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ZQ500 Series PrintersUser Guide 2015, ZIH Corp.P1064404-002 Rev. BJanuary, 20161ZQ500 Series User Guide

Table of ContentsProprietary Statements.5Document Conventions.7Introduction to the ZQ500 Series Printer.8ZQ500 Series Technology.9Smart Battery.9Printing Technology.10Direct Thermal.10Thermal Shutdown.11QR Code.11Made for iPhone (MFi).11Near Field Communication (NFC).11ZQ500 Series Overview.12Getting Ready to Print.14Installing the Battery.14Battery Safety.15Charger Safety.15Charging Status Indicators.16Battery Health Indicator.16SC2 Dimensions.17Model UCLI72-4 Quad Charger (AC18177-5).17AC Power Adapter (p/n P1031365-024).19Vehicle Cradle (P1063406-029) & 4-Bay Power Station (P1063406-027).20Loading Media Procedure.22Operator Controls.24Buttons.25Power Up Sequences.25Run Time Sequences without LED Flashes.26LED’s.26Alerts.26Sleep Mode.27Power Save Mode.28Segmentation Mode.28Draft Mode.282ZQ500 Series User Guide

Verify Printer is Working.28Printing a Configuration Label.29Connecting the Printer.29Cable Communication.30Wireless Communications with Bluetooth.31Bluetooth Networking Overview.31WLAN Overview.34Setting Up the Software.35Designing Labels/Receipts.35Print Quality Comparisons.37Near Field Communication (NFC).37ZQ500 Series Accessories.39Belt Clip.39Hand Strap.39Shoulder Strap.40Soft Case.40Exoskeleton.41Mag Card Reader.42Preventive Maintenance.43Extending Battery Life.43General Cleaning Instructions.43Troubleshooting.46Front Control Panel.46Printer Status Indicators.46Troubleshooting Topics.47Troubleshooting Tests.49Printing a Configuration Label.49Communications Diagnostics.49Specifications.54Printing Specifications.54Memory and Communications Specifications.54Label Specifications.55CPCL Font and Bar Code Specifications andCommands.56ZPL Font and Bar Code Specifications andCommands.57Communication Port.583ZQ500 Series User Guide

USB.58Physical, Environmental and Electrical Specifications.58Printer Dimensions.59ZQ500 Series Accessories.61Appendix AUSB Cables.62Appendix BAlert Messages.63Appendix CMedia Supplies.64Appendix DMaintenance Supplies.64Appendix ESerial Number and PCC Number Locations.65Appendix FBattery Disposal.66Product Disposal.66Appendix GUsing Zebra.com.67Appendix H.69Product Support.69Index.704ZQ500 Series User Guide

Proprietary StatementsThis manual contains proprietary information of Zebra Technologies Corporation. It isintended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permissionof Zebra Technologies Corporation.Product ImprovementsSince continuous product improvement is a policy of Zebra Technologies Corporation, allspecifications and signs are subject to change without notice.Agency Approvals and Regulatory InformationDesign Safety certified by TUVEN55022 Class B European ElectromagneticRadiation StandardEN60950-1: 2nd Ed. Safety StandardEN55024: European Immunity StandardTUV (Mexico)RCM (Australia/NZ)FCC part 15 Class BRoHS IICanadian STD RSS-247IP54 RatedLiability DisclaimerInasmuch as every effort has been made to supply accurate information in this manual,Zebra Technologies Corporation is not liable for any erroneous information or omissions.Zebra Technologies Corporation reserves the right to correct any such errors and disclaimsliability resulting therefrom.No Liability for Consequential DamageIn no event shall Zebra Technologies Corporation or anyone else involved in the creation,production, or delivery of the accompanying product (including hardware and software)be liable for any damages whatsoever (including, without limitation, damages for loss ofbusiness profits, business interruption, loss of business information, or other pecuniaryloss) arising out of the use of or the results of use of or inability to use such product, evenif Zebra Technologies Corporation has been advised of the possibility of such damages.Because some states do not allow the exclusion of liability for consequential or incidentaldamages, the above limitation may not apply to you.CopyrightsThe copyrights in this manual and the label print engine described therein are owned byZebra Technologies Corporation. Unauthorized reproduction of this manual or the softwarein the label print engine may result in imprisonment of up to one year and fines of up to 10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability.This product may contain ZPL , ZPL II , and ZebraLink tm programs; Element Energy Equalizer Circuit; E3 ; and AGFA fonts. Software ZIH Corp. All rights reserved worldwide.ZebraLink and all product names and numbers are trademarks, and Zebra, the Zebra logo,ZPL, ZPL II, Element Energy Equalizer Circuit, and E3 Circuit are registered trademarks ofZIH Corp. All rights reserved worldwide.Monotype , Intellifont and UFST are trademarks of Monotype Imaging, Inc. registered inthe United States Patent and Trademark Office and may be registered in certain jurisdictions.AndyTM , CG PalacioTM, CG Century SchoolbookTM, CG TriumvirateTM, CG TimesTM, MonotypeKai TM, Monotype MinchoTM and Monotype SungTM are trademarks of Monotype Imaging, Inc.and may be registered in some jurisdictions.HY Gothic Hangul TM is a trademark of Hanyang Systems, Inc.AngsanaTM is a trademark of Unity Progress Company (UPC) Limited.Andale , Arial , Book Antiqua , Corsiva , Gill Sans , Sorts and Times New Roman aretrademarks of The Monotype Corporation registered in the United States Patent and Trademark Office and may be registered in certain jurisdictions.Century Gothic , Bookman Old StyleTM and Century SchoolbookTM are trademarks of TheMonotype Corporation and may be registered in certain jurisdictions.HGPGothicB is a trademark of the Ricoh company, Ltd. and may be registered in some jurisdictions.5ZQ500 Series User Guide

