Zebra ZD510-HC troubleshooting guide: errors, faults and fixes

Short answer: In most cases the wristband cartridge is empty, but Zebra also mentions a media detection error or a cartridge error. Replace the cartridge; if the alert persists with a cartridge that is not empty, see the cartridge not recognised entry.

Likely cause

According to the Zebra light table, this orange flashing indicates that the media is out (typical case), that a media detection error has occurred or that there is a cartridge error.

Caution: Never pull on the wristbands to get them out of the cartridge or the printer: Zebra warns that the cartridge can become permanently unusable.

What to do

1. Press EJECT (printer idle or paused) to remove the cartridge.
2. If the cartridge is empty, insert a new cartridge and press in the middle until it clicks (see loading the cartridge).
3. If the cartridge still contains wristbands, follow the cartridge not recognised entry (wristband sticking out, chip detached, dirty contacts).
4. If media detection is the cause, clean the media sensor (see cleaning the sensor).

At start-up, the same orange flashing simply indicates that no cartridge is loaded.

Sources: Meaning of the Indicator Light Patterns (opens in a new window) · Loading the Media Cartridge (opens in a new window) · Media Cartridge Handling and Use Cautions (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: The cartridge is running out of wristbands: by default, the alert comes on when 20 are left. The printer continues printing; have a new cartridge ready.

Likely cause

Zebra states that the media low alert is triggered by default when 20 wristbands remain. The cartridge chip lets the printer know how many wristbands are left.

What to do

1. Continue printing: this is a warning, not an error.
2. Have a new cartridge ready, left in its protective packaging until it is loaded.
3. When the lights flash orange (Media Out), eject the empty cartridge with EJECT and load the new one.

Sources: Meaning of the Indicator Light Patterns (opens in a new window) · Media Cartridge Features (opens in a new window) · Media Storage Tips (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: The top cover has been opened. Close it by pressing down on it, then press PAUSE/FEED so that the printer resets the installed cartridge.

Likely cause

According to Zebra, this alert indicates that the top cover has been opened. This cover is not used in normal operation: it is opened for maintenance, to retrieve a wristband that does not retract into the cartridge or after an accidental immediate ejection.

What to do

1. Close the top cover by pressing down on it until it is fully closed.
2. Press PAUSE/FEED to reset the installed cartridge.
3. If there is no cartridge, load one (see loading the cartridge).
4. If a wristband remains stuck under the cover, see the cartridge ejection entry.

The cover opens when you press both release buttons, located on each side at the front, at the same time. The guide then refers to its “Resolving Alerts and Errors” chapter, which could not be read.

Sources: Meaning of the Indicator Light Patterns (opens in a new window) · Opening the Upper Cover (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: The printer's internal temperature is outside its operating range, because the room is too hot or too cold. Let the printer return to the specified range: if it is too hot, it waits before printing and resumes by itself.

Likely cause

Zebra states that the internal operating temperature range has been exceeded, as the environment may be too hot or too cold. The guide sets the operating range at 0 to 40 °C and 20 to 85% humidity, non-condensing.

Caution: Zebra points out that padding under the printer restricts airflow and can cause overheating.

What to do

1. Let the printer return to its operating temperature and humidity range.
2. If a job arrives during the alert and the printer is too hot, it waits before printing, then resumes when the temperature is safe again.
3. Check the location: flat, solid surface, clear space around the printer, nothing placed on top, no padding underneath.

Sources: Meaning of the Indicator Light Patterns (opens in a new window) · Select a Location for the Printer (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: The printhead has reached its safety shutdown temperature, to avoid being damaged. Let the printer cool down: printing resumes automatically.

Likely cause

According to Zebra, the printhead has gone into thermal shutdown to protect itself.

Caution: The printhead may be hot and cause severe burns: Zebra asks you to let it cool down before doing any work under the cover.

What to do

1. Let the printer cool down.
2. Printing resumes automatically once the printhead has cooled down.
3. If the alert recurs frequently, check that the room stays within the 0 to 40 °C range and that air circulates around the printer (see Operating Temp).

Sources: Meaning of the Indicator Light Patterns (opens in a new window) · Cleaning the Media Sensor (opens in a new window) · Select a Location for the Printer (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: The printer has encountered a data processing error or does not have enough memory to store a format, graphic or font. Check the file sent (format, data, syntax) and the available memory.

