Category: Product Operation Instructions

I. Introduction to the Zebra ZT210 Barcode Printer
Note: Components in the printer are color-coded
 ● Touch points that require operation are gold.
● Components related to the ribbon system are black plastic, and media-related components are gray. These components, along with other components, are shown in light blue in this manual.
1.1 Printer Components

Component serial number	Component Name	Component serial number	Component Name
1	control Panel	6	Medium supply guide plate
2	Medium gate	7	Medium tension regulating assembly
3	ribbon pickup axis	8	Print head opening lever
4	ribbon supply shaft	9	Printing device
5	Media supply rack	10	Printing roller

1.2 Control Panel
The control panel displays the printer’s current status and allows users to control basic printer operations.

Panel serial number	Panel Name
1	Status indicator light
2	“Pause” indicator light
3	“Data” indicator light
4	“Consumables” indicator light
5	“Network” indicator light
6	Pressing the PAUSE button will start or stop the printer operation.
7	Pressing the FEED button each time forces the printer to feed a blank label.
8	When the printer is paused, the CANCEL button can cancel label formatting. ● Press once to cancel the formatting of the next label . ● Press and hold for 2 seconds to cancel all label formatting.

1.3 Media Types
The ZT210 printer can use various media types:
● Standard Media – Most standard media use an adhesive material that allows multiple individual labels or continuous labels of a certain length to be pasted onto a backing. Standard media is available in media rolls or folded stacks.
● Cardboard Tags – Tags are usually made of thick paper. The label material has no adhesive or backing and usually has pre-perforated holes between each cardboard tag. Cardboard tag media may be available in media rolls or folded stacks.

1.4 Ribbon Introduction
A ribbon is a thin film coated with wax, resin, or wax resin on one side. During the heat transfer process, the wax or wax resin can be transferred to the media. The media determines whether a ribbon is needed and what width of ribbon must be used.
If a ribbon is used, its width must be greater than or equal to the width of the media. If the ribbon is narrower than the media, parts of the printhead will wear out prematurely due to lack of protection.
Heat transfer media require a ribbon to print, while thermal media do not. To ensure whether a ribbon must be used for a specific media, a media scratch test can be performed.

II. Zebra ZT210 Barcode Printer Setup and Operation
2.1 Selecting a Data Communication Interface
Connect the printer to one or more available connections. The ZT210 printer may also be equipped with the ZebraNet wired or wireless print server option or a parallel port.
Caution: Ensure the printer is powered off before connecting the data communication cable. Continuously connecting the data communication cable when the power is on may damage the printer.

interface	Standard parts or optional parts	illustrate
RS-232 serial port	Standard parts	Limitations and Requirements: ● Maximum cable length: 15.24 meters ● Printer parameters must be changed to match the host computer ● If using a standard modem cable, a blank modem must be connected to the printer.
The connection and configuration of baud rate, data and stop bits, parity, and XON/XOFF or DTR control must be matched with the host computer.
USB	Standard parts	Limitations and Requirements: ● Maximum cable length: 5 meters ● Can be paired with the host computer without changing printer parameters
No additional configuration is required for connection and setup.
8-bit parallel data interface	Options	Limitations and Requirements: ● Maximum cable length: 3 meters ● Recommended cable length: 1.83 meters ● Wired or wireless Ethernet print server (if installed) will occupy this port on the printer ● No printer parameter changes are required for compatibility with the host computer
No additional configuration is required for connection and setup.
Wired Ethernet print server	Options	Limitations and Requirements: ● Printing can be done from any computer on the user’s local area network (LAN ) . ● Communication with the printer can be achieved via the printer’s web interface. ● The printer must be configured to use a LAN. ● Parallel connections or wireless Ethernet print servers (if installed) will occupy this port on the printer. Caution: Do not plug a USB cable into the printer’s wired Ethernet print server interface, as this may damage the interface.
Connection and configuration require configuring parameters such as network IP.
Wireless print server	Options	Limitations and Requirements: ● Printing can be done from any computer on a wireless LAN (WLAN). ● Communication with the printer can be achieved via the printer’s web interface . ● The printer must be configured to use a wireless LAN. ● Parallel connections or wired Ethernet print servers (if installed) will occupy this port on the printer. Caution: Do not plug a USB cable into the printer’s wired Ethernet print server interface, as this may damage the interface.
Connecting and configuring requires configuring parameters such as the wireless network IP address.

All necessary interface cables must be provided for the specific situation. Ethernet cables do not require shielding, but other data cables must be fully shielded and equipped with metal or metallized connector housings. Using unshielded cables will result in electromagnetic radiation levels exceeding regulatory limits. To minimize the level of electrical noise pickup in the cables, the following should be done:
● Use the shortest possible data cables
● Do not tightly bundle data cables and power cables together
● Do not tie data cables to power cable conduits

2.2 Select Printing Mode

Printing mode	When to use/required printer options	Printer operation
Tear paper (default setting)	Suitable for most applications, this mode is available for any printer option and most media types.	The printer prints the label upon receiving the label format, and the printer operator can remove the label at any time after printing is complete.
peeling	Use only when the printer is equipped with the peel-off option.	The printer peels the label off the backing during printing and pauses after the label is removed, with the backing retracting from the front of the printer. ● In “Peel” mode, the backing is ejected from the front of the printer .
Paper cutter	If the printer has a paper cutter option and the user wants to cut off the labels, this option can be used.	The printer prints the label, then cuts it off.

2.3 Loading the Ribbon
The ribbon is for thermal transfer labels only. To print labels using thermal printing, do not load the ribbon into the printer.
Important: To protect the printhead from wear, use a ribbon wider than the media, and the ribbon coating must be on the outer side.
To load the ribbon, complete the following steps:
(1) Rotate the printhead release lever counterclockwise to loosen the printing unit.
(2) Rotate the release lever clockwise to adjust the ribbon position.
(3) Load the ribbon onto the ribbon supply shaft, pushing the paper roll back as far as possible.
(4) Before shipping, the printer has an empty ribbon core on the ribbon pickup shaft. If this ribbon core is missing, place an empty ribbon core on the ribbon pickup shaft and push the paper roll back as far as possible.
(5) Pass the ribbon under the printing unit assembly.
(6) Wind the ribbon clockwise onto the ribbon core on the ribbon pickup shaft, rotating the pickup shaft several times to allow the ribbon to wind around it a few times.
(7) If media is already loaded, rotate the printhead opening lever clockwise until the printhead is locked in place.
(8) Close the media door.
(9) Press the pause button if necessary to start printing.

2.4 Loading Media
(1) Rotate the printhead opening lever counterclockwise to release the printhead mechanism.
(2) Insert the media into the printer, performing the operation as needed for roll media and folded media.
(3) Slide the outer media guide fully out.
(4) Let the media slide under the media tension adjustment assembly and printing mechanism, pulling the end of the media out from the front of the printer.
(5) Ensure the media has passed through the hole on the media projection sensor and reached below the inner media guide; the media should just touch the back of the media projection sensor slot.

(6) Load the media according to the printer mode.
(7) Slide the outer media guide in until it just touches the edge of the media.
(8) Rotate the printhead opening lever clockwise until the printhead is locked in place.
(9) Close the media door.
(10) Pressing pause will exit pause mode and start printing. Depending on user settings, the printer may perform label calibration or feed a label.
(11) A self-test can be performed as needed to check if the printer is printing correctly.

III. Zebra ZT210 Barcode Printer Configuration and Adjustment
3.1 Changing Printer Settings
This section lists the printer settings that users can change, as well as the tools used to change these settings, including the following functions:
● ZPL and Set/Get/Do (SGD) commands
● If the printer has an available wired or wireless print server connection, the printer’s web page.
3.1.1 Printer Settings

Settings	illustrate
Printing depth	Set the depth to the lowest value that provides the best print quality. If the depth value is set too high, the label image may not print clearly, the barcode may not scan correctly, the ribbon may burn through, or the print head may wear out prematurely.
Accepted values:	0.0-30.0
Related ZPL commands	^MD, ~SD
SGD command used	print.tone
Printer webpage	View and modify printer settings > General settings > Depth
Printing speed	Choose the label printing speed (in inches per second); lowering the printing speed usually results in higher print quality.
Accepted values:	2, 3, 4, 5, 6
Related ZPL commands:	^PR
SGD commands used:	media.speed
Printer webpage	not applicable
Media type	Select the media type to use. ● If you select “Continuous Media”, you must include the label length instruction in the label format (if using the ZPL language, the command is ^LL). ● If you select “Gap/Notch” or “Mark” for different types of non-continuous media, the printer will feed the media to calculate the label length.
Accepted values:	● Continuous; ● Gap/Gap; ● Marking
Related ZPL commands:	^MN
SGD commands used:	ezpl.media_type
Printer webpage	View and modify printer settings > Media settings > Media type
Printing method	Specify whether the printer uses “thermal” mode (no ribbon) or “thermal transfer” mode (using thermal transfer media and ribbon).
Accepted values:	● Thermal transfer printing; ● Thermal printing
Related ZPL commands:	^MT
SGD commands used:	ezpl.print_method
Printer webpage	View and modify printer settings > Media settings > Print method
Tear position	Adjust the media’s position on the cutter bar as needed after printing: ● A higher number indicates the media has moved out, meaning the tear line is closer to the next label. ● A lower number indicates the media has moved in, meaning the tear line is closer to the label that was just printed.
Accepted values:	-120 to 120
Related ZPL commands:	~TA
SGD commands used:	ezpl.tear_off
Printer webpage	View and modify printer settings > General settings > Tear paper
Print width	Specify the label width to use. The default value is the printer’s maximum width, depending on the printhead DPI value. Note: Setting the width too narrow may cause some label formats to fail to print on the media. Setting the width too wide will waste format memory and cause labels to print out of bounds or onto the print roller. This setting will affect the horizontal position of the label format if the image is flipped using the ^POI ZPLII command.
Accepted values:	0000 to 1248
Related ZPL commands:	^PW
SGD commands used:	ezpl.print_width
Printer webpage	View and modify printer settings > Media settings > Print width
Printing mode	Select the printing mode compatible with the printer options.
Accepted values:	● Paper tearer; ● Paper cutter; ● Peel
Related ZPL commands:	^MM
SGD commands used:	media.printmode
Printer webpage	View and modify printer settings > General settings > Print mode
Left side of the label	Adjust the horizontal printing position of the label as needed. Positive numbers will move the left edge of the image towards the center of the label by the selected number of points, while negative numbers will move the left edge of the image towards the left side of the label.
Accepted values:	-9999 to 9999
Related ZPL commands:	^LS
SGD commands used:	zpl.left_position
Printer webpage	View and modify printer settings > Advanced settings > Left side
Reprint mode	If reprint mode is enabled, press and hold the PAUSE+CANCEL buttons on the printer control panel to reprint the previously printed label.
Accepted values:	● Open; ● Close
Related ZPL commands:	^JZ
SGD commands used:	ezpl.reprint_mode
Printer webpage	not applicable
Maximum tag length	The maximum label length should be set to be at least 25.4 mm longer than the actual label length plus the label spacer. If this value is set to less than the label length, the printer will assume that continuous media is loaded and will be unable to calibrate. For example, if the label length including the label spacer is 152 mm, the parameter should be set to at least 178 mm.
Accepted values:	The printer supports label lengths from 0 to the maximum.
Related ZPL commands:	^ML
SGD commands used:	ezpl.label_length_max
Printer webpage	View and modify printer settings > Media settings > Maximum length