UniversTM is a trademark of Heidelberger Druckmaschinen AG, which may be registered incertain jurisdictions, exclusively licensed through Linotype Library GmbH, a wholly ownedsubsidiary of Heidelberger Druckmaschinen AG.Futura is a trademark of Bauer Types SA registered in the United States Patent and Trademark Office and may be registered in some jurisdictions.TrueType is a trademark of Apple Computer, Inc. registered in the United States Patent andTrademark Office and may be registered in certain jurisdictions.All other product names are the property of their respective owners.“Made for iPod”, “Made for iPhone”, and “Made for iPad” mean that an electronic accessoryhas been designed to connect specifically to iPod, iPhone, or iPad, respectively, and hasbeen certified by the developer to meet Apple performance standards. Apple is not responsible for the operation of this device or its compliance with safety and regulatory standards.Please note that the use of this accessory with iPod, iPhone, or iPad may affect wirelessperformance.Bluetooth is a registered trademark of the Bluetooth SIG. 1996–2009, QNX Software Systems GmbH & Co. KG. All rights reserved. Published under license by QNX Software Systems Co.All other brand names, product names, or trademarks belong to their respective holders.2015 ZIH Corp. Works with:Certified by:IP54MIL-STD8106ZQ500 Series User Guide

Document ConventionsThe following conventions are used throughout this document to convey certain information:Cautions, Important, and NoteCaution Warns you of the potential for electrostatic discharge.Caution Warns you of a potential electric shock situation.Caution Warns you of a situation where excessive heat could causea burnCaution Advises you that failure to take or avoid a specific actioncould result in physical harm to you.Caution Advises you that failure to take or avoid a specific actioncould result in physical harm to the hardware.Important Advises you of information that is essential to complete atask.Note Indicates neutral or positive information that emphasizes orsupplements important points of the main text.7ZQ500 Series User Guide

Introduction to the ZQ500 Series PrintersThank you for choosing our Zebra ZQ500 Series MobilePrinters. You will find these rugged printers will become aproductive and efficient addition to your workplace thanksto their innovative design and state of the art features. ZebraTechnologies is the leader in industrial printers with worldclass support for all of your bar code printers, software, andsupplies.This user’s guide gives you the information you will needto operate the ZQ510 and ZQ520 printers. These printers use some of the latest technologies such as Near FieldCommunication (NFC) and Made for iPhone (MFi). MFi printers provide Apple co-processor (MFi) support which allows anApple device such as an iPhone or iPad to authenticate andconnect over Bluetooth .These printers use CPCL and ZPL programming languages.To create and print labels using the CPCL and ZPL languages, refer to the Programming Guide for CPCL and ZPL (p/nP1012728-008). See Appendix G for instructions on how to access manuals on zebra.com.ZQ500 Series Software Utilities: Zebra Net Bridge : printer configuration, fleet management Zebra Setup Utility: single printer configuration, quick setup Zebra Designer Pro: label design Zebra Designer Drivers: Windows driver OPOS Driver: Windows driver Multiplatform SDK(These utilities can be found on the Zebra website l.See Appendix G.)8ZQ500 Series User Guide

