmware. If these licenses restricted ZPL
fonts are removed by an explicit ZPL object delete command, they must be repurchased and
reinstalled via a font activation and installation utility. EPL fonts do not have this restriction.

Identifying Fonts in the Printer

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

Localizing the Printer with Code Pages

The printer supports two sets of language, region, and character sets for permanent fonts loaded into
the printer for each printer programming language; ZPL and EPL. The printer supports localization with
common international character map code pages.
For ZPL code page support, including Unicode, see the ^CI command in the ZPL programmer’s guide.

Asian fonts and Other Large Font Sets Asian

Asian language ideographic and pictographic fonts have large character sets with thousands of characters
that support a single language code page. In order to support the large Asian character sets, the industry
adopted a double-byte (67840 maximum) character system instead of the single-byte characters (256
maximum) used by Latin-based language characters to address large font sets. In order to address multiple
languages with a single font set, Unicode was invented. A Unicode font supports one or more code points
(relate these to code page character maps) and is accessed in a standard method that resolves character
mapping conflicts. The ZPL programming language supports Unicode. Both of the printer’s programming
languages support the large pictographic double-byte character Asian font sets.
The number of fonts that can be downloaded is dependent upon the amount of available flash memory not
already in use and the size of the font to be downloaded.
Some Unicode fonts are large, such as MS (Microsoft) Arial Unicode font (23 MB) available from Microsoft
or the Andale font (22 MB) offered by Zebra. These large font sets typically support a large number of
languages as well.

Getting Asian Fonts

Asian bitmap font sets are downloaded into the printer by the user or integrator. The ZPL fonts are
purchased separately from the printer. EPL Asian Fonts are available for free to download from the Zebra
Web site.
• Simplified and Traditional Chinese (The SimSun scalable font is pre-loaded onto printers sold with a
Chinese power cord.)

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• Japanese — JIS and Shift-JIS mappings

• Korean including Johab
• Thai

Zebra Keyboard Display Unit (ZKDU) – Printer Accessory

The ZKDU is a small terminal unit that interfaces with the printer to enable ease of access to EPL or ZPL
label forms stored in the printer.

The ZKDU is used for the following functions:

• List label forms stored in the printer
• Retrieve label forms stored in the printer
• Input variable data
• Printing labels
• Switching between EPL and ZPL to support dual-format printer language format/form types. These
forms can be stored and printed in late model Zebra label printers.

NOTE: The ZKDU is strictly a terminal unit. It does not store data and cannot be used to change
printer or printing parameters.

Zebra Basic Interpreter (ZBI) 2.0

Use ZBI to create custom controls and interpret non-Zebra formatted data from other applications, systems,
and data input devices (scanners, keyboards, scales, etc.).
Customize and enhance the printer using the ZBI 2.0 programming language. ZBI 2.0 allows Zebra printers
to run applications and take input from scales, scanners, and other peripherals without a PC or network
connection. ZBI 2.0 works with the ZPL printer command language so that printers can understand non-
ZPL data streams and convert them into labels. That means the Zebra printer can create barcodes and
text from input received, non-ZPL label formats, sensors, keyboards, and peripherals. Printers can also be
programmed to interact with PC-based database applications to retrieve information to be used on printed
labels.
• ZBI 2.0 can be activated by ordering a ZBI 2.0 Key Kit or activated by purchasing a key from Zebra.
• Use the ZBI Key Manager (also known as ZDownloader utility) to apply the key.

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• An intuitive ZBI-Developer is used to create, test, and distribute ZBI 2.0 applications. The built-in virtual
printer allows you to quickly create, test, and prepare programs for use.
Go to the Zebra Web site and search for Zebra Basic Interpreter 2.0. See zebra.com/software.

Setting the Power Failure Recovery Mode Jumper

The printer can be configured to restart itself after a power failure, unattended, with the Power Failure
Recovery Mode set.
• Remove the power supply cable from the back of the printer.
• Remove any attached printer interface cables.

NOTE:
The Power Failure Recovery Mode is only available on printers with a Printer Connectivity Module
installed in the printer.
The Printer Connectivity Modules have a Power Failure Recovery jumper set to OFF. With the
jumper set to ON, the printer will automatically Power ON when plugged into an active (ON) AC
power source.
1. Remove the module access door and connectivity module. See Configuring Wired Connectivity Options
and Power Failure Recovery Mode on page 41 for 'Removing a Connectivity Module Card' instructions.
2. Move the AUTO (Power Failure Recovery Mode) jumper from the OFF position to the ON.
3. Reinstall the connectivity module and module access door. See Configuring Wired Connectivity Options
and Power Failure Recovery Mode on page 41 for 'Installing a Connectivity Module Card' instructions.

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Maintaining the Printer
Maintaining the Printer

This section covers how you can maintain the printer in an optimal operating condition.
The printer may require periodic maintenance to keep the printer functional and printing high-quality
labels, receipts, tags, etc.

Cleaning Supplies
Use the recommended cleaning supplies to maintain printer function and prevent damage to the printer
from unapproved cleaning materials.
The following printer cleaning supplies are recommended for use with the printer:
• Printhead Cleaning Pens for simple operator printhead cleaning
• Isopropyl alcohol (minimum 99.7% pure). Use a labeled alcohol dispenser. Never re-moisten cleaning
materials used to clean the printer)
• Fiber-free Cleaning Swabs for media path, guides, and sensors.
• Cleaning Wipes for media path and interior (for example Kimberly-Clark Kimwipes).
• Can of Compressed Air.

IMPORTANT:
The cutter mechanism does not require maintenance cleaning. Do not clean the blade or
mechanism. The blade has a special coating to resist adhesives and wear.
Using too much alcohol can result in contamination of the electronic components requiring a
much longer drying time before the printer will function properly.
Do not use an air compressor in place of the can of compressed air. Air compressors have micro
contaminants and particles that get into the air compressor system and damage the printer.

CAUTION—EYE INJURY: Use eye protection to protect your eyes from particles and objects
when using compressed air.

See Also
Get Zebra Supplies and Accessories for cleaning the printer at zebra.com/accessories

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Recommended Cleaning Schedule

Use the following guidelines to help you print high-quality labels and keep the printer running well.

Printhead
Interval:
Clean the printhead after every 5 rolls printed.
Procedure:
See .

Standard Platen (Drive) Roller

Interval:
As needed to improve print quality. Platen rollers can slip causing print image distortion and in
worst-case scenarios not move the media (labels, receipts, tags, etc.).
Procedure:
See Platen Cleaning and Replacement on page 130.

Media Path
Interval:
Clean as needed.
Method:
Clean it thoroughly with fiber-free cleaning swabs and cloths moistened with isopropyl alcohol
(minimum 99.7% pure). Let the alcohol evaporate completely.
Procedure:
See Media Path Cleaning on page 125.

Interior
Interval:
Clean the printer as needed.
Method:
Use a soft cloth, brush, or compressed air to wipe or blow dust and particles out of the printer.
Use isopropyl alcohol (minimum 99.7% pure) and a fiber-free cleaning cloth to dissolve
contaminants like oils and grime.
Procedure: See the following:
Media Path Cleaning on page 125
Sensor Cleaning on page 128

Platen Cleaning and Replacement on page 130

Exterior
Interval:
Clean as needed.
Method:
Use a soft cloth, brush, or compressed air to wipe or blow dust and particles out of the printer.
Use isopropyl alcohol (minimum 99.7% pure) and a fiber-free cleaning cloth to dissolve
contaminants like oils and grime

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Label Dispenser Option

Interval:
As needed to improve label dispensing operations.
Procedure:
See Cleaning the Label Dispenser Option on page 127.

Cutter Option
Interval:
Not an operator serviceable component. Do not clean inside the cutter opening or blade
mechanism. You may use exterior cleaning to clean the cutter bezel (housing).
Method:
Call a service technician.
Procedure:
Not applicable.

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

IMPORTANT:
The blade has a special coating to resist adhesives and wear. Cleaning it may ruin the blade.
Using un-approved tools, cotton swabs, solvents (including alcohol), etc.; all may damage or
shorten the cutter’s usable life or cause the cutter to bind.

Cleaning the ZD411T Printhead

Clean the printer's printhead often to maximize print quality and printer life.
Always use a new cleaning pen on the printhead (an old pen carries contaminants from its previous use
that may damage the printhead).

CAUTION—ESD: The printhead becomes hot while printing. To protect from damaging the
printhead and risk of personal injury, avoid touching the printhead. Only use the cleaning pen to
perform printhead maintenance.

CAUTION—HOT SURFACE: The discharge of electrostatic energy that accumulates on the

surface of the human body or other surfaces can damage or destroy the printhead and other
electronic components used in this device. You must observe static-safe procedures when
working with the printhead or the electronic components under the top cover.