3.1.2 Calibration and Diagnostic Tools

Calibration and diagnostic tools	illustrate
Print information	Print specified information on one or more labels.
Received value:	● Settings—Prints the printer’s configuration label . ● Network—Prints settings values ​​for the installed print server. ● Format—Prints available formats stored in printer memory, flash memory cards, or other optional memory cards. ● Image—Prints available images stored in printer memory, flash memory cards, or other optional memory cards. ● Font—Prints available fonts in the printer, including standard printer fonts and any optional fonts. Fonts can be stored in RAM or flash memory. ● Barcode—Prints available barcodes in the printer; barcodes can be stored in RAM or flash memory. ● All—Prints the first six labels. ● Sensor Chart—Displays settings values ​​compared to actual sensor readings.
Related ZPL commands:	Settings: ~WC; Network: ~WL; Sensor Charts: ~JG; Other: ^WD
SGD command used	none
Control Panel Key	Setup and Network: Perform one of the following actions: ● Press and hold the CANCEL button while the printer is powered on. ● While the printer is in the “Ready” state, press and hold the FEED+CANCEL buttons for 2 seconds. Sensor Chart: Press and hold the FEED+CANCEL buttons while the printer is powered on.
Printer webpage	View and modify printer settings > Print list on labels
Power-on operation	The Power-On Setup specifies the actions the printer will perform when powered on: ● Calibration: Adjusts sensor levels and thresholds to determine label length and feeds media to the next halftone. ● Feed: Feeds the label to the first alignment point. ● Length: Uses the current sensor value to determine the label length and feeds media to the next halftone. ● No Movement: Instructs the printer not to move the media. You must manually confirm that the halftone is correctly positioned. Alternatively, you can press the Feed button to position the next halftone. ● Short Calibration: Sets the media and halftone thresholds without adjusting sensor gain, determines the label length, and feeds media to the next halftone.
Received value:	● Calibration ● Paper Feed ● Length ● No Movement ● Brief Calibration
Related ZPL commands:	^MF
SGD command used	ezpl.power_up_action
Printer webpage	View and modify printer settings > Calibration
Printhead closing operation	The printhead shutdown setting configures the actions the printer performs when the printhead is closed: ● Calibration: Adjusts sensor levels and thresholds to determine label length and feeds media to the next shim. ● Feed: Feeds the label to the first alignment point . ● Length: Uses the current sensor value to determine the label length and feeds media to the next shim. ● No Movement: Notifies the printer not to move the media. You must manually confirm that the shim is correctly positioned. Alternatively, you can press the feed button to position the next shim. ● Short Calibration: Sets the media and shim thresholds without adjusting sensor gain, determines the label length, and feeds media to the next shim.
Received value:	● Calibration ● Paper Feed ● Length ● No Movement ● Brief Calibration
Related ZPL commands:	^MF
SGD command used	ezpl.head_close_action
Printer webpage	View and modify printer settings > Calibration
Load default values	Reset printer or print server settings to default values: ● Factory—Restores all printer settings except network settings to factory defaults. Be careful when resetting defaults, as you will need to reset any settings you have manually changed. ● Network—Reinitializes the printer’s wired or wireless print server. When using a wireless print server, the printer will also reconnect to the wireless network. ● Load Last Saved Values—Loads the last permanently saved settings.
Received value:	● Factory ● Network ● Last saved value
Related ZPL commands:	Factory: ^JUF; Network: ^JUN; Last saved value: ^JUR
SGD command used	none
Control Panel Key	● Factory: Press and hold the FEED + PAUSE buttons while the printer is powered on to reset the printer parameters to factory values. ● Network: Press and hold the CANCEL + PAUSE buttons while the printer is powered on to reset the network parameters to factory values. ● Last saved value: Not applicable.
Printer webpage	● Factory: View and modify printer settings > Restore default configuration ● Network: Print server settings > Reset print server ● Last saved value: View and modify printer settings > Restore saved configuration
Media and ribbon sensor calibration	Calibrate the printer and adjust the sensitivity of the media and ribbon sensors.
Received value:	not applicable
Related ZPL commands:	^JC
SGD command used	ezpl.manual_calibration
Control Panel Key	Press and hold the PAUSE+FEED+CANCEL buttons for 2 seconds to initiate the calibration process.
Printer webpage	Unable to initiate calibration steps via webpage
Communication diagnostic mode	This diagnostic tool allows the printer to output hexadecimal values ​​for all data received by the printer.
Received value:	● Disable ● Enable
Related ZPL commands:	~JD is used to start; ~JE is used to stop.
SGD command used	device.diagnostic_print
Control Panel Key	With the printer in the “Ready” state, press and hold the PAUSE + FEED buttons for 2 seconds.
Printer webpage	not applicable

3.1.3 Network Settings

Network settings	illustrate
IP address	View or set the printer’s IP address . View and change the printer’s IP address as needed. Changes to this setting are only saved if the IP PROTOCOL protocol is set to PERMANENT. To make saved changes take effect, the print server should be reset.
Received value:	000 to 255 are used for each field
Related ZPL commands:	^ND
SGD command used	Wired: internal_wired.ip.addr; Wireless: ip.addr, wlan.ip.addr
Printer webpage	View and modify printer settings > Network communication settings > TCP/IP settings
Subnet mask	View or set the subnet mask . View and change the subnet mask as needed. This menu item is only displayed if a wired or wireless print server is installed on the printer. To save changes to this setting, set the IP PROTOCOL protocol to PERMANENT and then reset the print server.
Received value:	000 to 255 are used for each field
Related ZPL commands:	^ND
SGD command used	Wired: internal_wired.ip.netmask; Wireless: wlan.ip.netmask
Printer webpage	View and modify printer settings > Network communication settings > TCP/IP settings
gateway	View or set the default gateway . View and change the default gateway as needed. This menu item only appears if a wired or wireless print server is installed on the printer. To save changes to this setting, set the IP PROTOCOL protocol to PERMANENT and then reset the print server.
Received value:	000 to 255 are used for each field
Related ZPL commands:	^ND
SGD command used	Wired: internal_wired.ip.gateway; Wireless: wlan.ip.gateway
Printer webpage	View and modify printer settings > Network communication settings > TCP/IP settings
IP protocol	Configure IP Resolution Method. This parameter specifies whether the user (permanent) or server (dynamic) should select an IP address. If the dynamic option is selected, this parameter informs the wired or wireless print server how to receive IP addresses from the server.
Received value:	● All ● GLEANING Only ● RARP ● BOOTP ● DHCP ● DHCP and BOOTP ● Permanent
Related ZPL commands:	^ND
SGD command used	Wired: internal_wired.ip.protocol; Wireless: wlan.ip.protocol
Printer webpage	View and modify printer settings > Network communication settings > TCP/IP settings
MAC address	To view the MAC address, you need to find the Media Access Control (MAC) address of the print server installed in the wired or wireless printer.
Received value:	not applicable
Related ZPL commands:	none
SGD command used	Wired: internal_wired.mac.addr; Wireless: wlan.mac.addr
Printer webpage	View and modify printer settings > Network communication settings > Wireless settings
ESSID	The Extended Service Set Identifier (ESSID) is an identifier used for wireless networks. This setting cannot be modified from the control panel; it provides the ESSID for the current wireless configuration.
Received value:	A 32-character alphanumeric string (default is 125).
Related ZPL commands:	none
SGD command used	wlan.essid
Printer webpage	View and modify printer settings > Network communication settings > Wireless settings
Reset Network	This option can reset the wired or wireless print server. The print server must be reset for changes to the network settings to take effect.
Received value:	not applicable
Related ZPL commands:	~WR
SGD command used	device.reset
Printer webpage	Print Server Settings > Print Server Factory Settings

3.1.4 Language Settings

Language settings	illustrate
language	Changing the printer display language as needed will affect the language of the following information: ● Main menu ● User menu ● Error messages ● Printer configuration label, network configuration label, and other optional labels printed via the user menu.
Received value:	English, Spanish, French, German, Italian, Norwegian, Portuguese, Swedish, Danish, Spanish 2, Dutch, Finnish
Related ZPL commands:	^KL
SGD command used	display.language
Printer webpage	View and modify printer settings > General settings > Language
ZPL replacement	Enabling ZPL overrides this menu item, allowing the following commands to replace the printer’s current settings: ● ^MM (Print Mode) ● ^MT (Thermal or Thermal Transfer Printing Method) ● ^MN (Media Type: Non-continuous or Continuous)
Received value:	● Disable; ● Enable
Related ZPL commands:	none
SGD command used	zpl.zpl_override
Printer webpage	none
command characters	The format command prefix is ​​a two-digit hexadecimal value used as a parameter position marker in the ZPL/ZPLII format specification. The printer looks for this hexadecimal character, which indicates the start of a ZPL/ZPLII format instruction. Set the format command character to match the value in the label format. Important: The same hexadecimal value cannot be used for the format command prefix, control characters, and separator characters. The printer must use different characters to function correctly. If the user sets the value via the control panel, the printer will ignore the value already in use.
Received value:	00 to FF
Related ZPL commands:	^CC or ~CC
SGD command used	zpl.caret
Printer webpage	View and modify printer settings > ZPL Control
Control characters	Setting the Control Prefix Character Value: The printer looks for this two-digit hexadecimal character to indicate the start of ZPL/ZPLII control instructions. Set the control prefix character to match the value used in the label format.
Received value:	OO to FF
Related ZPL commands:	^CT or ~CT
SGD command used	zpl.control_character
Printer webpage	View and modify printer settings > ZPL Control
separator	The separator value is set to a two-digit hexadecimal value, used as a parameter position marker in the ZPL/ZPLII format specification, to match the value used in the label format.
Received value:	OO to FF
Related ZPL commands:	^CD or ~CD
SGD command used	zpl.delimiter
Printer webpage	View and modify printer settings > ZPL Control
ZPL mode	Set ZPL Mode: Select a mode that matches the values ​​used in the label format. This printer accepts label formats written using ZPL or ZPLII voice; no rewriting of any existing ZPL format is required. The printer operates in the selected mode until the mode is changed using one of the following methods.
Received value:	● ZPLII; ● ZPL
Related ZPL commands:	^SZ
SGD command used	zpl.zpl_mode
Printer webpage	View and modify printer settings > ZPL Control

3.1.5 Sensor Settings

Sensor settings	illustrate
Sensor type	Select the appropriate medium sensor for the medium being used by the user. Reflective sensors can be used for all medium types, while transmissive sensors can only be used for simple slit media.
Received value:	● Transmissive; ● Reflective
Related ZPL commands:	^JS
SGD command used	device_sensor_select
Printer webpage	View and modify printer settings > Media settings
Tag sensor	Set the sensitivity of the tag sensor
Received value:	0-255
Related ZPL commands:	none
SGD command used	ezpl.label_sensor
Printer webpage	View and modify printer settings > Calibration
Take the label	Adjust the brightness of the indicator light when the tag is removed.
Received value:	0-255
Related ZPL commands:	none
SGD command used	ezpl.take_label
Printer webpage	View and modify printer settings > Calibration

3.2 Calibrate the Ribbon and Media Sensors
Use the steps in this section to calibrate the printer. This process adjusts the sensitivity of the media and ribbon sensors.
Important: Strictly follow the calibration process as described in this manual. Even if only one sensor needs adjustment, all steps must be performed. You can cancel the process by pressing CANCEL at any step.
To perform sensor calibration, complete the following steps:
⑴ With the printer in the “Ready” state, initiate media and ribbon calibration using one of the following methods:
◆ Press and hold the Pause + Feed + Cancel button for two seconds.
◆ Send the ezpl.manual_calibration SGD command to the printer.
The printer will do the following:
● The Status and Consumables indicators flash yellow once.
● The Pause indicator lights up yellow.
⑵ Rotate the printhead opening lever counterclockwise to release the printing device.
⑶ Allow the media to extend approximately 203 mm outside the printer.
⑷ Remove the exposed label, leaving only the backing.
⑸ Pull the backing paper into the printer, ensuring only the backing is between the media sensors.
(6) If a ribbon was used, it should be removed.
(7) Rotate the printhead opening lever clockwise until the printhead is locked in place.
(8) Press pause to begin the media calibration process.
◆ The “Pause Indicator” goes out.
◆ The “Consumables Indicator” flashes.
When this process is complete:
◆ The “Consumables Indicator” flashes.
◆ The “Pause Indicator” flashes yellow.
(9) Rotate the printhead opening lever counterclockwise to release the printing device.
(10) Pull the media forward so that the label is below the media sensor. (11
) Reinstall the ribbon (if used).
(12) Close the printhead.
(13) Close the media door.
(14) Press the pause button to start printing.