Likely cause

Zebra cites two causes: a data processing error (wrong file format, corrupted data, programming syntax errors…) or a lack of available memory to store content (formats, graphics, fonts…).

What to do

1. Check the file or job sent: file format, data integrity, command syntax.
2. If you store formats, graphics or fonts in the printer, check that memory is still available.
3. To analyse what the printer receives, use the communication diagnostics test.

The detailed steps in the guide (“Alert: Memory Storage Exception”) could not be read; this entry covers the causes from the light table.

Sources: Meaning of the Indicator Light Patterns (opens in a new window) · Communications Diagnostics Test (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: The previous wristband was not removed from the exit slot before a new print or feed. Tear it off at the perforation, against the tear-off edge of the exit.

Likely cause

According to Zebra, the media was not removed from the printer exit before a new print or feed was started. The wristbands are pre-perforated and stop with the perforation at the tear-off edge of the exit.

Caution: Do not touch the wristband until printing or feeding has finished, and do not pull on the media when the cartridge is in the printer.

What to do

1. Wait for the printer to finish printing or feeding the wristband.
2. Tear off the printed wristband at the perforation, against the tear-off edge of the exit slot.
3. Start the next print.

Sources: Meaning of the Indicator Light Patterns (opens in a new window) · Media Cartridge Handling and Use Cautions (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: The Zebra guide does not describe a manual calibration: on insertion, the cartridge chip automatically sets the length, print area, speed and darkness. If detection is a problem, print the media sensor profile (hold PAUSE/FEED until two orange flashes).

Likely cause

According to Zebra, the printer adjusts most settings itself according to the cartridge inserted. The sensor profile is used to troubleshoot cases where the sensor struggles to find the start and end of the wristbands, or mistakes a pre-printed area for the end of a wristband.

Printing the media sensor profile

1. Check that the printer is switched on and ready.
2. Hold PAUSE/FEED: the green lights go off and the orange lights flash once.
3. Keep holding the button until the second orange flash, then release it.
4. The profile prints on two wristbands. Two peaks indicate that the sensors are working and detecting the black mark on the back of the wristband.
5. If not, clean the media sensor (see cleaning the sensor).

Holding PAUSE/FEED opens a configuration mode in which each orange flash (every 2 seconds) corresponds to a function: 1 configuration report, 2 sensor profile, 3 network reset, 4 full reset. Release after the right number of flashes.

Sources: Changing and Restoring Printer Settings (opens in a new window) · Media Sensor Profile (opens in a new window) · Control Panel Buttons (opens in a new window) · Media Cartridge Features (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: The media sensor is located under the top cover and the printhead assembly. Open the cover, remove the printhead assembly by its aluminium tab and blow the sensors clean with canned dry air, without using a swab.

Likely cause

Zebra specifies that the sensor must only be cleaned with canned dry air: its components are easily damaged if rubbed.

Caution: The printhead may be hot and cause severe burns: let it cool down. Discharge static electricity by touching the rear metal plate near the power switch, or use an anti-static wrist strap and mat. Remove rings, watches, necklaces, badges and metal objects that could touch the printhead or fall into the cartridge slot. Do not use a swab on the sensor.

Official sensor cleaning procedure

1. Press both top cover release buttons at the same time: the cover opens slightly.
2. Lift the cover as far as it will go, then tilt it backwards: the media path, printhead, platen roller and sensor become accessible.
3. Lift the aluminium tab on the printhead assembly and remove the assembly by this tab.
4. Blow the sensors clean with canned dry air.
5. Refit the printhead assembly by engaging its two lower tabs in the two slots in the frame, then close the cover.

Zebra advises finishing by cleaning the media path with the cleaning card (see cleaning).

Sources: Cleaning the Media Sensor (opens in a new window) · Opening the Upper Cover (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: Switch on the printer and wait for the lights to flash orange. Insert the cartridge the right way round and press in the middle until it clicks: the printer prepares a wristband, reads the chip, then the ring turns green.

Likely cause

According to Zebra, the printer loads the media automatically: on insertion, it authenticates the Zebra cartridge using its chip, checks the remaining quantity and sets the speed, darkness, print area and length itself.

Caution: Zebra asks you never to pull the media out of the cartridge (risk of damaging it) and never to open the cartridge (permanent damage). Do not insert a cartridge with a wristband sticking out: first cut off the protruding part with scissors.