NOTE: When you load new media or ribbon, you can also clean the printhead.

The printer is open for replacing the media roll or performing printer service.
1. If the transfer ribbon is installed, remove it before proceeding.

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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 outer edges of media to the area outside of the media path. Do
not use the cleaning pen on the platen roller.

3. Wait one minute before closing the printer.

Media Path Cleaning

Use a cleaning swab and/or a lint-free cloth to remove debris, dust, or crust that has built up on the
holders, guides, and media path surfaces.

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Lightly moisten the swab or cloth with isopropyl alcohol (minimum 99.7% pure). For hard-to-clean
areas, use extra alcohol on a cleaning swab to soak the debris to break up any adhesive that may have
accumulated on surfaces in the media compartment.
Do not clean the printhead, sensors, or platen as part of this process.
1. Wipe the inside surfaces of the roll holders and the underside of the media guides with cleaning swabs
and wipes.
2. Wipe the movable sensor slide channel (but not the sensor). Move the sensor to get to all areas.
3. Wait one minute before closing the printer. Discard used cleaning supplies.

1 — Media Guides 2 — Don’t Clean Sensor 3 — Media Roll Holders

Cleaning the Cutter Option

This procedure is a continuation of cleaning the media path for printers with a cutter option installed.
The plastic media path surfaces can be cleaned but not the internal cutter blades or mechanism.

IMPORTANT: The cutter blade mechanism does not require maintenance cleaning. DO NOT
clean the blade. This blade has a special coating to resist adhesives and wear.

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

ATTENTION: Using un-approved tools, cotton swabs, solvents (including alcohol), etc. all may
damage or shorten the cutter’s usable life or cause the cutter to jam.
1. Wipe the ridges and the plastic surfaces of the media entry (inside) and exit slot (outside) of the cutter.
Clean inside the areas outlined in blue.
2. Repeat as necessary to remove any adhesive or contaminant residue after it dries.

Cleaning the Label Dispenser Option

This procedure is a continuation of cleaning the media path for printers with a label dispenser option
installed.
1. Open the door and clean the peel bar, inner surfaces, and ridges on the door.
2. Wipe the roller while rotating it. Discard the swab or cloth.
3. Clean the roller again with a new swab or cloth to remove diluted residue.

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4. Clean the sensor window. The window should be clear of streaks and residue.

1 — Peel Bar 2 — Pinch Roller 3 — Ridges

4 — Label Taken Sensor 5 — Inside Wall

Sensor Cleaning
Removing dust (normally) cleans these sensors.
Dust can accumulate on the media sensors. Blow or gently brush dust away while a soft cloth.

IMPORTANT: Do not use an air compressor to remove dust. Compressors add moisture, fine grit,
and lubricant which can contaminate the printer.
Adhesive particles and airborne substances can cover or coat the optical components in non-typical use
media and operating environments.

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1. Clean the Movable Sensor’s window (1). Gently brush away dust or use a can of compressed air; if
necessary, use a dry swab to brush away dust. If adhesives or other contaminants remain, use an
alcohol moistened swab to break them up.

2. Use a dry swab to remove any residue that may be left from the first cleaning.
3. Repeat steps 1 and 2 as required until all residue and streaks are removed from the sensor.

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

Platen Cleaning and Replacement

The platen (drive roller) normally does not require cleaning. Normally, paper and liner dust can accumulate
without affecting print operations.
Clean the platen (and media path) whenever the printer has significantly poorer performance, print quality,
or media handling. The platen is the print surface and drive-roller for your media. If sticking or jamming
continues even after cleaning, you must replace the platen.

IMPORTANT: Contaminants on the platen roller can damage the printhead or cause the media
to slip or stick when printing. Adhesive, dirt, general dust, oils, and other contaminants should be
cleaned off the platen immediately.
Clean the platen with a fiber-free swab (such as a Texpad swab) or a lint-free, clean, damp cloth very lightly
moistened with isopropyl alcohol (minimum 99.7% pure).
Removing the Platen Roller
1. Open the cover (and dispenser door, if the dispenser is installed). Remove media from the platen area.

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2. Pull the platen bearing latch release tabs (1) on the right and left sides towards the front of the printer
and rotate them up.

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3. Lift the platen out of the printer’s lower frame using the bearing arms (1).

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

5. Cleaning Only — Clean the platen with the alcohol moistened swab. Clean from the center out. Repeat
this process until all of the roller surfaces have been cleaned. If there has been heavy adhesive build-
up or label jam, repeat with a new swab to remove residual contaminants, as the initial cleaning may
thin but not completely remove adhesives and oils.
6. Discard the cleaning swabs after use - do not reuse them.

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

8. Align the platen with the gear to the left and lower it into the printer’s bottom frame.
9. Rotate the platen bearing latch release tabs down on the right and left sides towards the rear of the
printer and snap them into place.
10. Allow the printer to dry for one minute before closing the dispenser door, media cover, or loading
labels.

Replacing the ZD411T Printhead

This procedure guides you through replacing the printhead.
Read this procedure first before you begin your repair.
• Turn the printer OFF.
• Open the printer to gain access to the printhead (1).

CAUTION—HOT SURFACE: The printhead becomes hot while printing. To protect from
damaging the printhead and risk of personal injury, avoid touching the printhead. Only use the
cleaning pen to perform printhead maintenance.

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CAUTION—ESD: The discharge of electrostatic energy that accumulates on the surface of

the human body or other surfaces can damage or destroy the printhead and other electronic
components used in this device. You must observe static-safe procedures when working with the
printhead or the electronic components under the top cover.

Removal

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1. Push the printhead release latch toward the printhead (shown as green for visibility). The right side
printhead releases down and away from the printhead lock arm.

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2. Swing the loose right side of the printhead out of the printer. Pull it to the right a little to get the left
side of the printhead clear. Pull the printhead down and free of the ribbon carriage to gain access to its
attached cables.

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3. Gently but firmly pull the two printhead cable bundle connectors (1) off of the printhead (2).

Installation
4. Align the new printhead up to the printer. Push the right printhead cable connector into the printhead.
The connector is keyed to only insert one way.

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5. Push the left printhead cable connector (2) onto the printhead (1).

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6. Insert the center tab on the printhead assembly into the center slot on the printhead mounting bracket
in the ribbon carriage.

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7. Insert the left side tab of the printhead assembly (2) into the recessed slot (1) on the left side of the
ribbon carriage.

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8. Push the right side of the printhead into the printer until the latch locks the right side of the printhead
into the printer.

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9. Verify that the printhead moves up and down freely when pressure is applied and remains locked when
released.

After Installation
1. Clean the printhead. Use a new pen to wipe body oils (fingerprints) and debris off the printhead. Clean
from the center of the printhead to the outside. See Cleaning the ZD411T Printhead on page 124.
2. Plugin the printer power is disconnected.
3. Load full-width label or receipt paper roll. Printing with a full-width roll verifies all elements of the
printhead function.
4. Print a Configuration Report. See Print a Configuration Report to Test Printing on page 87.

Updating Printer Firmware

The printer’s firmware may need to be updated periodically to get new features, improvements, and printer
upgrades for media handling and communications.

Use Zebra Setup Utilities (ZSU) to load new firmware.

1. Open Zebra Setup Utilities.
2. Select your installed printer.

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3. Click on the Open Printer Tools button and a Tools window opens.
4. Click on the Action tab.
5. Load the printer with media. See Loading Roll Media in the ZD411T Printer on page 68.
6. Observe the user interface and wait.
If the firmware version is different than the version installed on the printer, the firmware downloads to the
printer.
The data indicator flashes green while the firmware is downloading. Then the printer restarts with all
indicators flashing.
When the firmware update completes, the STATUS indicator displays solid green, as the firmware is
validated and has finished installing.
A printer Configuration Report is automatically printed and the firmware update has been completed.

Other Printer Maintenance

There are no other user-level maintenance procedures beyond those detailed in the rest of this section.
The Real-Time Clock (RTC) battery, printer fuses, or power supply fuses are not user-serviceable in this
printer.

RTC Battery
A Real-Time Clock (RTC) is included with the printer. The clock’s battery is rated to provide approximately
ten (10) years of service and is not user-replaceable. See a Zebra authorized service technician to replace
the circuit board.
You can discern a low battery if the printer provides a consistently delayed date stamp. Battery
replacement must be performed by a qualified service technician. Only use a Zebra-approved replacement
battery.

IMPORTANT:
Recycle batteries according to local guidelines and regulations. Wrap the battery when disposing
(or storing) to avoid a short circuit.
Do not heat, disassemble or dispose of battery in fire.
Do not short circuit the battery. Short-circuiting the battery may result in heat generation, fire or
bursting.