3.3 Adjusting Printhead Pressure
If the print color is too light on one side, if the media is too thick, or if the media shifts to one side during printing, you may need to adjust the printhead pressure to the lowest printhead pressure that will provide the best print quality.
The printhead pressure adjustment wheel has half-scale increments from 1 to 4.

If necessary, the printhead pressure adjustment wheel should be adjusted using the following method:

If the medium…	but…
Greater pressure is needed to improve print quality.	Increase the position of the two adjusting wheels by one position.
Slide to the left while printing	Increase the outer adjusting wheel by one position, or decrease the inner adjusting wheel by one position.
Slide to the right when printing	Increase the inner adjusting wheel by one position, or decrease the outer adjusting wheel by one position.
The printed content on the left side of the label is too light in color.	Increase the size of the inner adjusting wheel by one position.
The printed content on the right side of the label is too light in color.	Increase the outer adjustment wheel by one position.

3.4 Adjusting Ribbon Tension
For the printer to function properly, both the ribbon supply shaft and the ribbon pickup shaft must use the same tension setting (normal tension or low tension). For most applications, the normal tension setting should be used. If using a narrow ribbon or encountering specific ribbon issues, low tension may be necessary.
Normal Tension Setting : To position the ribbon shaft in its normal position, forcefully push out the end cap until it extends and locks in place. This setting can be used for most applications.

Low Tension Setting : To position the supply shaft in the low tension position, forcefully push in the end cap until it retracts and clicks into place. This setting should only be used when necessary, such as when the ribbon causes the wear indicator to be at the beginning of the ribbon roll, or when normal tension causes the ribbon to stop at the end of the roll.

IV. Zebra ZT210 Barcode Printer Routine Maintenance
4.1 Cleaning Plan and Procedures
Routine preventative maintenance is an important part of ensuring the printer works correctly. By diligently maintaining the printer, users can minimize the possibility of potential malfunctions and help achieve and maintain the standard print quality they require.
As printing continues, the media or ribbon passing through the printhead will gradually wear down the ceramic protective layer, exposing and eventually damaging the printed elements (dots). Avoid Abrasion:
◆ Clean the printhead regularly.
◆ Optimize the balance between these two by using the lowest possible printhead pressure and burn-in temperature settings.
◆ When using thermal transfer mode, ensure the ribbon width is greater than or equal to the media width to protect the printed elements from exposure to more corrosive label materials.
Depending on the application and media, more frequent cleaning may be required.
Printhead, Method: 95% alcohol solvent, Time Interval: After using one roll of media for thermal mode, after using a perfect ribbon for thermal transfer or after every three rolls of media.
Roller, Method: 95% alcohol solvent, Time interval: After one media roll is used up in thermal mode, after using a Perfect Silk ribbon in thermal transfer, or after every three media rolls.
Media sensor, Method: Air jetting, Time interval: After one media roll is used up in thermal mode, after using a Perfect Silk ribbon in thermal transfer, or after every three media rolls.
Ribbon sensor, Method: Air jetting, Time interval: After one media roll is used up in thermal mode, after using a Perfect Silk ribbon in thermal transfer, or after every three media rolls.
Media path: Method: 95% alcohol solvent, Time interval: After one media roll is used up in thermal mode, after using a Perfect Silk ribbon in thermal transfer, or after every three media rolls.
Ribbon path: Method: 95% alcohol solvent, Time interval: After one media roll is used up in thermal mode, after using a Perfect Silk ribbon in thermal transfer, or after every three media rolls.

4.2 Replacing Printer Components
Printer components such as the printhead and print rollers may wear down over time and can be easily replaced.

V. Troubleshooting Zebra ZT210 Barcode Printer
5.1 Meaning of Indicator Lights
The indicator lights on the control panel are used to display the current status of the printer.

Indicator light status	Printer status description
	When the printer is powered on, the status indicator light remains green (other indicator lights remain yellow for 2 seconds), indicating that the printer is ready.
	The “Pause” indicator light remains consistently yellow, indicating that the printer is paused.
	The “Status” indicator light is consistently red. The “Consumables” indicator light is consistently red. The media is low, requiring attention to the printer, but it can continue operating without user intervention.
	The “Status” indicator light will remain steadily red. The “Consumables” indicator light will flash red , indicating the ribbon is low and the printer needs attention; however, it can continue operating without user intervention.
	The “Status” indicator light is steadily yellow. The “Consumables” indicator light is flashing yellow. The printer is in “Thermal” mode, which does not require a ribbon, but the ribbon is already installed in the printer.
	The “Status” indicator light is steadily red. The “Pause” indicator light is steadily yellow. The printhead is open, so you need to pay attention to the printer, but it can continue to work without user intervention.
	The status indicator light is consistently showing a yellow warning, indicating that the printhead temperature is too high.
	A flashing yellow indicator light indicates one of the following conditions: ● Printhead temperature too low; ● Power supply unit temperature too high; ● Main logic board (MLB) temperature too high.
	The “Status” indicator light is consistently red. The “Pause” indicator light is consistently red. The “Data” indicator light is consistently red. When changing the printhead, if an original Zebra printhead was not used, simply install an original Zebra printhead to continue operation.
	The status indicator light is flashing red, indicating that the printer cannot read the printhead’s DPI settings.
Printers with ZebraNet wired Ethernet option
	The “Network” indicator light is off; there is no usable Ethernet connection.
	The “Network” indicator light remains steadily green, indicating a 100Base connection has been detected .
	The “Network” indicator light is steadily displaying yellow, indicating a 10Base connection.
	The network indicator light is steadily showing red , indicating an Ethernet error and the printer is not connected to the network.
Printers with ZebraNet wireless Ethernet option
	The “Network” indicator light is off. When power is applied, a radio signal is detected, and the printer attempts to connect to the network. The indicator light flashes red while the printer is establishing a connection. The indicator light flashes yellow while the printer is authenticating with the network.
	The “Network” indicator light is steadily displaying green, indicating a strong and reliable wireless signal. Your network is connected to your network and has been verified.
	The flashing “Network” indicator light shows a green Wi-Fi signal that is associated with your network and has been verified, but the WLAN signal is weak.
	The network indicator light is steadily displaying red , indicating a WLAN error and the printer is not connected to the network.

5.2 Printing Issues
The following lists issues related to printing and print quality, possible causes, and suggested solutions.

question	Possible reasons	Recommended solution
Common print quality issues	Incorrect printer speed setting	To achieve the best print quality, you should set the lowest possible print speed for your application via the control panel, driver, or software.
The incorrect combination of labels and ribbons was selected for your application.	1. Switch to different types of media or ribbons to find a compatible combination; 2. Contact MinYong Digital as needed for information and advice.
The printer’s print depth setting is incorrect.	To achieve the best print quality, the print depth should be set to the lowest setting suitable for your application.
Dirty printhead	Clean the print head and print roller
Incorrect or uneven printhead pressure	Set the printhead pressure to the minimum value that will yield the best print quality.
The print alignment mark on the label is missing, and the vertical offset of the alignment mark at the top of the form is too large.	The printing roller is too dirty	Clean the print head and print roller
The dielectric guide plate is not in the correct position.	Ensure correct positioning of the media guide plate
Incorrect media type setting	Configure the printer to work with the correct media type (slit/cut, continuous, or marking).
Incorrect media loading	Correctly load the media
Long, incomplete printing marks appeared on multiple labels.	Damaged printing components	Replace the print head
Colored ribbon folds	Solve according to the methods in “Ribbon Fault”
A thin, slanted gray line appears on the blank label.	Colored ribbon folds	Solve according to the methods in “Ribbon Fault”
The entire ribbon is printed too dark or too light.	The media or ribbon was not designed for high-speed printing.	Replace consumables suitable for high-speed operation
The wrong combination of media and ribbon was selected for your application.	1. Switch to different types of media or ribbons to find a compatible combination; 2. Contact MinYong Digital as needed for information and advice.
Users use ribbons for thermal media.	Thermal media do not require ribbons; it is necessary to determine whether thermal media has been used.
Incorrect or uneven printhead pressure	Set the printhead pressure to the minimum value that yields the best print quality.
The label has stains.	The media or ribbon is not designed for high-speed printing.	Replace consumables suitable for high-speed operation
Misaligned/Skipped ribbon	Printer not calibrated	Calibrate printer
Incorrect label format	Check your label format and correct it as needed.
One to three labels are misaligned or have printing errors.	The printing roller is too dirty	Clean the print head and print roller
The medium does not meet specifications	Use media that meet specifications.
Vertical offset of the top position of the label	Printer not calibrated	Calibrate printer
The printing roller is too dirty	Clean the print head and print roller
Label or image vertical offset	The printer uses non-continuous labels, but is configured to work in continuous mode.	Set the printer to the correct media type and calibrate the printer as needed.
Incorrect calibration of the medium sensor	Calibrate printer
The printing roller is too dirty	Clean the print head and print roller
Incorrect printhead pressure setting	Adjust the printhead pressure to ensure proper operation.
Incorrect loading of media or ribbon	Ensure that the media and ribbon are loaded correctly.
Media incompatibility	Media that meets the printer’s technical specifications must be used to ensure that the labels are evenly spaced with a gap of 2 to 4 millimeters.
Unable to scan the barcode printed on the label	The barcode does not meet specifications because it is printed too dark or too light.	Adjust the depth or printing speed settings as needed.
There is not enough blank space around the barcode.	Leave at least 3.2mm clearance between the barcode and other printed areas on the label, as well as between the barcode and the label edge.
Automatic calibration failed	Incorrect loading of media or ribbon	Ensure the media and ribbon are loaded correctly.
The sensor did not detect the medium or color band.	Calibrate printer
The sensor is too dirty, or the positioning is incorrect.	Ensure the sensor is clean and correctly positioned.
Incorrect media type setting	Set the printer to use the correct media type.

5.3 Ribbon Failures
The table below lists the ribbon failures that may occur, their possible causes, and suggested solutions.

Fault	Possible reasons	Recommended solution
ribbon damaged or melted	The depth setting is too high.	1. Lower the depth setting; 2. Thoroughly clean the printhead.
The ribbon coating is faulty and cannot be used with this printer.	Replace with a ribbon that has the correct coating.
The ribbon is slipping or cannot move forward correctly.	Incorrect ribbon tension setting	Change the tension setting of the ribbon shaft.
Colored ribbon folds	Incorrect ribbon insertion	Correctly load the ribbon
Incorrect burning temperature	To achieve the best print quality, the print depth should be set to the lowest setting suitable for your application.
Incorrect or uneven printhead pressure	Set the printhead pressure to the minimum value that yields the best print quality.
Improper medium feeding caused it to deviate from one side to the other.	Ensure the medium is level by adjusting the medium guide plate.
The print head or print roller may be installed incorrectly.	Contact Minyong Digital
The printer did not detect that the ribbon was used up.	The printer may have been calibrated without a ribbon, and then a ribbon was inserted without performing a user recalibration, or the printer’s default settings may not have been loaded.	Now calibrate the printer using the ribbon, or load the printer defaults.
In thermal transfer mode, the printer does not detect the ribbon even though it is correctly loaded.
Even if the ribbon is correctly loaded, the printer still displays “ribbon exhausted”.	The printer was not calibrated for the labels and ribbons to be used.	Calibrate printer

Label barcode label ribbon

1. Introduction to the Components of the Zebra TLP2844 Barcode Printer
1.1 External Introduction: Paper Feed Button/Status Indicator/Release Button/Power Switch/Power Jack/Interface Connector

1.2 Internal Introduction: Ribbon Feed Shaft/Ribbon Pickup Shaft/Pickup Gear/Ribbon Carrier/Ribbon Sensor/Top Cover Lock/Media Hook/Gap Sensor/Elevation Sensor/Media Guide Rod/Print Roller/Media Guide Rod Adjuster/Print Head/Tear Rod/Fixing Screw/Peeling Option

2. Zebra TLP2844 Barcode Printer Operation Controls Instructions
2.1 Power Switch
Press up to turn on the printer, press down to turn off the printer.
Caution: Always turn off the power before connecting or disconnecting the communication cable and power cord .
2.2 Paper Feed Button
Forces the printer to feed a blank label.
Removes the printer from a “paused” state (the printer enters a “paused” state due to programming commands or error conditions).
Use the paper feed button to view the printer settings and status.
2.3 Status Indicators
Used as printer operation indicators.