Official loading procedure

1. Switch on the printer with the power switch at the back.
2. Wait for the self-test to finish: when the media light and status ring flash orange, the printer is waiting for a cartridge.
3. Orient the cartridge as shown on the printer, insert it and press in the middle until it clicks and locks.
4. The printer prepares a wristband, brings it to the exit slot and reads the cartridge settings and data.
5. The printer is ready when the status ring is green and the media light is off.

Only genuine Zebra cartridges work in the printer; they are neither reusable nor refillable.

Sources: Loading the Media Cartridge (opens in a new window) · Media Cartridge Features (opens in a new window) · Media Cartridge Handling and Use Cautions (opens in a new window) · ZD510 (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: The printer authenticates each cartridge by its chip: only genuine Zebra cartridges work. Check that no wristband is sticking out and that the chip is properly in place, then clean the gold contacts on the cartridge and on the chip reader.

Likely cause

Zebra states that the cartridge chip contains the authentication and media data, which are read on insertion. Orange flashing can indicate a cartridge error. A dirty cartridge can also contaminate the chip, and a protruding wristband prevents correct insertion.

Caution: Clean the chip reader pins with vertical movements only: horizontal movements can damage them. Do not clean the exit slot or the media window of the cartridge, and keep alcohol away from the wristbands.

What to do

1. Check that it is a genuine Zebra cartridge: the guide specifies that only genuine Zebra supplies work.
2. If a wristband is sticking out of the cartridge, cut it off straight with scissors, then reinsert the cartridge to see whether the printer can use it again.
3. If the chip has come off the cartridge, put it back in place (see detached chip).
4. With the cartridge ejected, use a lint-free cloth or swab lightly moistened with isopropyl alcohol (99% minimum) to clean the outside of the cartridge and the gold contacts at the back, without touching the chip; then, with a new swab, clean the gold contacts of the chip. Let the alcohol evaporate.
5. Clean the chip reader contacts at the bottom of the cartridge slot: lint-free swab moistened with alcohol, using vertical movements only. Let the alcohol evaporate, reconnect the power, switch on and reinsert the cartridge.

Sources: Media Cartridge Features (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) · Meaning of the Indicator Light Patterns (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) · Media Cartridge Handling and Use Cautions (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) · Cleaning the Media Cartridge (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) · Cleaning the Printer's Smart Chip Reader Contacts (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) · Smart Chip Disengages from Cartridge (opens in a new window) – Environmentally Friendly Cartridge Troubleshooting Guide (P1139689-01EN) (official documentation).

Short answer: Press EJECT with the printer idle or paused; if it is stuck, pressing for 6 seconds forces ejection. If the cartridge is still stuck, switch off and unplug the printer, then release the cartridge from underneath with a flat-head screwdriver, as described by Zebra.

Likely cause

The Zebra guide provides three levels: normal ejection (the current wristband is retracted, then the cartridge is ejected), forced ejection without retracting the wristband, and manual ejection of the cartridge from underneath the printer.

Caution: Risk of electric shock: Zebra asks you to switch off the printer and unplug it before manual ejection. Do not pull on the wristband to get it out of the printer.

What to do

1. With the printer idle or paused, press and release EJECT: the current wristband is retracted, then the cartridge is ejected.
2. If needed, hold EJECT for 6 seconds: the cartridge is ejected without retracting the protruding wristband (troubleshooting function).
3. Manual ejection: switch off the printer and unplug it. Insert a flat-head screwdriver into the central slot under the printer (front half, near the circular hole) and push towards the back to operate the black release tab.
4. Turn the printer back over and check that the cartridge is released. If a wristband is stuck under the top cover, press both cover release buttons to free it.
5. Take out the cartridge, cut off the protruding wristband straight with scissors, and check that the cartridge loads correctly before reusing it.
6. Close the top cover by pressing down on it.

The EJECT button only works when the printer is idle or paused.

Sources: Control Panel Buttons (opens in a new window) · Manual Cartridge Eject (opens in a new window) · Opening the Upper Cover (opens in a new window) · Media Cartridge Handling and Use Cautions (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: For an eco-friendly cartridge (light grey plastic), Zebra describes a procedure: release the spool, turn it to bring the media back towards the opening, then push it into the slot. Standard black plastic cartridges cannot be repaired by the user.