Fuses
There are no replaceable fuses in the printer or power supply.

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Troubleshooting
Troubleshooting

This section provides troubleshooting procedures and information.

Resolving Alerts and Errors

The printer uses alerts to notify you that the printer needs attention.

Alert: Printhead/Cover Open

A print command or a FEED button has been pressed and the printer has detected that the printhead
(cover) is not closed.

Cause: Cover Open

A print command has been issued or the FEED has been pressed and the printer reports the cover is open.

Remedy: Close the Cover

1. Close the cover/printhead.
2. Push down on the front top corners of the printer’s cover. You should normally hear and feel the cover
latches snap in place to lock the cover closed.

Remedy: Head-Open Switch

Call a service technician.

Alert: Media/Labels Out

A print command has been issued, the FEED has been pressed, or you are printing, and the printer can not
detect media to print in the print path.

Cause: Out of Media/Labels

There are no labels or media on the roll in the printer. See Detecting a Media Out Condition on page 88.

Remedy: Install New Media

Operator Action

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Load media in the printer. See Loading Roll Media in the ZD411T Printer on page 68.

Cause: Label(s) Missing on Roll

A label is missing in the middle of the roll or fan-fold stack.

NOTE: Some label vendors use a missing label at the end of a media roll to alert the printer that
it is out of media. Do not use the remaining labels. They may transfer adhesives used to attach
media to the roll.

Remedy: Advance the Roll

Operator Action
1. Open the printer and pull the roll to the next label at the front of the printer.
2. Close the printer. Press the PAUSE to let the printer resume printing.
3. If the printer is paused without advancing the labels, press FEED one to two times.

Cause: Misaligned Media Sensor

The movable media sensor is not set properly for your media type.

Remedy: Adjust the Media Sensor

Operator Action
See Using the Movable Sensor on page 76.

Cause: The printer is set for non-continuous media with continuous media installed
The printer is set for noncontinuous (web/gap or black mark) media, but continuous media is loaded.

Remedy: Load the correct label type.

Operator Action
Load media in the printer. See Loading Roll Media in the ZD411T Printer on page 68.

Remedy: Calibrate the printer for continuous roll media.

Operator Action
1. Set the media sensor for continuous media. See Using the Movable Sensor on page 76.
2. Finish loading your media roll.
3. Calibrate the media. See Run a SmartCal Media Calibration on page 85.

Cause: Dirty Media Sensor

Adhesive, dust, or other contaminants are blocking proper sensor operation.

Remedy: Clean the Movable Media Sensor

Operator action
Clean the Movable Media Sensor. See Sensor Cleaning on page 128.
The printer may need more media path cleaning. Inspect the media compartment of other dirty areas of the
media path and roll holders. See Media Path Cleaning on page 125.

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Cause: Media Sensor is not Working

Possible data corruption of memory or faulty components.

Remedy: Update Firmware

Internal Printer Support
See Updating Printer Firmware on page 143.

Remedy: Sensor Component Failure

Call a service technician.

Alert: Cut Error

Condition
The printer has detected that the cutter blade is bound and is not moving properly

IMPORTANT: Cutter Service — There are no operator serviceable parts in the cutter unit.
Never remove the cutter cover (bezel). Never attempt to insert objects or fingers into the cutter
mechanism.

IMPORTANT: Using unapproved tools, cotton swabs, solvents (including alcohol), etc. all may
damage or shorten the cutter’s usable life or cause the cutter to jam.

Cause
Adhesive and paper particles can bind the blade.

Remedy
Operator Action
1. Turn the printer off by holding the power using the POWER down for 5 seconds. Wait for the printer to
shut down completely. Turn the printer ON.
2. If the printer does not recover from this error, call a service technician. This is not an operator
serviceable item.

Alert: Printhead Over Temperature

Condition
The printhead is over-temperature and paused to allow the printhead to cool.

Cause: Large Dense Print Jobs

The printer is printing a large batch job, typically with large amounts of print.

Remedy: Printer Stops and Cools Before Resuming

Internal Printer Support - Operator Action
The print operation will resume after the printhead has cooled sufficiently to continue.

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Cause: Operating Environment is Too Hot

The ambient temperature at the printer's location exceeds the specified operating range. Sometimes,
ambient temperatures in the printer can be higher if it is in direct sunlight.

Remedy: Printer Stops and Cools Before Resuming

Internal Printer Support - Operator Action
Move the printer location or cool ambient temperature where the printer is operating.

Alert: Printhead Under Temperature

Condition

Cause: Operating Environment is Too Cold

The ambient temperature at the printer's location is below the specified operating range.

Remedy: Increase Operating Environment Temperature or Move the Printer Location

Internal Printer Support - Operator Action
Printhead has had a critical temperature (or power failure).
1. Turn the printer off. Move the printer location and wait for it to warm naturally. Moisture may condense
in and on the printer if the temperature changes too quickly.
2. Set the printer up for operation and turn the power on to continue using the printer. See Select a
Location for the Printer on page 64.

Cause: Printhead Failure

The printhead is below operating temperature for proper printing.

Remedy: Replace the Printhead

Internal Printer Support
Replace the printhead. See Replacing the ZD411T Printhead on page 134.

Alert: PRINTHEAD SHUTDOWN

Condition
The printhead has had a printhead circuit fault protection shutdown.

Cause
has shut down due to critically high temperatures to protect the printhead.

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Remedy
1. Turn the printer off by holding the POWER button down for 5 seconds. Wait for the printer to shut down
completely. Wait a few minutes for cooling and turn the printer ON.
2. Replace the printhead if restarting and cooling have not corrected this issue.
3. Call a service technician if the printer does not recover from this error. This is not an operator
serviceable item.

Alert: Out Of Memory

Condition
The printer can not store data in the printer in the specified memory location. There are four types of
storage memory: Graphic, Format, Bitmap, and Font. There is not enough memory to perform the function
specified on the second line of the error message.

Cause: Not Enough Memory to Store a File

There is not enough memory to perform the function on the specified file type.

Remedy: Free Up Memory

Internal Printer Support
1. Free up some of the printer’s memory by adjusting the label format or printer parameters to make the
print area smaller.
2. Remove unused graphics, fonts, or formats.
3. Ensure that the data is not directed to a device that is not installed or is unavailable.

Resolving Print Issues

This section helps you identify issues with printing or print quality, the possible causes, and the
recommended solutions.

Issue: General Print Quality Issues

Condition
The printed image does not look right.

Cause: Darkness and Speed Settings Need to be Adjusted

The printer is set at an incorrect darkness level and/or print speed for your media.

Remedy: Run Print Quality Report

Internal Printer Support
Perform the Print Quality Report (FEED self-test) to determine the ideal darkness and speed settings for
your application. Do not set print speeds above the manufacturer’s maximum rated speed for your media

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(print material and ribbons both). See Generating a Print Quality Report (FEED self-test) on page 159 and
Adjusting the Print Quality on page 111.

Cause: Dirty Printhead

The printhead is dirty and distorting the image or putting voids in the printout.

Remedy: Clean the Printhead

Operator Action
Clean the printhead. See Cleaning the ZD411T Printhead on page 124.

Cause: Dirty or Damaged Platen (Drive) Roller

The platen roller is dirty or damaged.

Remedy: Clean or Replace the Platen

Internal Printer Support - Operator Action
Clean or replace the platen. Platens can wear out or get damaged. See Platen Cleaning and Replacement
on page 130.

Cause: Printhead is Worn Out

The printhead has worn out.

Remedy: Replace the Printhead

Internal Printer Support - Operator Action
Replace the printhead. The printhead can wear out and be damaged. See Replacing the ZD411T Printhead
on page 134.

Cause: Thermal Transfer Printing Looks Distorted

Thermal Transfer printing - Printing looks fuzzy, has smudge marks, or has voids or holes in print with no
particular pattern.

Remedy: Verify Media and Ribbon Types are Matched

Internal Printer Support - Operator Action
• The print material (wax, wax-resin, or resin) may not match the material (paper, media coating, or
synthetics) in use. Set the printer for no higher than the maximum recommended print speed of the
ribbon.
• Perform the Print Quality Report (FEED self-test) to determine the ideal darkness and speed settings
for your application. Do not set print speeds above the manufacturer’s maximum rated speed for your
media (print material and ribbons both). See Generating a Print Quality Report (FEED self-test) on page
159 and Adjusting the Print Quality on page 111.

Cause: Using the Wrong Power Supply

The power supply has a lower voltage or power rating. Printing is a high-power process.