3. Zebra TLP2844 Barcode Printer Installation Steps
3.1 Loading Rolled Media
When loading media, the rolled media must be placed on the media hook, and then the media guide lever must be adjusted. The correct media for the required printing type must be used. If printing without a ribbon, thermally sensing media must be used; if using a ribbon, thermal transfer media must be used. The printer’s ribbon sensor detects whether the feed shaft is moving.
Regardless of whether the media is rolled inwards or outwards, it must be loaded into the printer in the same way.
① Open the printer, making sure to pull the release lever towards the front of the printer.
② Remove the outer portion of the media. During transport, the rolled media may become soiled during handling or accumulate dust during storage. Removing the outer portion prevents sticky or unclean media from being dragged between the print head and the print roller.
③ Separate the media hooks and keep them open.
④ Determine the method for rolling the media so that the printing side faces upward as it passes through the printing roller.
⑤ Place the rolled media downward between the hooks, then close the hooks and pass it through the center of the rolled media.
⑥ Turn the guide rod adjuster knob to the back to open the media guide rod.
⑦ Pass the media through the guide rod.
⑧ Turn the guide rod adjuster knob to the front to close the media guide rod. The guide rod should just touch the edge of the media, but should not restrict it.
⑨ If no ribbon is needed, close the top cover. Note that you need to open the top cover lock, lower the top cover, and press it down until the release button clicks into place.
3.2 Loading the Ribbon
When using a ribbon, a heat transfer medium must be used. When loading the ribbon, first install the supply roller and pickup roller, and then tighten the ribbon on the carrier.
① Install the ribbon supply shaft, pass the ribbon through the carrier, press the right end of the supply shaft onto the supply hub, align the slot at the left end of the supply roller, and mount it on the spokes of the left hub.
② Install the pickup roller shaft. Press the right end of the pickup roller onto the pickup hub, align the slot on the left end of the pickup roller, and mount it onto the spokes of the left hub.
③ Connect and tighten the ribbon. The ribbon must be aligned so that it is wound straight onto the pickup roller. Connect the ribbon to the pickup roller, use the tape on the new pickup roller, rotate the ribbon pickup gear counterclockwise, tighten the ribbon, close the top cover, making sure to open the top cover lock, lower the top cover, and press down until the release button clicks into place.
3.3 Media Length Detection
Before connecting the printer to the computer, ensure the printer is in normal operating condition. This allows the printer to perform a media measurement operation and print the status output.
After loading the media, perform the following steps to measure the length of each label.
① Ensure the printer power is off.
② Press and hold the paper feed button . ③
Turn on the printer power.
④ Release the paper feed button when the status indicator light flashes.
⑤ The printer will advance the media, measure and check the length of individual labels, then print a status summary report and remain in diagnostic dump mode.
⑥ To begin normal operation, tap the paper feed button. The printer will then print “out of DUMP” and advance the label.
3.4 Connecting the Printer and Computer
Caution: Turn off the power before connecting the interface cable. Before connecting or disconnecting the communication cable, the through power connector must be inserted into the power jack on the back of the printer.
Interface cable requirements:
① The data cable must be fully shielded and equipped with a metal or metallized connector housing. The shielded cable and connector must prevent radiation and receive electrical noise.
② Minimize the pickup level of electrical noise in the cable.
③ Keep the data cable as short as possible (1.83m recommended).
④ Do not tightly bundle the data cable and power cord together.
⑤ Do not tie the data cable to the power cord conduit.
3.5 Printing in Peel Mode
Using the optional distributor, you can print in “Peel Mode,” where the label backing travels through different channels, and only one label is placed at a time for subsequent placement.

① Remove several labels from the printing backing .
② Open the top cover.
③ Open the distributor door.
④ Turn on the label sensor.
⑤ Insert the backing in front of the peel bar and behind the peel roller.
⑥ Close the distributor door.
⑦ Close the top
cover. ⑧ Press the paper feed button to move the label forward
. During the printing job, the printer will peel off the backing, revealing a single label. Remove the label from the printer so that the printer can print the next label.
3.6 Using the Cutter Option
If the printer is equipped with a baffle with an electric blade, it can dispense one or more media and then automatically cut them off from the media roll. This option can cut continuous paper and label backings in rolls of media, keeping the cutter dry and eliminating the need to use any solutions or solvents to clean the blade.

4. Replacement of Vulnerable Parts in Zebra TLP2844 Barcode Printer
4.1 Replacing the Print Roller
① Disassembly

Open the printer, remove all media, use a pointed tool to release the latches on both sides, then rotate forward to lift the print roller from the bottom of the printer base.
② Assembly
Check that the right bearing is on the print roller shaft, align the print roller with the left gear, place it downwards on the bottom of the printer base, and rotate the latch backwards to lock it in place.
4.1 Replacing the Print Head
Note: Turn off the printer power, unplug the power cord, and then replace the print head.
Prepare a work area to prevent static discharge. The work area must be anti-static. Use a properly grounded conductive shockproof pad to support the printer, and wear a conductive wrist strap.
① Disassembly

Pull the release button forward, then lift the top cover upwards to open the printer and remove the ribbon from the tray. ① Grasp the printhead spring and pull it to the left, then slide it off the carriage. Use the spring to spring the printhead clip away from the right end of the carriage. Pull the printhead and bracket forward. Use a #2 screwdriver to remove the screw securing the ground wire. Disconnect the two bundles of printhead wires from the connector.
② Assembly:
New printheads come with clips and grounding screws. Align the printhead and bracket. Connect the left and right connectors to the black and white wire harness. Connect the ground wire and secure it with the screws. Tighten the screws with a #2 screwdriver. Insert the bracket pin into the left end of the carriage, aligning it with the right end of the bracket. Insert the printhead clip through the right end of the ribbon carriage into the bracket. Slide the left end of the printhead spring into the left end of the ribbon carriage, then slide the right end into the other end of the carriage. The “V” angle should align with the notch at the top of the printhead bracket. Clean the printhead with a cleaning pen. Reload the media and ribbon. Plug in the power cord. Print the status report to ensure it is working properly.

5. Troubleshooting Zebra TLP2844 Barcode Printer
5.1 Diagnosing Faults Based on Status Indicator Lights
■ No color: Check the power connection between the AC power outlet and the printer.
■ Stable amber: Possible causes: ① Top cover opening sensor is active. Press down on the top cover, close it, and lock it in place. ② Printer has syntax or command errors. Check the program and resend the print job.
■ Flashing red: Possible causes: ① Firmware download is in progress. The indicator light will first be red, then green. ② After turning on the printer, a signal to start media length detection is emitted. Release the paper feed button.
■ Stable red: Possible causes: ① Media or ribbon is used up. Load new media and press the paper feed button to continue. ② Power failure. Turn off the power and then turn it on again. ③ The printer is preparing to receive Flash programming during firmware download.
5.2 Diagnosing Printer Faults Based on Operation:
■ Media not moving forward: Possible causes and solutions: ① Check the interface cable connection from the computer to the printer. ② Check if the top cover is closed and locked in place. ③ Check if the label is correct. ④ Check if the printing side of the media is facing upwards. ⑤ When printing with thermal transfer, check if the transfer ribbon is aligned correctly and if the toner edge is facing outwards. ⑥ If the printer has syntax or command errors, check the program and resend the print job.
■ Media moving but not printing: Possible causes and solutions: ① Check if the label type is correct (thermal transfer or thermal sensor). ② Check if the loaded roll of media has the thermal side facing upwards. ③ Clean the print head with a cleaning pen. ④ Check if the top cover is closed and locked in place.
■ Printing The print color is fading or the print quality is poor. Possible causes and solutions: ① Clean the print head with a cleaning pen. ② Adjust the print speed/density in the software. ③ Check the media and ensure the print side is facing upwards. ④ Check if the thermal media used is correct.
■ Only part of the label is printed or the label printing is skipped. Possible causes and solutions: ① Perform media length detection. ② The label is stuck to the print head. ③ The top cover is not fully locked . ④ It may be a software problem
. ■ Printing stops, and the indicator light is amber or red. Possible causes and solutions: ① Perform media length detection. ② It may be a label paper quality problem; use only approved labels. ③ The label may be stuck. ④ Insufficient memory for the label size. ⑤ It may be a software problem.
5.3 Troubleshooting based on media operation
■ Printing continues between labels. Possible causes and solutions: ① Check if the label sensor is open. ② The label sensor is blocked or dirty; remove debris or dust. ③ Continuous media may be set.
■ Printing stops after printing one label. Possible causes and solutions: ① Check if the quantity setting is correct.
5.4 Diagnosing Print Quality Issues
■ No content printed on the label. Possible causes and solutions: ① The correct media for the required printing method must be used. If printing without a ribbon, thermal transfer media must be used. If using a ribbon, thermal transfer media must be used. The printer’s ribbon sensor detects whether the supply shaft is moving. ② Is the media loaded correctly?
■ The printed image appears problematic. Possible causes and solutions: ① The print head is not clean; clean the print head. ② The print head temperature is too low. ③ Adjust the printer density or printing speed. ④ The correct media is incompatible with the printer.
■ Several labels have many blank vertical lines (blank lines). Possible causes and solutions: ① The print head is not clean; clean the print head. ② The print head components are damaged; replace the print head.
■ Printing does not start from the top of the label, or one to three labels have printing errors. Possible causes and solutions: ① The media may not have passed under the media guide. ② The printer needs calibration
. ■ The label format has been sent to the printer, but the printer cannot recognize it. Possible causes and solutions: ① Is the printer in pause mode? If yes, press the paper feed button. ② If the status LED is lit or flashing, determine the fault based on the status indicator light. ③ Check if the data cable is installed correctly. ④ If a communication problem occurs, check if the correct communication port has been selected on the computer.

6. Cleaning the Zebra TLP2844 Barcode Printer:
● Printhead; Interval: As needed or after every five rolls of media; Method: Allow the printhead to cool down for one minute, then use a new cleaning pen to wipe the print elements from start to finish (the fine gray lines on the printhead). If print quality is still poor after cleaning, try using a printhead cleaning film to remove dust.
● Print Roller; Interval: As needed; Method: Manually rotate the print roller and thoroughly clean with 95% alcohol and a cleaning swab, cleaning card, or lint-free soft cloth.
● Peel Bar; Interval: As needed; Method: Thoroughly clean with 95% alcohol and a cotton swab.
● Tear Bar; Interval: As needed; Method: Thoroughly clean with 95% alcohol and a cotton swab.
● Exterior; Interval: As needed; Method: Wet cloth.
● Interior; Interval: As needed; Method: Brush or air jet.
● Cutter; Interval: As needed; Method: Remove debris using tweezers.