Likely cause

The Zebra cartridge troubleshooting guide specifies that this repair only applies to eco-friendly cartridges. For a standard cartridge (black plastic), you must contact your Zebra account manager so that a report can be sent to the quality team.

Caution: Do not pull the media beyond the edge of the exit slot.

Official procedure (eco-friendly cartridge)

1. Engage the spool tab so that the media spool turns freely.
2. Turn the spool until the end of the media comes close to the cartridge opening.
3. Lift the cartridge tabs to open the media slot.
4. Using a screwdriver or a similar object, push the media through the slot.

According to the user guide, black plastic cartridges cannot be recycled locally, unlike light grey plastic cartridges.

Sources: Media Retracts into Cartridge (opens in a new window) – Environmentally Friendly Cartridge Troubleshooting Guide (P1139689-01EN) · Media Cartridge Features (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: Lift the cartridge latch located just above the chip very slightly, put the chip back in place, then close the latch fully. Do not open any other latch.

Likely cause

The Zebra cartridge troubleshooting guide covers this case: the chip stores the authentication and media data that the printer reads on insertion.

Caution: Do not open any other latch: this can affect how the cartridge works in the printer. The latch under the chip must be fully closed.

Official procedure

1. Lift the cartridge latch located directly above the chip, just enough to create a small gap.
2. Put the chip back in place by pressing on it.
3. Close the latch and check that it is fully locked.
4. Reinsert the cartridge into the printer.

Sources: Smart Chip Disengages from Cartridge (opens in a new window) – Environmentally Friendly Cartridge Troubleshooting Guide (P1139689-01EN) · Media Cartridge Features (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: Zebra provides a cleaning card that cleans the printhead, the platen roller and the feed roller, to be used every 5 cartridges. Insert the card from the back with the cover closed, then hold EJECT for about 15 seconds while switching on the printer: the card moves forwards and back.

Likely cause

The Zebra guide recommends cleaning the media path after every 5 cartridges printed, and last when cleaning other parts. The cleaning card gently cleans the printhead, the platen roller and the media feed roller.

Caution: The cleaning card contains isopropyl alcohol, which is flammable: dispose of it in accordance with local regulations. Too much alcohol can contaminate electronic components and greatly lengthen the drying time.

Official procedure (cleaning card)

1. Remove the cartridge with EJECT.
2. Switch the printer off.
3. Press both top cover release buttons at the same time: the cover opens slightly.
4. Take the cleaning card out of its packaging.
5. From the back of the printer, slide the card into the media entry slot, under the black printhead support and above the grey inner body, until about 1 cm protrudes at the front.
6. Close the top cover.
7. Hold down EJECT while switching on the printer, and keep it held down for about 15 seconds during start-up and the self-test.
8. Release EJECT when the card starts to move: the printer cleans the media path.
9. Cleaning is complete when the card stops and returns to its starting position. Remove it and throw it away.
10. Wait about two minutes for the alcohol to evaporate, then reinsert the cartridge.

Sources: Cleaning the Media Path (opens in a new window) · Using a Cleaning Card (opens in a new window) · Cleaning Supplies (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: By default, darkness follows the cartridge value (CARTRIDGE mode) and commands that change it are ignored. To change it, set the darkness mode to USER or RELATIVE, then set the darkness to the lowest level that gives good quality.

Likely cause

Zebra describes three darkness modes: CARTRIDGE (cartridge value, the default), USER (value set by the user for all cartridges) and RELATIVE (offset added to the default value of each cartridge).

Caution: Zebra warns that excessive darkness makes the print fuzzy, prevents barcodes from being read correctly and wears out the printhead prematurely.

What to do

1. Open the printer's web pages (IP address read from the configuration report), then “View and Modify Printer Settings” > “General Setup” > “Darkness”. The corresponding SGD command is media.darkness_mode.
2. Choose USER or RELATIVE mode: in CARTRIDGE mode, the darkness value is ignored.
3. Set the darkness (typical value 21, range 0 to 30) to the lowest level that gives good print. The ZPL commands ^MD and ~SD or the SGD command print.tone also act on this setting.
4. Check the result on a wristband and with your barcode scanner.

The web pages ask for the printer password: refer to the Zebra guide and change it if it is still set to its default value.