Remedy: Use the Proper Power Supply

Operator Action
• Find the power supply that goes with the printer.

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Issue: No Print on the Label

Wrong Media Installed for Media Type Setting
No print on labels.

Cause: Using Thermal Media for Direct Thermal Printing

See the test procedure, Determining Thermal Media Types on page 173.

Remedy: Install Direct Thermal Media

Operator Action
• Load your chosen direct thermal media in the printer.

Cause: Media Loaded Incorrectly

Remedy: Reload your Media

• The media printable surface must face up towards the printhead. See Getting Ready to Print on page 67
followed by Loading Roll Media in the ZD411T Printer on page 68.

Issue: Print Image Moves or is Distorted

Condition
Print image distortion or print positioning issues.

Cause: Media Needs to be Reloaded

has not been loaded incorrectly, the movable media sensor is not set properly, or the media needs to be
calibrated.

Remedy: Inspect Area and Reload the Media

Internal Printer Support - Operator Action
1. Leave printer power ON and remove the media.
2. Visually inspect the media path, roll holders, and media guides for paper dust and adhesive
buildup. Visually inspect the platen (drive) roller for damage or paper dust and adhesive.
See next Cause: Printer Needs to be Cleaned for this Issue.
3. Verify that the sensor is set and positioned correctly for your media type and sensing location. Check
to see the Movable Sensors window is clean.
See Using the Movable Sensor on page 76.
4. Reload the media.
See Loading Roll Media in the ZD411T Printer on page 68.

Cause: Printer Needs to be Cleaned

Remedy: Clean the Interior of the Printer

Internal Printer Support - Operator Action

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1. Clean the printer's media path, platen roller, and media sensors.
See Media Path Cleaning on page 125.
2. Clean the printer's sensors.
See Sensor Cleaning on page 128.
3. Clean the platen (drive) roller
See Platen Cleaning and Replacement on page 130.
4. Clean the printhead last.
Clean the printhead. See .
5. Reload the printer media and run a SmartCal media calibration.

Platen Roller is Damaged or Worn Out

Over time the platen roller can wear out or become damaged. As the platen roller gets older, it smoother
and grips the media less and becomes less soft and wears out.

Replace the Platen Roller

Internal Printer Support
Remove and replace the platen roller.
See Platen Cleaning and Replacement on page 130.

Communication Issues
This section identifies problems with communications, the possible causes, and the recommended
solutions.

Issue: USB Printer Fails to Install after Connecting Printer (Before Installing the
Printer Driver)

USB printer driver fails to install

The printer is connected to the Windows computer via USB and is not properly recognized by the system.
The incorrectly Windows-assigned printer can not do a Windows test print from the selected USB-attached
printer.

The USB Cable was installed before the printer drivers were pre-installed.
Windows installed the Windows generic printer driver.

Remedy
Operator
1. Disconnect the printer USB cable from the Windows computer.

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2. The Zebra printer is not shown in the printers section of the Devices and Printers window in the
connected Windows computer. The printer incorrectly shows as Unspecified. You can use the
Windows taskbar to search for Control Panel and open it. Select the Devices and Printers to open.

Zebra printers display ZTC as a prefix to identify them easily.

3. Click on theUnspecified Zebra printers in the Devices and Printers window and delete.
4. If you have not previously loaded the Windows Printer Driver v8 , then load the Windows Printer
Driver v8 now. See Pre-installing the Window's Driver to help you add the correct drivers to the system.
5. Plug the printer USB cable into the Windows computer. The Zebra printer should now be added into the
Printers section of the Devices and Printers window.

Issue: Label Job Sent, No Data Transfer

Condition
A label format was sent to the printer but was not recognized. The DATA indicator does not flash.

Cause
The communication parameters are incorrect for typically serial interface communications.

Remedy
Internal Printer Support
• Check the printer driver or software communications settings (if applicable).
• Serial Port Only - Check the printer’s handshake protocol and serial port settings. The setting used must
match the one being used by the host computer.
• The serial cable you are trying to use may not be a standard DTE or DCE type cable, is damaged, or is
too long per the RS-232 Serial ports specifications
• The interface cable may be too long, does not meet interface specifications, not properly shielded or
routed by electronic noise sources (fluorescent lights, transformers, motors, etc.).
• See Serial Interface on page 94 (setup), Interface Cable Requirements on page 91, and Serial Port
Interface (connector wiring).

Issue: Label Job Sent, Skips Labels or Prints Bad Content

Condition
A label format was sent to the printer. Several labels print, then the printer skips, misplaces, misses, or
distorts the image on the label.

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Cause: Serial Communications Miss-Match

The serial communication settings are incorrect for the printer or the host computer system and operating
system software.

Remedy: Set Serial Communications

Internal printer support
Check the printer driver or software communications settings (if applicable). Ensure that the flow control
settings and other serial port handshake settings match the host system.
See Serial Interface on page 94 (setup).

Issue: Label Job Sent, Data Transfers, But No Print

Condition
A label format was sent to the printer. Several labels print, then the printer skips, misplaces, misses, or
distorts the image on the label.

Cause: Data Parsing Character Miss-match

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

Remedy: Set Data Parsing Characters.

• Verify the ZPL programmings prefix (COMMAND CHAR) and delimiter (DELIM./CHAR) characters. See
Configuration Setting to Command Cross-Reference on page 186.

Cause: Incorrect Data

Incorrect data is being sent to the printer.

Remedy: Correct Label Format Programming

Internal Printer Support
• Check the communication settings on the computer. Ensure that they match the printer settings.
• Check the label format syntax.
See the ZPL Programmers at zebra.com/manuals. for more information on printer and label
programming.

Miscellaneous Issues
This section identifies miscellaneous issues with the printer, the possible causes, and the recommended
solutions for them.

Issue: Settings are Lost or Ignored

Condition
Some programming parameters are set incorrectly.

Cause: Unsaved Printer/Format Settings Lost

Printer settings were changed without saving them.

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Remedy: Save Printer/Format Settings

Internal Printer Support
The ZPL ^JU command was not used to save your configuration before turning the printer off. Cycle the
printer OFF and then back ON to verify settings have been saved.

Cause: Incorrect Label Syntax

The label format/form commands or commands sent directly to the printer have syntax errors or have been
used incorrectly.
• An internal command or other action turned off the ability to change the parameter.
• An internal command or other action changed the parameter back to the default setting.

Remedy: Save Printer/Format Settings

Internal Printer Support
• Reset printer settings. Sometimes it is helpful to reset the printer to factory default.
• Update printer firmware in case of memory corruption.
See Updating Printer Firmware on page 143.
• Check the label format syntax.
See the ZPL Programmers at zebra.com/manuals. for more information on printer and label
programming.

Issue: Non-continuous Labels act as Continuous Labels.

Condition
A non-continuous label format with matching label media loaded in the printer was sent to the printer but
prints like it is continuous roll media.

Cause
The printer is configured for continuous media.

Remedy
Internal Printer Support
• Set the printer for the correct media type (gap/notch, continuous, or mark).
• Calibrate the printer using Run a SmartCal Media Calibration on page 85.
• If necessary use Manual Media Calibration Mode on page 162 for hard-to-calibrate media types.

Issue: Printer Locks-Up

Condition
The printer is not responding to operator actions and commands sent to the printer. The status may be all
on or in unknown status patterns.

Cause: Memory Corruption or Failure

The printer memory has been corrupted by an unknown event.

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Remedy: Reload Printer Firmware and Test

Internal Printer Support
1. Reset the printer to factory defaults.
Use one of the following methods to reset factory defaults.
• See Resetting Printer Factory Defaults (PAUSE + FEED Self Test) on page 159.
• Use the Zebra Setup Utility and Open Printer Tools > Action > Load printer defaults.
2. Reload printer firmware. See Updating Printer Firmware on page 143.
3. If the printer does not recover from this error, call a service technician. This is not a user-serviceable
item.

Issue: Battery has a Red Indicator

Condition
The battery has a detected fault condition.

Cause: Battery Failure

The battery has reached its usable life or has a general component failure.

Cause: Battery is too hot or too cold

Remedy: Test and Replace the Battery, if necessary.

Internal Printer Support - Operator Action
1. Remove the battery from the printer and check the charge status by charging the battery.
2. Let the battery cool down or warm up to ambient temperature and recheck the battery charge.
3. Insert a new fully-charged battery into the printer and safely dispose of the battery per locale
requirements.

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Onboard Printer Tools

This section provides a variety of tools and utilities built into the printer. They are designed to assist you
with setup, configuration, and debugging (printer and command programming).