7. To update the firmware of your Zebra TLP2844 barcode printer,
download the 2844_V4_70_1A_CHN.prg file from the Zebra website (http://www.zebra.com.cn/), and then copy this file to the port

1. Introduction to various parts of Zebra_GT800 barcode printer
1.1 Status indicator light/feed button/release latch/interface connector/folding media entry slot/DC power switch and socket

1.2 Ribbon roll hook supply shaft/pick-up shaft/web sensor/media guide gear adjuster/paper roll hook and media guide/black line sensor/elevation angle sensor/platen roller/print head/ribbon end sensor

1.3 Power switch/color depth control switch

CAUTION: Turn off the printer before connecting or disconnecting communications and power cords
The Operator Color Depth Control switch allows the operator to modify color depth settings without changing the program or driver settings sent to the printer. This allows the user to adjust settings for small changes in the media and printer.
The control switch has three settings: low (1), medium (2), and high (3). The Low (1) setting does not change the actual Color Depth setting set through programming or driver settings. The Medium (2) setting increases the depth level by 3 stops; for example, if the printer is set to the default depth setting of 20, the actual color depth setting applied when printing will be 23. The “High (3)” setting adds 6 color depth levels to the color depth setting level.
Important: Setting the color depth to high or low will reduce the readability of the barcode.

2. Zebra GT800 barcode printer installation instructions
2.1 Load roll media
When loading media, rolls of media must be placed in the media supply bay and the correct media must be used for the type of printing required.
① Turn on the printer. Note that you need to pull the release button lever towards the front of the printer;
② Open the roll media hook, use your other hand to pull the media guide open, place the roll media on the paper roll hook, and release the guide plate. Adjust the position of the roll media so that the print side faces up when it passes over the printing roller;
③ Pull out the media so that the media protrudes from the front of the printer. Check whether the roll media can rotate freely. Do not put the roll media into the bottom of the media compartment. Check whether the printing side of the media is facing up;
④ Push the media under the two media guides;
⑤ If you do not need to install the thermal transfer ribbon, close the top cover;

2.2 Load the thermal transfer ribbon
The GT800 printer features a flexible ribbon system. It supports 300 meters and 74 meters of ribbon, and it also supports two ribbon roll adapters that can use 25.4 mm inner diameter ribbon rolls.

Requirements for thermal transfer ribbons:
● Media and ribbon types should match for best printing results
● To protect the print head from wear and tear, use a ribbon wider than the media.
● For thermal printing, do not install ribbon in the printer
● Use an empty ribbon roll that matches the inner diameter of the thermal transfer ribbon roll. Ribbon wrinkles or other printing failures may occur.
● Do not use ribbon rolls with damaged grooves, worn corners, broken, or shredded ribbon rolls. The grooves in the ribbon core should be intact so that the ribbon core can be fixed on the spindle. Otherwise, the ribbon core will slip, causing ribbon curling, ribbon end sensing errors, or other intermittent errors.
2.2.1 Load the standard core thermal transfer ribbon
Check whether there are gaps on both sides of the ribbon and empty ribbon core. If there are no gaps, please install them according to the non-standard core installation method.
① Open the printer cover and place the empty ribbon core on the printer pickup shaft. Push the right side of the empty ribbon core into the spring-pressed rotating shaft (right side), align the ribbon core with the center of the left rotating shaft hub, and rotate the ribbon core until the notch is aligned and locked.
② Place the new ribbon roll on the bottom ribbon supply shaft of the printer, push it into the right shaft, and lock the left side. The operation method is the same as fixing the pickup ribbon core.
③ Connect the ribbon to the pickup ribbon core, use the tape on the new pickup shaft, or use a piece of thin tape, align the ribbon, and let it wrap straight around the ribbon core.
④ Rotate the ribbon pick-up hub backward at the top to tighten the slack of the ribbon. The rotating hub helps to accurately align the ribbon pick-up position with the ribbon supply axis, and the ribbon leader should be completely covered by the ribbon.
⑤ Check that the media has been loaded and is ready to print, then close the printer cover.
⑥ When the printer is powered on, press the “Feed” button, let the printer feed a section of media of at least 20cm, tighten the slack part and ribbon wrinkles, make the ribbon straight, and align the ribbon on the rotating shaft.
⑦ Change the print mode setting from thermal to thermal transfer to set the printer temperature profile for thermal transfer media. This setting can be done through the printer driver, application software, or printer programming commands.
2.2.2 Load non-standard core thermal transfer ribbon
Loading non-standard core ribbon into the printer requires the use of a Zebra ribbon core adapter.
When using ribbons with non-standard cores for printers, at least the following requirements should be met:
● The inner diameter of the ribbon core should be 25.4mm. Material: Hard materials such as fiberboard and plastic core may not work properly.
● Ribbon width range: 110 to 33 mm.
● The maximum outer diameter of the ribbon is 66mm.

Adapters center the ribbon and ribbon core onto the media and printer. The adapter has a “ribbon core lock” spring that secures the soft fiberboard on the inside of the ribbon core and serves as a ruler to measure from the centerline of the printer when loaded into the printer.
① Load an empty ribbon core into the ribbon core adapter. The empty ribbon core should be the same as or slightly larger than the width of the ribbon roll. Place the center of the ribbon core roughly on top of the center line of the adapter. You can use an empty standard ribbon core without using an adapter and an empty non-standard ribbon core. The printer comes with a 300 meter empty ribbon core.
② Load the non-standard ribbon roll into the ribbon core adapter, align the adapter flange to the left, and check whether the ribbon unfolds the back of the ribbon roll as shown. Place the center of the ribbon core roughly on top of the centerline of the adapter.

The 110mm maximum width media roll does not need to be centered. For media smaller than the maximum width and up to the minimum width of 33mm, the graduated scale on the adapter core should be used to align the ribbon roll with the media and printer.
③ Place the adapter with the empty ribbon core on the pickup spindle, and place the adapter with the ribbon roll on the bottom supply spindle. The right side of the ribbon core adapter mounts to the tapered end of the spring-loaded right side spindle. Push the adapter further onto the right side of the spindle and install the adapter onto the left hand wheel hub. Rotate the adapter and hub until the grooves on the adapter flange align and lock onto the spokes of the left spindle hub.

④ During the installation of the ribbon and empty ribbon core in the previous step, they may deviate from the center position. Check whether the ribbon roll and empty ribbon core are aligned with the center of the media (labels, paper, etc.). Note: You can use the centerline ruler on the ribbon core adapter to adjust the position.
If you forgot to check that the ribbon is wide enough for the media, you can still check now. To protect the print head, the ribbon must be wider than the media (including the label liner or backing).
⑤ Connect the ribbon to the pickup ribbon core. Use a thin piece of tape to secure the ribbon to the pickup core, aligning the ribbon so it wraps straight around the core.
⑥ Rotate the ribbon pickup hub backwards from the top to tighten the slack part of the ribbon. Rotating the hub can help accurately align the ribbon pickup position with the ribbon supply axis. The ribbon should be wound around the ribbon pick-up core at least one and a half times.
⑦ Check that the media is loaded and ready to print, then close the printer cover.
⑧ When the printer is powered on, press the “Feed” button, let the printer feed a section of media of at least 20cm, tighten the slack part and the ribbon wrinkles, make the ribbon straight, and align the ribbon on the rotating shaft.
⑨ Change the print mode setting from thermal to thermal transfer to set the printer temperature profile for thermal transfer media. This setting can be done through the printer driver, application software, or printer programming commands.

2.3 Print test (printer configuration) label
Before connecting the printer to the computer, make sure the printer is in normal working order. You can print a configuration status label to confirm.
① Make sure the media is installed correctly and the top cover of the printer is closed. If the printer is not already powered on, power it on. If the printer status indicator light flashes green during the initialization process (pause state), you should press the “Feed” button to set the printer in “Ready” mode. If the printer status indicator light does not turn solid green, please refer to the subsequent troubleshooting.
② Press the “Feed” button two to three times to let the printer perform calibration according to the loaded media. During this process, the printer may feed multiple labels.
③ When the status indicator light remains green, press and hold the “Feed” button until the status indicator light flashes once.
④ Release the “Feed” button. A configuration label will print out.

2.4 Pre-install Windows printer driver
Zebra has changed the installation method to use the printer through the Windows operating system based on the PC system. It is recommended to pre-install at least the ZebraDesigner Windows driver to take advantage of its simplicity and ease of use, as well as the convenience of the Windows operating system after Windows XP SP2 version.
Zebra provides Zebra Setup Utilities (ZSU), which is a set of Zebra printer drivers, utilities, and communication and installation tools that can be used for most Windows PC operating systems. Zebra Setup Utilities and Zebra windows printer drivers can be obtained from the user CD, or the latest version can be obtained from the Minyong website (www.chongshang.com.cn).
ZebraDesugber driver and Zebra Setup Utilities (including driver): Support Windows7, Windows Vista, Windows XP, Windows 2000, Windows Server2008 and Windows Server2003 operating systems. The driver supports 32-bit and 64-bit Windows operating systems and has been certified by Microsoft. The ZebraDesugber driver and Zebra Setup Utilities support the following printer communication interfaces: USB, parallel, serial, wired and wireless Ethernet, and Bluetooth (using the Bluetooth virtual printer port).
Zebra Setup Utilities should be installed first before powering up the printer connected to the PC. Zebra Setup Utilities will prompt you to power up the printer. Continue with the following steps to complete the printer installation.
2.4.1 Plug and Play (PnP) printer detection and Windows operating system
Newer Windows operating systems can automatically detect the printer when it is connected via the USB interface. Depending on the hardware configuration and Windows version, printers can be detected via plug-and-play when connected to USB, parallel, and serial ports. The printer driver currently does not support serial port plug-and-play installation. The printer’s serial port PC interface configuration must support and have two-way communication capabilities to achieve plug-and-play. The first time you connect a printer to your PC, the operating system will automatically launch the Add New Hardware wizard, and if the Zebra Setup Utility comes with a preinstalled driver suite, the printer driver will automatically be installed. Go to the Windows printer directory, right-click the mouse, select “Properties”, click the “Print Test Page” button to verify whether the installation is successful.
If you reconnect the printer to the USB port or power on the printer after the PC completes the reboot of the operating system, the Windows operating system will detect and reconnect the previously installed printer. Ignore the warning that a new device has been detected and close the taskbar prompt. After waiting a few seconds for the operating system and driver software to match, the warning message will exit and the printer is now ready to print.
2.4.2 Universal Serial Bus (USB) device communication
When using the USB interface, the printer is the terminal device (not the host or hub).
NOTE: A scanner, scale, or other data input (terminal) device must use a serial port (not a USB port) to send data to the printer.
2.4.3 Serial Ports and Windows Operating Systems
In addition to the data flow control settings, the default settings for the serial port communication of the Windows operating system match the default settings of the printer. The default data flow control setting of Windows is NONE. The GT800 printer needs to set the data flow control setting to Hardware.
Note: GT800 printers currently do not support plug-and-play device detection for Windows serial ports.
2.4.4 Ethernet
The GT800 printer options feature multiple methods and applications to help connect the printer to a network (WAN or LAN) and configure wired and wireless (Wi-Fi) printers. The Zebra Setup Utility configuration wizard supports printers using IP addresses to connect to printers on shared networks through Windows-based systems. The printer has an internal web page that makes it easy to configure the printer and network. This web page can be accessed using a web browser through the printer’s IP address. The free version of ZebraNet Bridge software allows users to centrally deploy, manage and monitor Zebra printers. Zebra’s printer auto-discovery feature can discover up to 3 printers from a preset PC screen anywhere on the global network. ZebraNet Bridge Enterprise can be purchased to manage large numbers of Zebra printers.