Sources: Commonly Used ZD510 Printer Settings (opens in a new window) · Accessing the Printer's Web Pages (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: The first 25 millimetres of each wristband cannot be printed, because the media does not reverse inside the printer. Place the content from the start position recommended by Zebra for your type of wristband, at least 1.2 mm from the edges.

Likely cause

According to Zebra, the print origin (0,0) is located 25 mm from the leading edge of the wristband. The guide also recommends avoiding the clip holes and tamper-evident slits.

What to do

1. Start printing at the recommended position: 279 mm adhesive wristband, 114 mm from the leading edge; 178 mm, 64 mm; 152 mm, 51 mm; 279 mm clip wristband, 159 mm; 178 mm, 83 mm.
2. Keep the content at least 1.2 mm from the top and bottom edges and away from the clip holes and tamper-evident slits.
3. To shift the image, use the Label Top (^LT, vertical) and Left Position (^LS, horizontal) settings; Tear Off (~TA) sets the position where the wristband stops after printing.

Sources: Wristband Print Zone (opens in a new window) · Commonly Used ZD510 Printer Settings (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: Direct thermal wristbands react to heat: sunlight or a heat source can mark them. Store the cartridges in a clean, dry, cool and dark place, in their packaging, and use the oldest unexpired ones first.

Likely cause

Zebra points out that direct thermal media is chemically treated to be heat-sensitive, and that many media have a shelf life or an expiry date.

Zebra storage advice

1. Store the cartridges in a clean, dry, cool and dark place, away from sunlight and heat sources.
2. Keep them away from chemicals and cleaning products.
3. Leave each cartridge in its protective packaging until it is loaded; put unused cartridges back in their packaging to protect the wristbands and the chip.
4. Use the oldest unexpired cartridges first.

The ZD510-HC prints in direct thermal, without ribbon, at 300 dpi.

Sources: Media Storage Tips (opens in a new window) · ZD510 (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: Zebra asks you to install Zebra Setup Utilities and the driver on the PC first, and to switch on the printer only once the driver installation has started. If the printer is powered on beforehand, the driver installation may be skipped.

Likely cause

According to the Zebra guide, powering on the printer before installing the utility can cause the driver configuration to be skipped.

Caution: Use shielded data cables, as short as possible (about 1.8 m recommended), without tying them to power cords.

What to do

1. Switch off the printer before connecting the USB cable; use a certified USB 2.0 cable (“Certified USB”).
2. Install Zebra Setup Utilities on the PC.
3. Only power on the printer after the driver installation has started, then follow the wizard.
4. Once connected, check communication: from Zebra Setup Utilities (printer tools, sending a configuration label) or with a Windows test page.

Sources: Pre-install Windows Printer Drivers (opens in a new window) · Connecting your Printer to a Computer (opens in a new window) · Interface Cable Requirements (opens in a new window) · After Your Printer is Connected (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: Print the configuration report by holding PAUSE/FEED until the first orange flash: it shows the IP address, the MAC address and the firmware version. Enter this IP address in a browser on a computer on the same network.

Likely cause

According to Zebra, access to the web pages requires the printer and the computer to be on the same local network and the printer to have an active wired or wireless Ethernet connection. On Ethernet, the printer must be configured for your network, usually through its web pages.

What to do

1. Connect a category 5 or higher UTP RJ-45 cable.
2. With the printer switched on and ready, hold PAUSE/FEED: the ring goes off, then flashes orange once. Release the button: the configuration report prints.
3. Note the IP address and enter it in the browser's address bar, on a computer on the same local network.
4. To change settings, open “View and Modify Printer Settings” and enter the printer password (see the Zebra guide).
5. If the network settings are inconsistent, reset the print server (see reset).

No default password is given here: consult the Zebra guide and change the password if it is still set to its original value.

Sources: Test Printing with a Configuration Report (opens in a new window) · Accessing the Printer's Web Pages (opens in a new window) · Connecting your Printer to a Computer (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: Solid green: printer associated with a good signal; flashing green: not yet associated despite a good signal; orange: weak signal; off: no signal. For configuration, Zebra uses the ZebraNet Bridge connectivity wizard, which generates a script with the network's ESSID and security settings.

Likely cause

Wi-Fi is a factory-installed option. The ESSID entered must already be defined on your access point, and the radio range decreases with walls and obstacles.