Printer Diagnostics
A variety of diagnostic tools and procedures are available to help you operate your printer and diagnose
problems. These include printer configuration and network configuration reports, diagnostic reports,
calibration procedures, and the ability to restore the printer settings to their factory defaults if needed.

Diagnostic Testing Tips

IMPORTANT: When performing self-tests, use full-width media. If the media is not wide enough,
the test labels may print on the platen (drive) roller.
To initiate a printer self test, you will need to press a specific user interface button or a combination of
buttons while turning printer power ON. Keep the button(s) pressed until the first indicator light turns off.
The selected self test automatically starts at the end of the normal power-up operation.
• When performing these self tests, do NOT send data to the printer from the central device.
• If your media is shorter than the label to be printed, the test label continues on the next label.
• If canceling a self test before it completes, always reset the printer by turning printer power OFF and
then ON.
• If the printer is dispensing the printer reports and liner is being taken up by the applicator, manually
remove the reports as they become available.

SmartCal Media Calibration

SmartCal is used to quickly calibrate the printer to the media currently loaded.
During SmartCal, the printer automatically determines the media sensing type (gap, black line, or notch),
and then measures the length of the media.
1. Make sure the media is properly loaded, the printer cover is closed, and printer power is ON.
2. Press and hold the PAUSE + CANCEL buttons for two seconds.
3. The printer will feed and measure several labels. When done, the printer will return to READY status.
If the printer should fail to recognize and correctly calibrate to the media, refer to the Manual Media
Calibration Mode on page 162 procedure later in this section.

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Printing a Configuration Report (CANCEL Self Test)

The Configuration Report diagnostic prints a set of printer and network configuration reports.
1. Make sure the media is loaded and the printer cover is closed.
2. There are two choices to print the report here.
• If printer power is OFF, press and hold the CANCEL button while turning the printer power ON.
• If printer power is ON, press FEED + CANCEL buttons for two seconds.
3. The Printer and Network Configuration Reports (below) is printed, and the printer returns to READY
status.

Sample Printer Configuration Sample Network Configuration

(for versions with wired and wireless Ethernet
installed)

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Printer Network (and Bluetooth) Configuration Report

For printers installed with Wired or Wireless connectivity options, print an additional printer configuration
report.
This information is needed to establish and troubleshoot Ethernet (LAN and WLAN), Bluetooth 4.2, and
Bluetooth LE network printing. The following printout is printed with the ZPL ~WL command.

iOS Bluetooth Support

• iOS devices have Bluetooth when the Wi-Fi and Bluetooth wireless connectivity option is installed in the
printer and is noted as supported at the bottom of the Bluetooth Configuration report.
• The iOS setting is noted on the bottom of the Bluetooth Configuration report as not supported when the
Wireless connectivity option is detected as not installed.
• See Printing a Configuration Report (CANCEL Self Test) on page 158 for a sample printout of the
Network Configuration report.

Resetting Printer Factory Defaults (PAUSE + FEED Self Test)

This resets the printer configuration to the factory default values for the non-network printer settings.

NOTE: The printer has a reset button under the printer, See the Reset Button.

1. Turn OFF the printer.

2. Press and hold the PAUSE + FEED buttons while turning ON the printer.
3. Continue holding the PAUSE + FEED buttons until the STATUS indicator is the only indicator lit.
4. Calibrate the printer for the media in use. See SmartCal Media Calibration on page 157.

Resetting Network Factory Defaults (PAUSE + CANCEL Self Test)

This procedure resets the network configuration settings to the factory default values.
1. Turn OFF the printer.
2. Press and hold the PAUSE + CANCEL buttons while turning ON the printer.
3. Continue holding the PAUSE + CANCEL buttons until the STATUS indicator is the only indicator lit.

Generating a Print Quality Report (FEED self-test)

Different types of media may require different darkness settings. This section contains a simple but
effective method for determining the ideal darkness for printing barcodes that are within specifications.
Load the printer with full-width media.
During the Print Quality Report (FEED self-test), a series of labels are printed at different darkness settings
at two different print speeds. The relative darkness and the print speed are printed on each label. The
barcodes on these labels may be ANSI-graded to check the print quality. The speed at which labels are
printed during this print quality test depends on the dot density of the printhead.
During this test, one set of labels is printed at low speed, and another set is printed at the high speed. The
darkness value starts at three settings lower than the printer’s current darkness value (relative darkness

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of –3) and increases until the darkness is three settings higher than the current darkness value (relative
darkness of +3).
The speed at which labels are printed during this print quality test depends on the dot density of the
printhead.
• 300 dpi printers: prints 7 labels at 51mm/sec (2 ips) and 102 mm/sec (4 ips) print speeds.
• 203 dpi printers: prints 7 labels at 51mm/sec (2 ips) and 152 mm/sec (6 ips) print speeds.
1. Print a configuration report to show the printer’s current settings. Press and hold the FEED and CANCEL
buttons for two (2) seconds to print the report.
2. Turn OFF the printer.
3. Press and hold FEED button while setting the printer power to ON. Continue to hold FEED button until
the Status indicator is the only indicator lit.
The printer prints a series of labels at various speeds and darkness settings higher and lower than the
darkness value shown on the printer's configuration report.

Figure 13 Print Quality Sample Test Print

Table 3 Visual Darkness Descriptions

Print Quality Description
Too dark • Labels that are too dark are fairly obvious. They may be readable but not In-
Spec.
• The normal barcode bars increase in size.
• The openings in small alphanumeric characters may appear filled in.
• Rotated barcodes have bars and spaces run together.

Slightly dark • Slightly dark labels are not as obvious.

• The normal barcode will be In-Spec.
• Small character alphanumerics will be bold and could be slightly filled in.
• The rotated barcode spaces are small when compared to the In-Spec code,
possibly making the code unreadable.

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Table 3 Visual Darkness Descriptions (Continued)

Print Quality Description
In-Spec The In-Spec barcode can only be confirmed by a verifier, but it should exhibit the
following visible characteristics.
• The normal barcode will have complete, even bars and clear, distinct spaces.
• The rotated barcode will have complete, even bars and clear, distinct spaces.
Although it may not look as good as a slightly dark barcode, the barcode will
be In-Spec.
• In both normal and rotated styles, small alphanumeric characters look
complete.

Slightly light • Slightly light labels are, in some cases, preferred to slightly dark ones for In-
Spec barcodes.
• Both normal and rotated barcodes will be in spec, but small alphanumeric
characters may not be complete.

Too light • Labels that are too light are obvious.

• Both normal and rotated barcodes have incomplete bars and spaces.
• Small alphanumeric characters are unreadable.

4. Inspect the test labels and determine which one has the preferred print quality for your application.
• If you have a barcode verifier, use it to measure bars/spaces and calculate the print contrast.
• If you do not have a barcode verifier, use your eyes or the system scanner to choose the optimal
darkness setting based on the labels printed in this self-test.
5. Note the relative darkness value and the print speed printed on the preferred test label.
6. Add or subtract the relative darkness value from the darkness value specified on the configuration
label. The resulting numeric value is the best darkness value for that specific label/ribbon combination
and print speed.
7. If necessary, change the current darkness value to the darkness value on the preferred test label.
8. If necessary, change the current print speed to the speed value on the preferred test label.

Activating Advanced Mode

Advanced Mode is used to access several manual adjustment modes in the printer. Each manual
adjustment mode is described in detail in the following sections.
1. Ensure media is loaded and printer power is ON.
2. Press the PAUSE button for two seconds, all indicators will flash yellow.

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3. The STATUS indicator will show solid yellow, indicating the currently selected mode is: Manual Media
Calibration.
• Pressing the FEED button will sequentially cycle through all available modes.
• Pressing the PAUSE button will activate the selected mode.
• Pressing the CANCEL button will exit Advanced Mode.

Manual Media Calibration Mode

The Manual Media Calibration performs an optimized series of focused sensor settings for hard-to-sense
media.
While in Advanced Mode, press PAUSE while the Status indicator is illuminated yellow to start Manual
Media Calibration.
1. The media indicator will flash yellow than the pause indicator will flash.
2. Open the printer and verify the media sensor is in the center position for label gap (transmissive)
sensing.

NOTE:
If your media uses black mark or notch sensing, ensure the media sensor is in the proper
location to see the mark or notch.
If your media is pre-printed, either on the front of the label or on the back of the liner, position
the sensor so that it is in a position with minimal printing. You may need to perform Manual
Media Calibration several times, moving the media sensor, until the printer completes the
calibration process and returns to the READY state.
3. Remove 3 inches or 80mm of labels from the liner.
4. Place the label-less area of the liner over the platen (drive) roller with the leading edge of the first label
under the media guides.
5. Close the printer and press PAUSE once.
The media indicator will flash as the media liner is measured. When complete, the pause indicator will
begin flashing.
6. Open the printer and reposition the media so that a label is located directly above the movable sensor.
Close the printer.
7. Press PAUSE once.
The printer will feed and measure several labels. If the printer is able to determine the correct
media type (gap, black mark, or notch) and measure the media length, the printer will return to
the READY state, the status indicator is solid green.