Unpacking and Inspection Check all exterior surfaces for damage. Open the media cover (refer to “Loading the Media” in theGetting Ready to Print section) and inspect the media compartment for damage.In case shipping is required, save the carton and all packing material.Reporting DamageIf you discover shipping damage: Immediately notify and file a damage report with the shippingcompany. Zebra Technologies Corporation is not responsible for any damage incurred during shipment of the printerand will not cover the repair of this damage under its warranty policy. Keep the carton and all packing material for inspection. Notify your authorized Zebra re-seller.ZQ500 Series TechnologyThe ZQ500 Series printers use several technologies made popular in other Zebra Mobile Printer product lines.Smart BatteryThe ZQ500 Series battery pack is a high capacity, smart LithiumIon battery that contains electronics which allow the printer tomonitor its operating parameters. Among these are the numberof charge cycles it has undergone and its date of manufacture.Using these parameters, the printer’s software can monitor thebattery’s condition and alert the user when to recharge or removethe battery from service.Operating TemperatureCharging TemperatureStorage Temperature-20 0C to 550C(-4oF to 131oF)0 0C to 40 0C(32oF to 104oF)-250C to 650C(-13oF to 149oF)The ZQ510 and ZQ520 printers will only function properly with genuineZebra smart battery packs.9ZQ500 Series User Guide

The smart battery’s health has three states: GOOD, REPLACE,and POOR. The battery health factor determines whether or notthe printer can operate and what is communicated to the user viathe display.# of Charge CyclesHealthPower-up Message 300GOODNone 300 but 550REPLACE“Battery DiminishedConsider Replacing” * 550 but 600REPLACE“Warning-BatteryIs Past Useful Life” * 600POOR“Replace BatteryShutting Down” *** Warning accompanied by one long beep.** Warning will flash on and off accompanied by beeping at arate of once per second. After 30 seconds the printer will shutdown.Note Power down the printer before removing the battery to minimizethe risk of corruption.Printing TechnologyThe ZQ500 Series printers use the Direct Thermal method toprint human readable text, graphics and barcodes. It incorporatesa sophisticated print engine for optimal printing under all operational conditions.Direct ThermalDirect thermal printing uses heat to cause a chemical reaction on specially treated media. This reaction creates a dark markwherever a heated element on the printhead comes in contactwith the media. Since the printing elements are arranged verydensely at 203 d.p.i. (dots per inch) horizontal and 200 d.p.i. vertical, highly legible characters and graphic elements may becreated a row at a time as the media is advanced past the printhead. This technology has the advantage of simplicity, as thereis no requirement for consumable supplies such as ink or toner. However, since the media is sensitive to heat, it will graduallyloose legibility over long periods of time, especially if exposed toenvironments with relatively high temperatures.10ZQ500 Series User Guide

Thermal ShutdownThe ZQ500 Series printers have a thermal shutdown featurewhereby the printer hardware will detect a printhead over-temperature condition at 65oC. The printer will automatically stopprinting until the printhead cools down to 60oC. Printing will thenrecommence without a loss of label data or without any degradation of print quality.QR CodeThe QR barcode includes human readable text (URL) whichlinks the user to printer information and short videos on topicssuch as buying supplies, features overview, loading media, printing a configuration report, cleaning instructions, and accessoryinformation. (See Page 13 for each printer’s URL address.)Made for iPhone (MFi)ZQ500 Series printers support communication with Apple devices running iOS 5 or later over a standalone Bluetooth 4.0 radioand the BT3.0 radio included with the 802.11n (dual) radio.Near Field Communication (NFC)A passive NFC tag with the Bluetooth printer address will provide instant access to printer-specific information via an NFCenabled smartphone. The ZQ500 Series printers are also activeNFC devices that can not only collect information but exchangethat information with other compatible devices.11ZQ500 Series User Guide

ZQ500 Series Overview (ZQ510 Shown)6(Not present in Linerless.Scraper present instead)41238745111091. Platen Roller2. Black Bar Sensor3. Media Support Disks4. Tear Bar5. Media Cover Button6. Media Cover7. Printhead8. Gap Sensor9. Strap Post10. USB Port11. DC Input12. Power Button13. Control Panel14. Belt Clip Opening15. Select Button16. Paper Feed Button121312ZQ500 Series User Guide1415 16