2.5 Connect the printer to the computer
The Zebra GT800 printer supports a variety of interface options and configurations. These include: Universal Serial Bus (USB) interface, RS232 serial interface, parallel interface (IEEE1284) and 10/100 Ethernet.
CAUTION: When connecting the interface cable, place the power switch in the off position. Before connecting or disconnecting communications cables, the power cord must be plugged into the power supply unit and the electrical outlet on the back of the printer.
Interface cable requirements:
Data cables must be of fully shielded construction and equipped with metal or metallized connector housings. To prevent radiated and received electrical noise, shielded cables and connectors must be used.
To minimize the level of electrical noise pickup in cables, do the following:
● Data cables should be as short as possible (1.83m long cable is recommended)
● Do not bundle data cables and power cords tightly together
● Do not tie data cables to power conduits

2.6 After connecting the printer
You can now establish basic communication with the printer and test printer communication, and then install other printer-related applications, drivers, or utilities.
Verifying the operation of the printing system is a relatively simple task. For Windows operating systems, the Zebra Setup Utility or the Windows “Printers and Faxes” control panel can operate and print a test label. For non-Windows operating systems, a (~WC) command can be used to copy a basic ASCII text file to print a configuration status label.
2.6.1 Test printing using Zebra Setup Utility
① Open Zebra Setup Utility
② Click the icon of the newly installed printer, select the printer and enable the printer configuration button under the printer in the window.
③ Click the “Open Printer Tools” button.
④ In the “Print” tab window, click the “Print configuration label” line and click the “Send” button. The printer will print the configuration status label.
2.6.2 Use the Windows “Printers and Faxes” menu to test the printing situation

① Click the Windows “Start” menu button and go to “Printers and Faxes”, or go to the “Control Panel” “Printers and Faxes” menu to open the menu.
② Select the newly installed printer icon, select the printer, and right-click the mouse to open the printer’s “Properties” menu.
③ From the printer’s “General” tab window, click the “Print Test Page” button, and the printer will print the Windows test print page.
2.6.3 Perform a test print to an Ethernet printer connected to the network (LAN or WAN) using the MS-DOS command prompt or from the Windows XP Start menu
① Create a text file using three ASCII characters: ~WC
② Save the file as: TEST.ZPL (any file name and extension)
③ Read the IP address on the network status printout of the printer configuration status label. While connected to the same LAN or WAN as the printer, type the following into the address bar of the web browser window and enter: ftp 123.45.67.01 (assuming the IP address is 123.45.67.01)
④ Type the file name, then enter “put” and press Enter. For this “test print” file it should be: put TEST.ZPL
2.6.4 For non-Windows operating systems, use copying the ZPL command file to perform test printing
① Create a text file using three ASCII characters: ~WC
② Save the file as: TEST.ZPL (any file name and extension)
③ Copy the file to the printer. For DOS environment, send the file to the printer connected to the system parallel port. The command is very simple: COPY TEST.ZPL LPT1

3. Zebra GT800 barcode printer printing operation
3.1 The printer is not operated or stored for a long time
A printhead that has been stored for a long time may stick to the platen roller. To avoid this, store the printer with a piece of media (label or paper) between the printhead and the platen roller. Do not ship the printer with a media roll installed, otherwise the printer or media may be damaged.

3.2 Printing mode
The GT800 printer works in different modes and various media configurations:
● Thermal printing (this method uses heat-sensitive media for printing)
● Thermal transfer printing (this method uses a ribbon to print on the media using the principle of thermal transfer)
● Standard tear-off mode allows users to tear off labels (or batch-printed label strips) after printing each label
● Label peeling mode: If a label peeler is installed, the label can be peeled off from the backing material during the printing process. After removing this label, the next label can be printed immediately.
● Stand-alone mode: The printer can print without being connected to a computer serial port when using the auto-run label function (according to programming) or using a data input device connected to the printer’s parallel port. In this mode, you can use data entry devices such as scanners, scales, Zebra KDU Plus, or Zebra KDU (Keyboard Display Unit).
● Network shared printing: Printers equipped with the Ethernet interface option have a built-in print server that can manage and monitor the status of Zebra printers on the network through the ZebraLink printer configuration web page and ZebraNet Bridge software.

3.3 Types of printing media
Important: For uninterrupted high-quality printing, Minyong strongly recommends the use of Minyong recommended consumables. A variety of specially designed papers, polyethylene, polyester and vinyl products can improve the printing performance of the printer and prevent premature wear of the print head.
The GT800 printer can use a variety of media types:
● Standard Media – Most label non-continuous media use an adhesive material that allows multiple individual labels or a length of continuous labels to be adhered to a backing.
● Continuous roll media – Most continuous roll media are thermal (similar to fax paper) and are suitable for receipt or ticket printing.
● Unbacked media – Unbacked labels have an adhesive material, but are wrapped around a core of media without a backing. The media is usually pre-punched and may also have black mark markings on the underlying surface of the media to indicate where the labels are separated. The top layer of labels on unbacked media has a special coating that prevents labels from sticking to each other. The printer must be equipped with a special “linerless” option to use linerless media and ensure that the media does not stick to the printer.
● Label Material – Labels are typically made from thick paper (up to 0.19mm thick), the label material has no adhesive or backing, and usually comes with pre-punched holes between each label.
① Non-continuous roll media
Roll media can be wound on core diameters from 12.7 to 38.1 mm. Labels have an adhesive backing that bonds the labels to the lining, and the labels are separated by spacers, notches, cut-out holes, or black marks. Labels are separated by perforations. Individual labels are separated by one or more of the following methods:
◆The textured media is separated by spacers, cut holes or notches.

◆Black mark media uses pre-printed black marks on the back of the media to show label separation locations.

◆Pre-punched media has perforations that allow easy separation between labels or label materials. The media may also have black marks or other separation between labels.

② Intermittent folded media, folded media folded in a staggered manner, folded media can have the same separation method as the intermittent media roll. The separation location may be at or near the fold.
③ Continuous roll media, roll media can be wound on a paper core with a diameter of 12.7 to 38.1 mm. Continuous rolls of media have no gaps, cutouts, notches, or black marks to indicate where labels are separated. Images can be printed anywhere on the label, and individual labels can be cut with a cutter. If using continuous media, a transmissive (gap) sensor should be used so that the printer can detect the media being ejected.

3.4 Adjust printing width
The print width must be set when:
● Using the printer for the first time
● Media width changed
You can set the print width in the following ways:
◆ Windows printer driver or application software such as ZebraDesigner.
◆ With the printer power on and the top cover closed, press and hold the “Feed” button for a few seconds. The green status indicator light will flash 5 times and then release the button. The printer will adjust the width. Starting from the minimum printing width to the maximum printing width of the printer, a frame will be printed continuously every 4mm. When the printer reaches the required maximum printing width, press the “Feed” button. Note: Printer drivers and applications may override this setting.
◆ Use ZPL programming to control printer operation, please refer to the “Print Width Command” (~PW) command.
◆ To control printer operation through “EPL page mode” programming, please refer to the “Set Label Width” (q) command.

3.5 Adjust print quality
Print quality is affected by printhead temperature or density settings, print speed, and the type of media used, experiment with these settings to find the best combination for your application. Print quality can be set using the Zebra Setup Utility’s “Configure Print Quality” program.
You can control the relative color depth (or density) setting in the following ways:
◆ With the printer power on and the top cover closed, press and hold the “Feed” button for a few seconds. The green status indicator light will flash 6 times and then release the button. The printer will adjust the depth, starting from the minimum color depth (printing density/heat) and ending at the printer’s maximum color depth. Use the ZPL depth setting range value to print a continuous bar code simulation pattern in increments of 4. If the pattern is clear and valid, press the “Feed” button. Do not continue to increase the color depth setting or the width of the barcode lines may be distorted, resulting in reduced readability. NOTE: Printer drivers and applications may override this setting.
It will override any color depth/density settings programmed via ZPL or EPL.
◆ (~SD) ZPL command for “set color depth”.
◆ “Color Depth” (D) ELP command.
If you find you need to adjust the print speed, you can use:
◆ Windows printer driver or application software such as ZebraDesigner.
◆ “Print Speed” (~PR) command.
◆ “Speed ​​Select” (S) command.

3.6 Media sensing
The printer has automatic media sensing, and the printer is designed to continuously check and adjust media length sensing to accommodate subtle changes. As printing begins or media is fed, the printer continuously checks and adjusts media sensing to accommodate subtle changes in media parameters from label to label and from roll to roll within the same roll. When starting a print job or feeding media, the printer automatically initiates media length calibration if the expected media length or spacing between labels falls outside the acceptable variation range. The automatic media sensing feature in the GT800 printer is also suitable for printer operation using EPL and ZPL label formats and programming.
If the printer does not detect a label or black line (or notch with black line sensing) after feeding the media at the default maximum label length of 1 meter, the printer will switch to continuous media mode and will retain these settings if not changed using software or programmatically or manually calibrated for different media.
You can also choose to set the printer to perform a brief media calibration after the printer is powered on, or when printing is turned off while the power is on. During the calibration process, the printer will feed multiple labels.
You can verify the printer’s media settings by printing the Printer Configuration label.
You can use the “ZPL Maximum Label Length Command” (~ML) to reduce the maximum distance to be checked by the media type automatic detection and sensing process. It is recommended to set this distance to no more than twice the longest label to be printed. If the maximum size label to be printed is 4*6 inches, you can reduce the detection distance of the maximum label length from the default distance of 39 inches to 12 inches.
If the printer is unable to automatically detect media type and calibrate automatically, perform a full calibration, which includes a printed pattern of sensor operation for the user media. This method disables the printer’s auto-media sensing feature until the printer’s default parameters are reset to factory defaults using the four-flash feed button pattern.
The media automatic calibration function can be modified, turned on or off according to user needs. Print jobs sometimes require the printer to use an entire roll of media. You can use the “ZPL media feed command” (~MF) to independently control the two media automatic feeding situations (power on when loading media, or close the printer cover when power on). The feed operations discussed in the ZPL Programmer’s Guide for the ~MF command apply primarily to media autosensing and calibration. Automatic media calibration operations for controlling media (label-to-label) calibration can be implemented using the ~XS command. These settings should not be changed if multiple media types of different lengths, materials, and detection methods (web/gap, black line, notch, or continuous) are used.
The media calibration and detection process can also be refined to match the media type loaded into the printer, which can be set using the “ZPL Media Tracking” command (~MN). Printers sometimes detect preprinted media as spaces between labels, or backings with printed content as black marks, and if the ~MN parameter is set for continuous media, no automatic calibration is performed during printing. The ~MN command also includes an autocalibration parameter (~MNA) that can be used to return the printer to its default settings for automatic detection of all media types.

3.7 Fonts and Printers
The GT800 printer meets your language and font requirements with a variety of internal fonts, onboard font scaling, international font sets and code page support, Unicode support, and font download options.
The font function of GT800 printer is related to the programming language. The EPL programming language provides support for basic bitmap fonts and international code page fonts. The ZPL programming language provides advanced font mapping and scaling technology, supporting outline fonts (TrueType or OpenType) and Unicode font mapping, as well as basic bitmap fonts and character code pages.
The GT800 printer features a variety of tools and application software that support downloading fonts to the printer for both printer programming languages.
The GT800 printer has resident prefixes for supporting Simplified or Traditional Chinese.
3.7.1 Printer localization through code pages
The GT800 printer supports two major programming languages, ZPL and EPL. Each programming language has a set of font sets to support regions, countries and character sets. The printer supports localization using commonly used international character mapping code pages, as well as configuration status printout.
●For zpl code page support including Unicode, see the ^CI command in the ZPL Programmer’s Guide.
●For the ZPL configuration status printout language, please refer to the ^KL command in the “ZPL Programmer’s Guide”.
●For EPL code page support, see I Commands in the EPL Programmer’s Guide.
3.7.2 Identify fonts in the printer
Fonts and memory can be shared through the programming language in the printer. Fonts can be loaded into multiple memory areas in the GT800 printer, and ZPL programming technology recognizes both EPL and ZPL fonts. EPL programming technology can only recognize EPL fonts.
ZPL font:
● Fonts suitable for ZPL printer operation can be managed and downloaded using Zebra Setup Utility or ZebraNet Bridge.
● To display all fonts loaded into your printer, send the ZPL ~WD command to the printer.
The .FNT file extension in the ZPL language is used to identify bitmap fonts in different printer memory areas.
The .TTF, .TTE, or .OTF file extension in the ZPL language is used to identify scalable fonts. EPL does not support these fonts.
EPL font:
● To download fonts for EPL printing, use the Zebra Setup Utility or ZebraNet Bridge to send the file to the printer.
● To display soft fonts (ext.) available for EPL, the EPL command EI should be sent to the printer.
All EPL fonts displayed are bitmap fonts and do not include the .FNT file extension or horizontal and vertical indicators displayed using the ZPL command ^WD in the above ZPL fonts.
● To delete non-Asian EPL fonts through EPL programming, use the EK command.
● To remove EPL Asian fonts from the printer, use the ZPL ^ID command.