What to do

1. Read the Wi-Fi light: solid green, associated with a strong signal; flashing green, not associated with a strong signal; solid orange, associated with a weak signal; flashing orange, not associated with a weak signal; off, not associated and no signal.
2. Weak or no signal: move the printer closer to the access point, taking walls and obstacles into account.
3. Configuration: launch the ZebraNet Bridge Enterprise connectivity wizard (version 1.2.5 or later), and choose the port, the wireless option and the printer type.
4. Choose DHCP or a fixed IP address, enter the ESSID already defined on your access point, then the security mode and its settings.
5. Send the script to the printer, then switch it off and on again.

The network security settings are the responsibility of your administrator; the guide also refers to the Zebra guide for wired and wireless print servers.

Sources: Wi-Fi Status (Optional) (opens in a new window) · Wi-Fi and Bluetooth Classic Wireless Connectivity Option (opens in a new window) · Setting Up the Wi-Fi Print Server Option (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: With the factory-installed Bluetooth option, first configure the printer over USB from Zebra Setup Utilities: enable Bluetooth, give the printer a name and make it discoverable. Then start the device search on the PC to complete pairing.

Likely cause

According to Zebra, the Bluetooth Classic option is configured through Zebra Setup Utilities. With a Bluetooth 2.1 or later device, Secure Simple Pairing (SSP) avoids having to enter a PIN; a numeric PIN is only needed with a Bluetooth 2.0 or older device.

What to do

1. Connect the printer to the PC via USB and open Zebra Setup Utilities.
2. Select the printer, then “Configure Printer Connectivity” and Bluetooth.
3. Enable Bluetooth, set a friendly name and set the “Discoverable” parameter: when it is On, the printer can be found by the PC.
4. If you want a PIN, enable authentication; for a Bluetooth 2.0 or older device, enter a numeric PIN and set security mode 2 or 3 in the advanced settings.
5. Send the configuration to the printer, then start device discovery on the PC to complete pairing.

Zebra points out that on Windows 8 the pairing code is only displayed briefly, and that some Bluetooth adapters do not handle SSP well: you may then need to install the printer over USB first and then switch to the virtual COM port. Zebra Print Touch NFC pairing also lets you pair a compatible Android device by touching it to the Print Touch logo.

Sources: Bluetooth Option Configuration (opens in a new window) · Zebra Print Touch (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: Put the printer into communication diagnostics mode with the ~JD command: it prints as text everything it receives. The codes FE, OE, PE or NE indicate a problem with the communication settings; exit the mode with ~JE.

Likely cause

Zebra presents this test as a way of checking the connection between the printer and the computer: each character received is printed in ASCII with its hexadecimal value, control codes included.

Official procedure

1. Send the ZPL command ~JD to the printer to enter diagnostics mode.
2. Send your print job: the printer prints the data received in ASCII, with the hexadecimal values below.
3. Look for the error codes: FE (framing error), OE (overrun), PE (parity), NE (noise). If they appear, check the communication settings.
4. Exit diagnostics mode with the ~JE command.

In diagnostics mode, the PAUSE/FEED button does not feed a wristband: exit this mode first.

Source: Communications Diagnostics Test (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: The power switch is at the back: pressed in, the printer is on; out, it is off. Then check the power supply: when it is connected to the printer's power socket and to the mains, its light should be green.

Likely cause

The Zebra guide describes an on/off switch on the rear panel and an external power supply with a green light. The ZD510-HC uses a medical-grade power supply.

Caution: Zebra prohibits operating the printer or its power supply where they could get wet (risk of serious injury). Position the printer so that you can easily reach and unplug the cord, and use a three-pin cord with an IEC 60320-C13 connector bearing the certification mark of your country.

What to do

1. Check the position of the power switch at the back of the printer (pressed in = on).
2. Connect the power supply to the printer's power socket, the mains cord to the power supply, then the cord to a mains socket.
3. Check that the power supply light is green.
4. At start-up, the printer runs its self-test; without a cartridge, the lights then flash orange.

Sources: Printer Features (opens in a new window) · Attaching Power (opens in a new window) · ZD510 (opens in a new window) · Loading the Media Cartridge (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: Download the ZD510 firmware from the Zebra website and send it via the Windows driver, Zebra Setup Utilities or a USB flash drive on the USB host port. Never cut the power during the update, especially when the ring is half orange, half green.

Likely cause

Zebra regularly publishes firmware updates. The guide warns that installing older firmware on a recent printer can disable features, such as support for recent network standards and security protocols.