Using the Manual Print Width Adjustment

Use this procedure to set the maximum print width without programming.

NOTE: Do not set the print width wider than the media width. The printhead and platen (drive)
roller can be damaged or degrade component life.
1. Press the PAUSE button while the Pause indicator is illuminated yellow.
2. The printer prints a 16 mm (0.63 in.) box and pauses momentarily.

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3. The printer then prints a slightly larger box and pauses again.

TIP: To return to the maximum print width setting, allow the printer to proceed without
pressing the FEED button.
4. When you see the printer print a box that matches the width of your media, press the FEED button to
set the print width and return to the READY state.

Adjusting the Darkness with Manual Print Darkness

Use this procedure to set the print darkness using pseudo barcodes without programming.
1. Press the PAUSE button while the DATA indicator is illuminated yellow
2. The printer prints a test pattern showing the current darkness number with several barcode patterns
and then pauses momentarily.
3. The printer then repeats the pattern with the next darkness level.
4. When you see the printer print a pattern with solid even black lines, press the FEED button to set the
darkness value and return the printer to a READY state.

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Factory Test Modes

The printer includes print modes that are intended for factory test only.

Test mode 1
When activated, the printer will begin printing various test patterns used to evaluate printer performance.

NOTE: Both of these test modes will consume a considerable amount of media as the tests are
performed.
Initiated by holding PAUSE button while turning ON printer power.

Test mode 2
Initiated by holding the PAUSE + FEED + CANCEL buttons for two seconds while the printer power is ON.

Using the Reset Button

The printer has a dedicated Reset button located on the bottom of the printer.
Press the printer's Reset button (1) with a paperclip or similar small object.

Pressing the button triggers the following results based on the length of the button press:

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0-1 second No action

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

Running a Communication Diagnostics Test

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

1. Ensure media is loaded and printer power is ON.

2. Set the print width equal to or less than the label width being used for the test.
3. Press and hold Pause + FEED for two seconds. When active, the STATUS indicator will alternate
between green and yellow.
The printer enters diagnostics mode and prints any data received from the host computer on a test
label.

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4. Check the test label for error codes. For any errors, check that your communication parameters are
correct.
Errors show on the test label as follows:
• FE indicates a framing error.
• OE indicates an overrun error.
• PE indicates a parity error.
• NE indicates noise.
Press and hold Pause + FEED for two seconds or turn the printer power OFF (O) and then back ON to exit
this self-test and return to normal operation.

Sensor Profile Report

Use this report to identify sensor location and sensing problems.

Identifying Sensor Profile Elements

Use the sensor profile image (which will extend across several labels or tags) to troubleshoot the following
situations:
• The printer experiences difficulty in determining gaps (web) between labels.
• The printer incorrectly identifies preprinted areas on a label as gaps (web).

Using the buttons on 1. Turn OFF the printer.

the user interface
2. Press and hold FEED + CANCEL while turning ON the printer.
3. Hold FEED + CANCEL until the STATUS indicator is the only indicator lit.

Using ZPL Send the ~JG command to the printer. See the Zebra Programming Guide for
more information about this command.

Compare your results to the examples shown in this section. If the sensitivity of the sensors must be
adjusted, calibrate the printer (see Manual Media Calibration Mode on page 162).
• The line labeled MEDIA (1) on the sensor profile indicates the media sensor readings.
• The media sensor threshold settings are indicated by WEB (2).
• The media out threshold is indicated by OUT (3).
• The upward spikes (4) indicate gaps between labels (the web/gap).
• The lines between the spikes (5) indicate where labels are located.
• The numbered line at the top (6) provides measurement in dots from the start of the printout.
If you compare the sensor profile printout to the length of your media, the spikes should be the same
distance apart as the gaps on the media. If the distances are not the same, the printer may be having
difficulty determining where the gaps are located.

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Figure 14 Sensor Profile (Gap/Web Media)

Figure 15 Sensor Profile (Black Mark, Tag Media)

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Interface Information
Interface Information

This section provides connector wiring and power information for the USB and serial port interfaces.

Universal Serial Bus (USB) Interface

This section explains the USB connector wiring for the USB A and B styles used by the printer.

IMPORTANT: When using third-party cables, the printer requires USB cables or the cable
packaging that bears the Certified USB mark to guarantee USB 2.0 compliance.

Figure 16 USB - A

1 2 3 4

Wiring - USB Connector A Style for connecting to the printer or device

Pin 1 — Vbus (+5VDC).
Pin 2 — D- (Data Signal, Negative Side)
Pin 3 — D+ (Data Signal, Positive Side)
Pin 4 — Shell (Shield/Drain Wire)

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 Interface Information

Figure 17 USB -B

2 1

3 4

Wiring - USB Connector B Style for connecting to the printer or device

Pin 1 — Vbus (Not Connected)
Pin 2 — D- (Data Signal, Negative Side)
Pin 3 — D+ (Data Signal, Positive Side)
Pin 4 — Shell (Shield/Drain Wire) Shell

IMPORTANT: USB Host +5 VDC power source is shared with serial port phantom power. It is
limited to 0.5mA per USB Specification and with onboard current limiting. The maximum current
available through the serial port and USB port will not exceed a total of 0.75 Amps.

See Also
usb.org

Serial Port Interface

This section explains the connector wiring Zebra Auto-Detecting DTE and DCE for 9-Pin RS-232 Interface.

Table 4 9-Pin RS-232 Interface

Pin DTE DCE Description (DTE)
1 — 5V Not used
2 RDX TXD RXD (receive data) input
to the printer
3 TXD RXD TXD (transmit data)
output from the printer
4 DTR DSR DTR (data terminal
ready) output from the
printer -- controls when
the host may send data
5 GND GND Circuit ground
6 DSR DTR DSR (data set ready)
input to the printer

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Table 4 9-Pin RS-232 Interface (Continued)

Pin DTE DCE Description (DTE)
7 RTS CTS RTS (request to send)
the output from the
printer -- always in the
ACTIVE condition when
the printer is turned on
8 CTS RTS CTS (clear to send) - Not
used by the printer
5V — +5 V @ 0.75 A - FET
Circuit current limited

IMPORTANT: The maximum current available through the serial port, USB port, or both will not
exceed a total of 0.75 Amps.
When XON/XOFF handshaking is selected in the printer driver, the data flow is controlled by the ASCII
control codes DC1 (XON) and DC3 (XOFF). The DTR control lead will have no effect.

Figure 18 Connecting the Printer to a DTE Device

Interconnecting to DTE Devices – The printer is configured as data terminal equipment (DTE). To connect
the printer to other DTE devices (such as the serial port of a personal computer), use an RS-232 null
modem (crossover) cable.

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 Interface Information

Figure 19 Connecting the Printer to a DCE Device

Interconnecting to DCE Devices – When the printer is connected via its RS-232 interface to data
communication equipment (DCE) such as a modem, a STANDARD RS-232 (straight-through) interface cable
must be used.

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Types of Thermal Media
Types of Thermal Media

The printer can use a wide variety of thermal print media outlined here.
For optimal printing quality and proper printer performance across our product line, Zebra strongly
recommends the use of Zebra Certified Supplies as part of the total solution. A wide range of paper,
polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the printing
capabilities of your printer and prevent premature printhead wear. To purchase supplies, go to zebra.com/
supplies.
ZD series printers use heat and pressure to expose direct thermal media or melt and transfer ink to the
media.
The printer can use various types of media:
• Standard media—Most standard (non-continuous) media uses an adhesive backing that sticks individual
labels or a continuous length of labels to a liner.
• Continuous roll media—Most continuous roll media is direct thermal media (similar to fax paper) and is
used for receipts or tickets.
• Tag stock—Tags are usually made from heavy paper up to 0.19 mm ([0.0075 in.) thick. Tag stock does
not have adhesive or a liner. It is typically perforated between tags.
• Fanfold—Non-continuous media that comes folded in a rectangular stack. Fanfold media is either gap/
notch or black mark media.

Determining Thermal Media Types

Thermal transfer media requires a ribbon for printing while direct thermal media does not. To determine if
ribbon must be used with a particular media, perform a media scratch test.
1. Scratch the print surface of the media with a fingernail or pen cap. Press firmly and quickly while
dragging it across the media surface. Direct thermal media is chemically treated to print (expose) when
the heat is applied. This test method uses friction heat to expose the media.
2. Did a black mark appear on the media?