3.8 Independent printing
The printer can be configured to work independently without being connected to a computer. The GT800 printer can automatically run a single label printing format. One or more downloaded tag formats can be accessed using a terminal device, embedded device, or Zebra KDU (keyboard display unit) to use the tag formats. These methods allow developers to integrate data input devices such as scanners or scales into printers through the serial port.
Label formats developed can be stored in the printer to support labels with the following characteristics:
● No data input is required, just press the “Feed” button to print.
● No data entry required, prints when labels are removed from the printer’s optional label peeler.
● One or more data variables can be entered through a terminal or embedded device. The label will be printed after the last variable data field is entered.
● One or more label formats invoked by scanning a barcode that contains programming information for the running label format.
● A label format designed as a step in the process, where each label includes a barcode that contains programming information to run the next label in the process.
Both printer programming languages ​​support special label formats that run automatically after a power cycle or reset. ZPL looks for a file named AUTOEXEC.ZPL, and EPL looks for a label format named AUTOFR. If both files are loaded into the printer, only AUTOEXEC.ZPL is run. If EPL AUTOFR is not disabled, it will always run. Both files must be deleted from the printer and then a reset or power cycle performed to completely delete the files.

3.9 Print counter
The GT800 printer is able to report maintenance alerts for the printhead, the printer can provide a cleaning function, and can provide advance warning when a calculated printhead life alarm arrives. If an RTC (Real Time Clock) is installed in the printer, date information can also be included in the printhead life and history reports. By default, print count alerts are disabled.
Multiple print counter messages and reports can be customized. To enable print counter alerts, send the following command to the printer:
● EPL command oLY
● ZPL command^JH,,,,,E

4. Zebra GT800 barcode printer maintenance
4.1 Clean the print head
Caution: The print head will become hot during the printing process. To prevent damage to the print head and personal injury, please do not touch the print head. Only use a cleaning pen or alcohol cotton for maintenance.
① Rub the cleaning pen on the black area of ​​the print head and clean from the middle to the outside. This can clean the sticky substance transferred from the edge of the media to the outside of the print head along the media path.
② Wait for one minute before closing the printer cover.

4.2 Media path considerations
Use a cleaning swab to remove accumulated debris, dust, and dirt from hooks, guides, and media path surfaces.
① The alcohol in the cleaning swab soaks these particles to make them lose their stickiness.
② Wipe the protruding piece to remove accumulated debris.
③ Wipe the inner edges of the two media guides and the media holder to remove accumulated dirt.
④ Clean the back of the ribbon cover (movable baffle) and turn the cover down to a position where the top cover of the media can contact this surface. Adhesive on the edges of the label media may slowly stain and accumulate on the inside surface.
⑤ Wait for one minute before closing the printer cover and discard the used cleaning swab.

4.3 Sensor cleaning
Dust can accumulate on the media sensor.
① Use a brush to gently brush off the dust, or use a compressed air can to blow off the dust. Do not use an air compressor – oil and sewage in the air pump will stain the printer and print head. Use dry cotton swabs to wipe away dust as needed. If there is still glue or other dirt, you can use alcohol to moisten the cleaning swab to remove it.
② Use a dry cleaning swab to remove any remaining dirt after the first cleaning.
③ Repeat steps 1 and 2 as needed until all residue and traces of dirt are removed from the sensor.

4.4 Cleaning and replacing the printing roller
The label printing roller (drive roller) generally does not require cleaning, and although paper dust and backing debris may accumulate, it will not affect the printing operation. Dirt on the print roller will damage the print head and cause the media to slip or stick during printing. Glue, dirt, dust, oil and other dirt should be removed from the print roller immediately.
If printer performance, print quality, and media handling are significantly reduced, the print roller (and media path) should be cleaned. The platen roller is the printing surface and the driving wheel for the media. If sticking or paper jams still occur after cleaning, the platen roller must be replaced.
You can use a fiber-free cleaning swab or a lint-free cloth moistened with a little alcohol to clean the print roller.
① Print cover and remove the media from the print roller area.
② Pull the left or right print roller bearing lock release tab toward the front of the printer and rotate it upward.
Note: The support arm of the print roller has a complicated structure. Move the support arm outside the printer to clean the grooves on the bearing seat. Then, slowly and gently pull the support arm toward the front of the printer to remove the print roller. Be careful when installing the bearings.
③ Take out the printing roller from the bottom bracket of the printer.
④ Use a cleaning swab moistened with alcohol to clean the printing roller from the center to the outside. Repeat this process until all platen roller surfaces are clean. If you find that there is a lot of accumulated sticky matter or serious label blockage, you should use a new cleaning swab to repeat the operation to remove residual dirt. The first cleaning can dilute the sticky matter and oil stains, but it may not be completely removed.
⑤ Install the printing roller into the printer. The cleaning swab cannot be reused and should be discarded after use.
⑥ Make sure that the bearing and drive gear are located on the printing roller shaft.
⑦ Align the printing roller and gear to the left, and put them downward into the bottom bracket of the printer.
⑧ Gently turn the locking pin of the print roller bearing downward toward the rear of the printer to release the tab, and lock it into the notches on both sides of the bearing groove.
The printer should be allowed to dry for about a minute before closing the media cover.

4.5 Replace the print head
CAUTION: Prepare your work area to prevent electrostatic discharge, anti-static measures must be taken in the work area, support the printer with a properly grounded conductive shock pad, and the operator themselves should wear a conductive wrist strap.
CAUTION: Turn off the printer and unplug the power cord before replacing the printhead.
4.5.1 Print head removal
① Turn on the printer. Remove the thermal transfer ribbon from the printer.
② Grasp the right side of the print head cover bracket and gently pull the bracket off the print head. There is a gap on the side of the cover for your thumb to grab. You can use other fingers to provide more force to pry the cover from the ribbon bracket.
③ Use the short guide arm on the left side of the print head cover to release the print head from the ribbon holder.

Push the shortened guide rod to the right side of the ribbon holder and press the printhead release tab.

If necessary, push the shortened guide rod to the left side of the ribbon holder and press the other release tabs of the printhead.
④ Use a cross-head screwdriver to remove the screw securing the ground wire (green).
Gently and slowly pull the two printhead cables straight out of the connectors to disconnect the cables from the printhead assembly. Pulling the connectors out at an angle can damage the printhead’s connector pins and sockets.
4.5.2 Reinstallation of print head
Reverse the print head removal steps to reinstall the print head.
① Connect the two print head cables to the print head.
② Connect the ground wire to the print head assembly.
③ Insert the center pivot tab of the print head assembly into the groove of the ribbon holder.
④ Lock the left and right sides of the print head assembly into the ribbon holder, and check whether the print head is correctly fixed by the locking tabs and the bracket. You can also press both sides of the print head toward the ribbon holder again to check whether the tabs are correctly fixed.
⑤ Check that the print head can move freely up and down when pressure is applied, and remains in the locked position when released.
⑥ Clean the print head.
⑦ Reload the media. Plug in the power cord, turn on the printer, and print a status report to make sure the printer is working properly.

5. Troubleshooting for Zebra GT800 barcode printer
This section provides printer failure reporting information that you may need to perform printer troubleshooting procedures. It also includes various diagnostic tests.
5.1 Status indicator light description

Indicator light status and color	Printer status	See numbers below for workarounds
go out	closure	1
Stay green	Open	2
Lasts amber	Stopped	3
flashing green	Stopped	4
Flashing red	Stopped	5
red double flash	Suspended	6
amber flashing	Suspended	7
Flashing red and green alternately	Need repair	8
Flashing red, flashing red and green	Requires repair or restart	9
Blinking red, amber and green (do not reset or power off)	Memory card defragmentation	10

5.2 Solutions to status indicator light errors
The following status error indicator solution numbers correspond to the “Status Indicator Description” table in 5.1. Each error number has one or more workarounds for troubleshooting the listed error.
1. The printer is not powered on
● Is the printer powered on? ● Check the power connections from the wall outlet to the power supply and from the power supply to the printer.
● Disconnect the printer from the wall outlet for 30 seconds, and then reconnect the printer to the wall outlet.
2. The printer is powered on and in standby mode.
No action is necessary.
3. The printer failed the power-on self-test (POST).
● If the error occurs when turning on the printer, please contact Digital for assistance. If the printer is working properly, the printer status light lights amber for 10 seconds before turning green (solid or blinking).

A memory error has occurred.
● If the error occurs after printing is complete, turn the printer off and on again, then resume printing.

Need to let the print head cool
● If this error still occurs, turn off the printer, wait for at least five minutes, and then turn it back on. If the amber light is still on, the printer needs service.
4. The printer is receiving data
● After receiving all data, the status indicator light will turn green and the printer will automatically resume operation.
5. The media is used up.
● Reload the roll media and press the Feed button to resume printing.

Ribbon ran out
● The printer has detected the end of the ribbon roll. Replace the ribbon.

Print head open
● Close the top cover and press the Feed button to resume printing.
6. The printer pauses.
● Press the “Feed” button to restart printing.
7. The print head temperature is too high.
● Printing will be paused, waiting for the print head to cool down to an acceptable printing temperature. Once this temperature is reached, the printer will automatically resume work.
8. The flash memory is not programmed.
● Return the printer to the point of purchase.
9. A serious failure occurs in the print head or motor.
● Return the printer to the point of purchase.
● The print head may have a “THERMAL SHUTDOWN” error. Turn the printer off, let the printer cool down for a few minutes, and then turn the power back on. If the error still occurs, the printer should be sent to Sensitive Digital.
10. The printer is defragmenting the memory.
CAUTION: Do not turn off the printer during defragmentation, as this may damage the printer.
● Defragmentation is a daily operation of the printer. Performing this operation can better manage the space usage of the memory card. The printer will defragment the memory card when factory defaults are restored and the printer detects that defragmentation is required.
When the printer is in this state, the printer should be allowed to complete defragmentation. If warnings are issued frequently, please check the label format. Frequent writing or erasing formats from memory may cause the printer to defragment frequently. The need for defragmentation can be minimized by using a format that avoids frequent rewriting of memory.
● If the warning condition does not go away, contact Technical Support. The printer needs repair.

5.3 Print quality issues
5.3.1 Nothing is printed on the label.
① In the case of printing without ribbon, the media may not be thermal media.
② For thermal transfer printers, the media cannot have winding problems, nor can mismatched printer ribbons be used.
③ Has the media been loaded correctly?
5.3.2 The printed image is incorrect
① The print head is dirty, clean the print head.
② The print head temperature is too low.
③ Adjust the print depth and/or print speed.
④ The media being used is incompatible with the printer.
⑤ The print head is worn. The print head is a consumable part and will wear out due to the friction between the media and the print head. Using substandard media may shorten the life of the printhead or damage the printhead. Replace the print head.
⑥ The printing roller needs to be cleaned or replaced. The print roller may lose traction for the following reasons:
●There are foreign objects on the surface.
●The smooth surface of the rubber material has been changed to a polished and slippery effect.
●A generally smooth printing surface may be damaged like a folding knife cut.
5.3.3 There are many places on multiple labels with no printed content (blank vertical lines)
① The print head is dirty, clean the print head.
② The print head element is damaged.
5.3.4 The printing action does not start from the top of the label, or one to three labels have printing errors.
① The media is not correctly stringed.
② The printer needs calibration.
③ ZPL label format – the correct media sensor may not be enabled. Manual calibration allows you to select the media sensing method for the label to be used. (^MN command)
④ ZPL Label Format – Check that the “Label Top” (^LT) command is set correctly for your application.
⑤ EPL Label Format – For label delivery, black line or notch sensing, or gap/cut sensing, the correct media sensor may not activate. Manual calibration allows you to select the media sensing method for the label to be used. (o and Q commands)
⑥ EPL Label Format – Check that the “Set Label Length” (Q) command is set correctly for your application.
5.3.4 The ZPL label format has been sent to the printer, but the printer cannot recognize it.
① Is printing in pause mode? If so, press the “Feed” button.
② Check whether the data cable is installed correctly.
③ If a communication failure occurs, first, check whether the correct communication port on the computer has been selected.
④ Check whether the correct “Format” and “Control Prefix” on the printer match what is used in the ZPL programming label format. The default format is an up arrow (^) character, and the control character is a tilde (~) character.
5.3.5 The EPL label format has been sent to the printer, but the printer cannot recognize it.
① Is printing in pause mode? If so, press the “Feed” button.
② Check whether the data cable is installed correctly.
③ If a communication failure occurs, first, check whether the correct communication port on the computer has been selected.
④ If the printer has the label peel function enabled, the printer will wait for the user to remove the label, and the backing paper/web must be correctly fed through the label peeler to work correctly in label peel mode.