Caution: Zebra insists: never restart the printer during a firmware update. Some security and compliance bodies require specific, tested firmware versions for the whole system.

Official procedure

1. Get the ZD510 firmware from the Zebra website (zebra.com/firmware or the ZD510-HC support page).
2. Send the file using one of the methods provided: Windows driver (Printing Preferences > Tools > Send File), Zebra Setup Utilities (Printer Tools > Action > Send File), USB flash drive on the USB host port, ZebraNet Bridge.
3. While the firmware is being written to memory, the status ring stays half orange, half green: do not switch off the printer.
4. For troubleshooting, forced download mode: switch off the printer, hold PAUSE/FEED while switching it back on and release the button during the 3-second rapid yellow/orange sequence. The ring then alternates green and orange.
5. Send the firmware over any connection: a green light rotates during the transfer, then the ring turns half orange, half green during writing. The printer then returns to normal operation.

In forced download mode, the printer ignores print jobs and buttons. The Zebra ZD510-HC support page provides the firmware (Printer OS) and the ZDownloader utility.

Sources: Downloading Firmware (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) · Manual 'Forced' Download (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) · ZD510-HC Wristband Printer Support (opens in a new window) – Zebra ZD510-HC support page (official documentation).

Short answer: Hold PAUSE/FEED: the ring flashes orange every 2 seconds. Release after 3 flashes to reset the print server (network), or after 4 flashes to restore all factory settings.

Likely cause

The Zebra guide associates each number of flashes with a function of the user configuration mode. The same resets exist in ZPL (^JUN^JUS for the network, ^JUF^JUS for all settings) and in the web pages.

Caution: Zebra asks you to use the restore-defaults function with care: all manually changed settings will have to be entered again.

Official procedure

1. With the printer ready, hold down the PAUSE/FEED button.
2. Count the orange flashes of the ring (one more every 2 seconds).
3. Release after 3 flashes to reset the wired and wireless print server settings.
4. Release after 4 flashes to restore all printer settings to factory values.
5. Beyond 4 flashes, the mode closes, the ring turns green again and releasing the button feeds a wristband.

A single flash prints the configuration report; two flashes, the media sensor profile. In the web pages: “Restore Default Configuration” and “Reset Print Server”.

Sources: Control Panel Buttons (opens in a new window) · Commonly Used ZD510 Printer Settings (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: The printer is paused. Press PAUSE/FEED to resume printing.

Likely cause

According to Zebra, pressing PAUSE/FEED during printing pauses the printer before the next wristband; it then waits for the button to be pressed again.

What to do

1. Briefly press PAUSE/FEED: printing resumes.
2. Avoid holding the button down: a long press opens configuration mode (see reset).
3. With the printer idle, a brief press on PAUSE/FEED feeds a blank wristband.

Sources: Meaning of the Indicator Light Patterns (opens in a new window) · Control Panel Buttons (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).

Short answer: Remove the cartridge, switch off and unplug the printer, empty out debris by turning it over, blow the slot clean with canned dry air and wipe the exterior with a soft, barely damp cloth. For approved disinfectants, Zebra refers to its guide to cleaning and disinfecting healthcare printers.

Likely cause

According to Zebra, the ZD510-HC has UV-resistant, disinfectant-ready plastics and sealed controls that are cleaned along with the exterior.

Caution: Never use liquid to clean the rear panel connectors, the chip reader contacts in the slot or the media platen roller. Do not use an air compressor (micro-contaminants), and wear safety glasses when using compressed air.

Official procedure

1. With the printer switched on, remove the cartridge by pressing EJECT.
2. Switch off the printer and disconnect the power cord and the interface cables.
3. Over a bin, turn the printer upside down to shake out debris (bits of paper, dust).
4. Blow the remaining dust out of the cartridge slot with canned dry air.
5. Wipe the exterior with a soft cloth moistened with soapy water, using as little solution as possible.
6. Let it dry completely, reconnect the power and cables, then clean the media path (see cleaning card).

Approved disinfection materials and methods: Zebra guide “Guide to Disinfecting and Cleaning Zebra Healthcare Printers” (not consulted here).

Sources: Cleaning the Exterior of the Printer (opens in a new window) · Cleaning Supplies (opens in a new window) – Zebra ZD510 Wristband Printer User Guide (P1099655-03EN) (official documentation).