Table 5 Media Scratch Test Results

If a black mark... Then the media is...
Appears on the media Direct thermal. No ribbon is required.
Does not appear on the media Thermal transfer. A ribbon is required.

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 Types of Thermal Media

General Media and Print Specifications

The printer has a wide variety of media and print handling variations. The range of basic media support
is specified here.
• Direct Thermal ZD621, ZD621R, ZD421 — Max. Media width: 108 mm (4.25 in.)
• Direct Thermal ZD411, ZD611 — Max. Media width: 57mm (2.25 in.)
• Thermal Transfer ZD621, ZD621R, ZD421 Cartridge — Max. Media width: 118 mm (4.65 in.)
• Thermal Transfer ZD411, ZD611 — Max. Media width: 57mm (2.25 in.)
• Thermal Transfer ZD421, ZD421CN — Max. Media width: 112 mm (4.41 in.)
• All Printers — Min. Media width: 15 mm (0.585 in.)
• Media length:
• 990 mm (39 in.) max.
• 6.35 mm (0.25 in.) min. – Tear Off or Label
• 12.7 mm (0.50 in.) min. – Peel
• 25.4 mm (1.0 in.) min. – Cutter
• Media thickness:
• 0.06 mm (0.0024 in.) min. – all requirements
• 0.1905 mm (0.0075 in.) max. – all requirements
• Media Roll Outer Diameter (O.D.) max. – 127 mm (5.0 in.)
• Media Roll Core Inner Diameter (I.D.):
• 12.7 mm (0.5 in.) I.D. – Standard roll configuration
• 25.4 mm (1 in.) I.D. – Standard roll configuration
• 38.1 mm (1.5 in.) I.D. – with optional media roll adapter
• 50.8 mm (2.0 in.) I.D. – with optional media roll adapter
• 76.2 mm (3.0 in.) I.D. – with optional media roll adapter
• Ribbon Rolls – 74 meter
• Ribbon Length – 74 m (243 ft.)
• Ribbon Width Max. – 110 mm (4.33 in.)
• Ribbon Width Min. – 33 mm (1.3 in.)
• Ribbon Core I.D. – 12.7 mm (0.5 in.)
• Wax, Wax/Resin, and Resin transfer materials
• Dot pitch:
• 203 dpi: 0.125mm (0.0049 in.)
• 300 dpi: 0.085mm (0.0033 in.)
• Barcode modulus x-dim:
• 203 dpi: 0.005 – 0.050 in.
• 300 dpi: 0.00327 – 0.03267 in.

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 Types of Thermal Media

Label Dispenser (Peeler)

The printer supports a field-installed label dispense option with a label taken sensor for batch processing
of labels.
• Paper Thickness:
• Min. – 0.06 mm (0.0024 in.)
• Max. – 0.1905 mm (0.0075 in.)
• Media Width:
• Min. – 15 mm (0.585 in.)
• Thermal Transfer ZD621, ZD621R, and ZD421 Cartridge Max. 118 mm (4.65 in.)
• Thermal Transfer ZD421 and ZD421CN Max. 112 mm (4.41 in.)
• Direct Thermal Printers Max. 108 mm (4.25 in.)
• Label Length:
• All Printers Max. (theoretical) – 990 mm (39 in.)
• Thermal Transfer Printers Max. (tested) – 279.4 mm (11 in.)
• Direct Thermal Printers Max. (tested) – 330 mm (13 in.).
• All Printers Min. – 12.7 mm (0.5 in.)

Standard (Media) Cutter

The printer supports a field-installed media cutter option for full-width cutting of label liner, tag or receipt
media.
• A medium-duty cutter for cutting label liner and light tag media (LINER/TAG). Do not cut through labels,
adhesive, or embedded circuitry.
• Paper Thickness:
• Min. – 0.06 mm (0.0024 in.)
• Max. – 0.1905 mm (0.0075 in.)
• Cut Width:
• Min. – 15 mm (0.585 in.)
• Thermal Transfer ZD621, ZD621R, and ZD421 Cartridge Max. 118 mm (4.65 in.)
• Thermal Transfer ZD421 and ZD421CN Max. 118 mm (4.65 in.)
• Direct Thermal Printers Max. 109 mm (4.29 in.)
• Min. distance between cuts (label length): 25.4 mm (1 in.).
• Cutting shorter media lengths between the cuts may cause the cutter to jam or errors.

NOTE: By design, the cutter is self-cleaning and does not require preventive maintenance of the
internal cutter mechanism.

Linerless (Media) Cutter - Direct Thermal only

The printer supports a field installed media cutter option for full width cutting of linerless media.
• A full width linerless media cutter (LINERLESS CUT).
• Paper Thickness:

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 Types of Thermal Media

• Cut Width:
• Minimum distance between cuts (label length): 25.4 mm (1 in.). Cutting shorter media lengths between
the cuts may cause the cutter to jam or error.

NOTE: By design, the cutter is self cleaning and does not require preventive maintenance of the
internal cutter mechanism. Go to Linerless Platen (Drive) Roller on page 242 cleaning and Media
Path Cleaning on page 247 to maintain optimal linerless media cut operation.

Various Types of Roll and Fan-Fold Media

The following table helps to identify what type of media to use to print labels.

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

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 Types of Thermal Media

Table 6 Types of Media Roll and Fanfold Media

Media Type How It Looks Description
Non-Continuous Roll media is wound on a core that can be 0.5 to 1.5 in. (12.7
Roll Media to 38.1 mm) in diameter. Labels have adhesive backing
that sticks them to a liner, and they are separated by gaps,
holes, notches, or black marks. Tags are separated by
perforations. Individual labels are separated by one or more
of the following methods:
• Web media separates labels by gaps, holes, or notches.

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

backside of the media to indicate label separations.
• Perforated media has perforations that allow the labels or
tags to be separated from each other easily. The media
may also have black marks or other separations between
labels or tags.

• Perforated media has perforations that allow the labels or

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

Non-Continuous Fanfold media is folded in a zigzag pattern. Fanfold media

Fanfold Media can have the same label separations as non-continuous roll
media. The separations would fall on or near the folds.

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 Types of Thermal Media

Table 6 Types of Media Roll and Fanfold Media (Continued)

Media Type How It Looks Description
Continuous Roll Roll media is wound on a core that can be 0.5 to 1.5 in. (12.7
Media to 38.1 mm) in diameter. Continuous roll media does not
have gaps, holes, notches, or black marks to indicate label
separations. This allows the image to be printed anywhere on
the label. A cutter can be used to cut apart individual labels.
With continuous media, use the transmissive (gap) sensor so
the printer can detect when the media runs out.

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ZD411T Printer Dimensions
ZD411T Printer Dimensions

This section provides external printer dimensions for the printer, and many of the accessories that are
available for the ZD411T.

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 ZD411T Printer Dimensions

ZD411T Thermal Transfer Printer Dimensions

This section provides external dimensions for the printer, and the printer with common accessories or
options installed.

Figure 20 ZD411T Standard Printer (dimensions in millimeters)

138.8 242.9

169.2

339.7

336.7

324.4

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 ZD411T Printer Dimensions

Figure 21 ZD411T Printer with Label Dispense Option (dimensions in millimeters)

252.7
277.3

294.2
318.8

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 ZD411T Printer Dimensions

Figure 22 ZD411T Printer with the Media Cutter Option (dimensions in millimeters)

262.8

355.9

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 ZD411T Printer Dimensions

Figure 23 ZD411T Printer with Attached Battery Base Option (dimensions in millimeters)

224.8

392.6

395.3

255.5
309.2

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 ZD411T Printer Dimensions

Figure 24 ZD411T Standard Mounting (dimensions in millimeters)

74.0
31.5

67.0

121.5
121.5

60.0

7.0

49.5
81.0

IMPORTANT: Use M3 thread-forming screws to mount the printer. The maximum hole depth is
8.5 mm.

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ZPL Configuration
ZPL Configuration

This section provides an overview of managing printer configuration, the Configuring Status Report, and
Printer and Memory Printouts.

Managing the ZPL Printer Configuration

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

ZPL Print Configuration File Format

The printer is easily updated using a ZPL programming configuration file.
Managing multiple printers can be done by creating a printer configuration programming file. The
configuration file is sent or auto-loaded from a prepared USB memory device. These can be used to clone
a printer’s setup. The figure shows the basic structure of a ZPL programming configuration file.