5.4 Manual calibration
Manual calibration is recommended if you are using preprinted media or if the printer does not automatically calibrate correctly.
① Make sure the media is loaded.
② Turn on the printer power.
③ Press and hold the “Feed” button until the green indicator light flashes once, then twice, and continues to flash until the flash combination reaches a set of seven flashes. Release the Feed button.
④ The printer will set up the media sensor for the label backing to be used. After this adjustment, the roll media will automatically feed until the label is positioned under the printhead, and a chart of the media sensor settings will print out. After the above operation is completed, the printer will save the new settings in memory and the printer will be ready for normal operation.
⑤ Press the “Feed” button to feed a whole blank label. If it does not feed, you should try returning the printer to defaults and performing a printer recalibration.
Note: Performing manual calibration disables the automatic calibration feature. To return to automatic calibration mode, restore the printer defaults.

5.5 Paper feed button mode

power off mode
When the printer is powered off, press and hold the “Feed” button when the printer is powered on.
flash sequence	operate
Amber-red flashing	Firmware Download Mode – The printer begins flashing red rapidly, indicating that it has entered “Firmware Download” mode. At this point, release the “Feed” button to initialize the printer and start downloading. When the printer status light begins blinking slowly red and green, the printer is ready to begin downloading firmware.
amber	Normal operation mode – the printer enters the normal initialization process. At this time, releasing the “feed” button allows the printer to start normally without downloading firmware and work in communication diagnostic mode.
green	Communication Diagnostic Mode – Immediately after the printer status indicator turns green, release the “Feed” button, the printer will print “Now in DUMP” on the top of the label, and then advance to the next label. After printing the first label, the printer will automatically enter diagnostic mode, and the printer will print out a text representation of the subsequently received data in diagnostic mode. To exit diagnostic mode and resume printing, power the printer off and on again. Another way to exit diagnostic mode is to press the Feed button multiple times. This clears the printer’s command cache and prints “Out of DUMP” on the label.

Power on mode
With the printer powered on and the top cover closed, press and hold the “Feed” button for a few seconds. The green indicator light will flash several times. The description on the right (Operation) shows what happens to the printer when the button is released after the light has flashed a specific number of times and before the next flash sequence begins.
flash sequence	operate
*	Configuration status – A detailed printer configuration status report can be printed. The label can be used to verify the printing effect, help the printer calculate the communication configuration, and perform maintenance, troubleshooting, and help users communicate with customer service.
* **	Standard Media Calibration – The printer detects and sets the media type and media length, which adjusts the media sensor for optimal performance for the loaded media (equal to ZPL command ~JC). The printer will feed one to four labels during the calibration process.
* ** ***	Serial Port Configuration – Applies only to printers with a serial interface port. To reset the communication parameters for a serial port other than database control, press and release the Feed button while the light flashes amber and green rapidly. To synchronize the baud rate automatically: Send the ^XA^XZ command sequence to the printer while the light is flashing amber and green rapidly. When the printer and host are synchronized, the light switches to solid green. Note: Labels will not print during the automatic baud rate synchronization process.
* ** *** ****	Factory Default – The printer can be reset to factory default settings (equal to ZPL command ~JUN). Some configuration setting values ​​were not returned to the initial installation settings. Other setting values ​​that are set, viewed, and controlled programmatically will also be reset. During the memory defragmentation process, the printer will perform a standard media calibration process. After the network printer enters factory default mode, the status light will turn amber within three seconds. During this process, the user can perform two actions: the printer will automatically reset to factory defaults as described above without performing any action, or the printer can enter factory default reset mode (equivalent to the ZPL command ^JUF) by holding down the “Feed” button when the network printer option is installed. Releasing the button after the first flash resets the network’s factory options (equivalent to the ZPL command ^JUN). Releasing the button after the second flash sequence (two flashes) only resets the printer defaults. After the third flash, release the button to reset the printer and network settings (ZPL commands ^JUN and ^JUF)
* ** *** **** *****	Printing width adjustment – from the minimum printing width to the maximum printing width of the printer, continuously print a frame every 4 mm. When the printer reaches the required maximum printing width, press the “Feed” button. Note that printer drivers and applications may override this setting.
* ** *** **** ***** ******	Print Depth (Density) Adjustment – Prints a continuous bar code simulated pattern in increments of four using the ZPL depth setting range value, starting from the minimum color depth (print density/heat) and ending at the printer’s maximum depth. If the pattern is clear and effective, press the Feed button and do not continue to increase the color depth setting, otherwise the width of the barcode lines may be distorted, resulting in reduced readability. Note that printer drivers and applications may override this setting.
* ** *** **** ***** ****** *******	Manual Media Calibration – The printer runs a comprehensive test to detect and set the media type and media length, which adjusts the media sensor for optimal performance for the installed media (equal to the ZPL~JG command). Manual calibration is recommended if you are using pre-printed media, if the printer does not automatically calibrate correctly it may print on the label backing. A graphical diagram of media sensing will be printed.
If the Feed button remains pressed after the 7 flash sequence, the printer will exit configuration mode when the user releases the Feed button.

6. Zebra GT800 barcode printer ZPL configuration
6.1 ZPL printer configuration format
Create a printer configuration programming file and send it to one or more printers to manage multiple printers, or use ZebraNet Bridge to replicate printer settings. The following shows the basic structure of the ZPL programming configuration file:
^XA——Start format command
The order of format commands is very important
Ⅰ.General printing and command settings
Ⅱ.Media handling and operation
Ⅲ.Media printing size
^JUS save command
^XZ——End format command
Create programming files. Programming files can be sent to the printer using the Zebra Setup Utility (ZSU). Programming files can be created using Windows Notepad (text editor).

6.2 Reference for comparing ZPL configuration status and commands

Order	List name	illustrate
~SD	DARKNESS	Default: 10.0
–	DARKNESS SWITCH	not applicable
^PR	PRINT SPEED	Default: 6IPS/152.4mm/sec (maximum)
~TA	TEAR OFF	Default value: +000
^MN	MEDIA TYPE	Default value: GAP/NOTCH (gap/cut)
SENSOR TYPE	Default value: WEB (texture)
SENSOR SELECT	Default: AUTO (^MNA – auto-detect)
^MT	PRINT METHOD	THERMAL-TRANS (thermal transfer) or DIRECT-THERMAL (thermal)
^PW	PRINT WIDTH	Default: 832 points
^LL	LABEL LENGTH	Default value: 1225 points (value calibrated in time by automatic web-gap detection for label media)
^ML	MAXIMUM LENGTH	Default value: 39.0IN 989MM
–	USB COMM.	Connection status: connected/not connected
–	PARALLEL COMM.	Available connections: BIDIRECTIONAL (bidirectional)
^SCa	BAUD	Default value: 9600
^SC,b	DATA BITS	Default: 8BITS (8 bits)
^SC,,C	PARITY	Default value: NONE
^SC,,,,e	HOST HANDSHAKE	Default: DTR or XON/XOFF
^MFa	MEDIA POWER UP	Default: NO MOTION
^MF, b	HEAD CLOSE	Default: FEED
~JS	BACKFEED	Default value: DEFAULT
^LT	LABEL TOP	Default value: +000
^LS	LEFT POSITION	Default value: +0000

Have you ever experienced a broken printhead pin in your barcode printer? Actually, there are some reasons behind this that you might not know.

🔍 First, the construction of the barcode printhead is crucial. It consists of a row of tiny, heated pins. The higher the density, the finer the pins, and naturally, the easier they are to break.

👀 When you find a straight blank line on the printed label, it means the printhead pin has broken. At this point, replacing the printhead becomes the only option, and it’s quite expensive!

🌫️ So, what are the main causes of printhead pin breakage? Let’s take a look:

• Dust on the paper surface: Like a large rock, it relentlessly scrapes the thin pins.
• Uneven surface of cheap labels: This is also a major cause of pin breakage.
• High-temperature printing: When using cheap ribbons and labels, the printhead temperature has to be increased to achieve clearer prints, but high temperatures are the culprit behind pin breakage and shortened printhead lifespan.

Labels lying on the floor: already covered in dust, yet rolled back for use, is undoubtedly a disaster for the print head.

Improper ribbon use: The ribbon should be wider than the label, as the edges of the label are very sharp and can cut hands and the print head.

Dirty rollers under the print head: Many protruding hard rubber pieces cause wear.

🛠️ To avoid these situations, we need to take good care of our printing equipment, choose high-quality ribbons and labels, and clean the print head and rollers regularly. Only in this way can we extend the life of the print head and reduce the risk of needle breakage.

💡 Remember these tips to make your barcode printer run more smoothly!

1. Barcode Scale Terminal Settings Note: — is a separator

1.1 Initialize the scale: Code — 24681357 — * — 15 — * — 1 — * (Scale restarts)

1.2 Set the scale IP address (e.g., 192.168.0.61): Code — 24681357 — * — 21 — * — (Enter the scale IP address) 192 168 000 061 — * — (Enter the subnet mask) 255 255 255 000 — ↓ Keep pressing and wait for the scale to restart

1.3 Rounding (total price in yuan): Code — 666666 — * — 02 — * — 1 (0 does not round; 1 rounds to the nearest cent; 2 discards the fraction; 3 carries over) — *

1.4 Enable temporary price change: Code — 666666 — * — 31 — * — 1 (0 Off; 1 On) — *

1.5 Set scale to print when weight is less than 20e: Code — 666666 — * — 23 — * — 1 — *

1.6 Enable continuous printing (weight remains unchanged): Code — 666666 — * — 10 — * — 1 — *

1.7 Set scale number: Code — 24681357 — * — 08 — * — Enter scale number — *

1.8 Convert kg to jin: Code — 666666 — 05 (Enter the unit price within the scale: 0–yuan/kg; 1–yuan/500g; 2–yuan/100g; 3–yuan/50g; 4–yuan/g) — * — 1 — * –06 (Print unit price, same as above) — 1 — *

1.9 Enable reverse rotation: Code — 24681357 — * — 25 — * — ↓ (Press and hold until REWIND is displayed) — 1 — *

1.10 Set Print Density: Code — 24681357 — * — 25 — * — ↓ (Press and hold until SPEED –mm/S is displayed to set the print speed) — Enter value (0-5, larger values ​​are slower) — * — ↓ (Press and hold until ENERGY -4 – +4 is displayed to set the print intensity) — Enter value — *

1.11 Test Printhead: Code — 24681357 — * — 25 — * — ↓ (7 times) — 1 — *

1.12 Save Transaction Data: Code — 666666 — * — 13 –* — 1 (0–Do not save; 1–Save; 2–Save and upload; 3–Wait for acceptance) — *

1.13 View Sales Revenue (Requires 1.12 to be enabled): Code — 333 — * –15 — 1 (1–Daily statistics; 2–Weekly statistics; 3–Monthly statistics)– * (Sales records can be cleared after printing)