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Table 7 Printer Management and Format Program Structure

Command Description
^XA Start Format Command
Place your commands Format commands are ordered sensitive
here.
• General print and command settings
• Media handling and behaviors
• Media print size and position
^JUS command to save settings
^XZ End Format Command

For information on creating a programming file, see the ZPL programmer’s guide (available from
zebra.com/manuals) and Configuration Setting to Command Cross-Reference on page 186.
You can use Windows Notepad (text editor) to create programming files and the Zebra Setup Utility (ZSU)
to send programming files to the printer.

Configuration Setting to Command Cross-Reference

Use the printer configuration report to understand the settings that influence printer behaviors and the ZPL
or SGD programming commands you can use to modify these behaviors.
The Printer Configuration Report provides a listing of a majority of the configuration settings that can be set
by ZPL or SGD commands. Some sensor values in the middle of the report (1) are used primarily used for
service purposes.

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1 Sensor settings used for service purposes

Table 8 ZPL Commands and Configuration Report Callout Cross-Reference

Command Listing Name Description
~SD DARKNESS Default: 10.0

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Table 8 ZPL Commands and Configuration Report Callout Cross-Reference (Continued)

Command Listing Name Description
— DARKNESS SWITCH LOW (Default), MEDIUM, or HIGH
^PR PRINT SPEED Default: 152.4 mm/s / 6 IPS (max.) - 203 dpi
101.6 mm/s / 4 IPS (max.) - 300 dpi
~TA TEAR OFF Default: +000
^MN MEDIA TYPE Default: GAP/NOTCH
SENSOR SELECT Default: AUTO (^MNA - Auto-Detect)
^MT PRINT METHOD THERMAL-TRANS or DIRECT-THERMAL
^PW PRINT WIDTH Default: 448 (dots for 203 dpi) or 640 (dots for 300 dpi)
^LL LABEL LENGTH Default: 1225 (dots) (dynamically updated while
printing)
^ML MAXIMUM LENGTH Default: 989MM (39.0IN)
— USB COMM. Connection Status: Connected / Not Connected
^SCa BAUD Default: 9600
^SC,b DATA BITS Default: 8 BITS
^SC,,c PARITY Default: NONE
^SC,,,,e HOST HANDSHAKE Default: AUTO ^SC,,,,
^SC,,,,,f PROTOCOL Default: NONE
— SGD — COMMUNICATIONS Default: NORMAL MODE

NOTE: Not supported with a ZPL

command, uses the Set Get Do
command in the ZPL manual. Refer to
device.command_override.xxxxx in the ZPL
Programmer’s manual.
SER COMM. MODE Default: AUTO
^CT / ~CT CONTROL CHAR Default: <~> 7EH
^CC / ~CC COMMAND CHAR Default: ^> 5EH
^CD / ~CD DELIM./CHAR Default: <,> 2CH
^SZ ZPL MODE Default: ZPL II
— SGD — COMMAND OVERRIDE Default: INACTIVE

NOTE: Not supported with a ZPL

command, uses the Set Get Do
command in the ZPL manual. Refer to
device.command_override.xxxxx in the ZPL
Programmer’s manual.
^MFa MEDIA POWER UP Default: NO MOTION
^MF,b HEAD CLOSE Default: FEED

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Table 8 ZPL Commands and Configuration Report Callout Cross-Reference (Continued)

Command Listing Name Description
~JS BACKFEED Default: DEFAULT
^LT LABEL TOP Default: +000
^LS LEFT POSITION Default: +0000
~JD / ~JE HEXDUMP Default: NO (~JE)
Default: DISABLED Default: DISABLED

From this point in the Configuration Receipt listing, the printout lists sensor settings and values which are
used to troubleshoot sensor and media operations, typically by Zebra Tech Support. These listings contain
printer features that are seldom modified from their default or that provide status information.

Table 9 ZPL Commands and Configuration Receipt Callout Cross-Reference

Command Listing Name Description
^MP MODES ENABLED Default: CWF (see ^MP command)
MODES DISABLED Default: (nothing set)
^JM RESOLUTION Default: 448 8/mm (203 dpi); 640 8/mm (300 dpi)
— FIRMWARE Lists ZPL Firmware Version
— XML SCHEMA 1.3
— HARDWARE ID Lists Firmware Boot-Block Version
LINK-OS VERSION
— CONFIGURATION CUSTOMIZED (after first use)
— RAM 2104k........ R:
— ONBOARD FLASH 6144k.........E:
^MU FORMAT CONVERT NONE
RTC DATE Date Displayed
RTC TIME Time Displayed
^JI / ~JI ZBI DISABLED (Requires key to enable)
— ZBI VERSION 2.1 (Displayed if installed)
— ZBI STATUS READY
^JH ^MA ~RO LAST CLEANED X,XXX IN
HEAD USAGE X,XXX IN
TOTAL USAGE X,XXX IN
RESET CNTR1 X,XXX IN
RESET CNTR2 X,XXX IN
NONRESET CNTR0 (1, 2) X,XXX IN
RESET CNTR1 X,XXX IN

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Table 9 ZPL Commands and Configuration Receipt Callout Cross-Reference (Continued)

Command Listing Name Description
RESET CNTR2 X,XXX IN
SLOT1 EMPTY / SERIAL / WIRED
MASS STORAGE COUNT 0
HID COUNT 0
USB HOST LOCK OUT OFF / ON
— SERIAL NUMBER XXXXXXXXXXX
^JH EARLY WARNING MAINT. OFF

The printer has the ability to set a command or a group of commands once for all receipts (or labels) that
follow. Those settings will remain in effect until they are changed by subsequent commands, the printer is
reset, or you restore factory defaults.

Printer Memory Management and Related Status Reports

The printer has various memory resources and storage for building and printing.
To help you manage printer resources, the printer supports a variety of format commands. You can use
these commands to manage memory, transfer objects (between memory areas and import / export files),
name object nams, test printer functions, and generate printer operating status reports. They are very
similar to the old DOS commands such as DIR (directory listing) and DEL (delete file). The most common
reports are also part of the Zebra Setup Utility and ZebraDesigner Windows driver.
It is recommended that a single command be processed within this type of format (form). A single
command is easily reused as a maintenance and development tool.

Table 10 Printer Management and Format Program Structure

Command Description
^XA Start Format Command
Put your commands Use a single command to manage the printer, test functions, and reports.
here
^XZ End Format Command

Many of the commands that transfer objects, manage, and report on memory are Control (~) commands.
They do not need the be within a format (form). They will be processed immediately upon receipt by the
printer whether in a format (form) or not.

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ZPL Programming for Memory Management

PL has various printer memory locations that are used to run the printer, assemble the print image, and
store formats (forms), graphics, fonts, and configuration settings.
The printer file-naming requirements as as follows:
• ZPL treats formats (forms), fonts, and graphics like files; and memory locations like disk drives in the
DOS operating system environment:
• Memory Object Naming: Up to 16 alphanumeric characters followed by a three alphanumeric
character file extension, for example, 123456789ABCDEF.TTF.
• Legacy ZPL printers with v60.13 firmware and earlier can only use the 8.3 filename format versus
today’s 16.3 filename format.
• Allows moving of objects between memory locations and deleting objects.
• Supports DOS-directory-style file list reports as printouts or status to the host.
• Allows use of wildcards (*) when accessing files.

Table 11 Object Management and Status Report Commands

Command Name Description
^WD Print Directory Label Prints a list of objects and resident barcodes and fonts
in all addressable memory locations.
~WC Print Configuration Report Prints a configuration report report.
^ID Object Delete Deletes objects from printer memory.
^TO Transfer Object Used to copy an object or group of objects from one
memory area to another.
^CM Change Memory Letter Reassigns a letter designation to a printer memory
Designation area.
^JB Initialize Flash memory Similar to formatting a disk. Erases all objects from the
specified memory locations B: or E:.
~JB Reset Optional Memory Similar to formatting a disk. Erases all objects from the
B: memory (factory option).
~DY Download Objects Downloads and installs a variety of printer-usable
programming objects: fonts (OpenType and TrueType),
graphics, and other object data types.
You can use ZebraNet Bridge to download graphics
and fonts to the printer.
~DG Download Graphic Downloads an ASCII Hex representation of a graphic
image. This is used by ZebraDesigner (label creation
application) for graphics.
^FL Font Linking Appends secondary TrueType font or fonts to the
primary TrueType font to add glyphs (characters).
^LF List Font Links Prints a list of the linked fonts.
^CW Font Identifier Assigns a single alphanumeric character as an alias to
a font stored in memory.

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IMPORTANT: Some ZPL fonts that are factory-installed in your printer cannot be copied, cloned,
or restored to the printer by reloading or updating firmware. If these license-restricted ZPL fonts
are removed using an explicit ZPL object delete command, they must be repurchased and
reinstalled using a font activation and installation utility. EPL fonts do not have this restriction.

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