1917212120XXXXXXXXXXXX M17. Battery18. Docking Contacts/Cover19. QR CodeXXXXXXXXXXXX M20.21.22.2018MAC Address/Bluetooth ID LabelsMounting PointsZebra Print TouchTM Icon NFC)229Note: Scanning the QR code with a smartphone will provide printerspecific information at www.zebra.com/zq510-info andwww.zebra.com/zq520-info.Note: Tapping the Zebra Print TouchTM icon with a Near FieldCommunication (NFC) enabled smartphone will provide instantaccess to printer-specific information. For more information aboutNFC and Zebra products, go to http://www.zebra.com/nfc.Bluetooth pairing applications via NFC is also possible. Please seeZebra Multi-platform SDK for more information.13ZQ500 Series User Guide

Getting Ready to PrintBatteryInstalling the BatteryImportant Batteries are shipped in sleep mode to preserve theirmaximum capacity while in storage prior to initial use. Plug in the ACadapter (see Pg. 19) or insert the battery into the Smart Charger 2 orQuad Charger (see Pg. 17) to wake it up before using for the first time.1. Locate the battery compartment on the bottom of theprinter.2. Insert the battery into the printer as shown in Figure 1. (Itis not possible to insert the pack in an incorrect orientation.)3. Rock the battery into the compartment as shown until itlocks in place.When the battery is first installed, the control panel indicators may briefly turn on and then go off which indicates thebattery is not fully charged.Figure 1: Installing the Battery (ZQ510 Shown)XXXXXXXXXXXX MXXXXXXXXXXXX M14ZQ500 Series User Guide

Battery SafetyCaution Avoid accidental short circuiting of any battery. Allowingbattery terminals to contact conductive material will create a shortcircuit which could cause burns and other injuries or could start afire.Important Always refer to the Important Safety Information datasheet shipped with each printer and the Technical Bulletin shippedwith each battery pack. These documents detail procedures toensure maximum reliability and safety while using this printer.Important Always dispose of used batteries properly. Refer toAppendix E for more battery recycling information.Caution Use of any charger not approved specifically by Zebra foruse with its batteries could cause damage to the battery pack or theprinter and will void the warranty.Caution Do not incinerate, disassemble, short circuit, or expose totemperatures higher than 65oC (149oF).Charger SafetyDo not place any charger in locations where liquids or metallicobjects may be dropped into the charging bays.15ZQ500 Series User Guide

Smart Charger-2 (SC2) Single Battery Charger (P1031365-063)The Smart Charger-2 (SC2) is a charging system for use withthe 2-cell and 4-cell lithium-ion smart batteries used in theZQ500 Series printers.Charging Status IndicatorsThe SC2 uses a LED indicator to indicate the charge state ineither Green, Yellow, or Amber as detailed below.DC Power InputIndicatorBattery StatusPresentGreenBattery not presentPresentGreenFully ntOffPresent and BatteryHealth POORThere will also be a battery charging graphic to indicate thatthis LED is the charging status indicator.Battery Health IndicatorThe SC2 features a tri-color (Yellow/Green/Amber) LED to indicate the health of the battery pack. An evaluation of the battery health begins upon insertion of the battery in the chargerand results in the appropriate LED being illuminated as shownbelow. The LED will remain illuminated as long as input poweris applied.BatteryIndicatorHealth StatusNone or non-smartOffSmart battery presentGreenGOODSmart battery presentYellowCAPACITY DIMINISHEDSmart battery presentFlashing yellowPAST USEFUL LIFESmart battery presentAmberUNUSABLE-REPLACE(discard per Instructions inAppendix ENote For detailed information on the SC2, refer to theSmart Charger 2 User Guide (p/n P1040985-001).16ZQ500 Series User Guide

Figure 2: Smart Charger-2 (SC2)Charge StatusLED IndicatorSmart BatteryHealth StatusLED IndicatorCharge Status IconHealth Status IconSC2 DimensionsHeightWidth65.1 mm (2.56 in.)101.5 mm (4 in.)Length120.9 mm (4.75 in.)Model UCLI72-4 Quad Charger (AC18177-5)The UCLI72-4 Quad Charger is designed to charge up to four (4)ZQ500 Series battery packs simultaneously. Batteries must be removed from the printer to be charged in the Quad Charger.1. Ensure that the charger has been installed properly per theQuad Charger instruction manual. Ensure that the power indicator on the front panel is on.2. Plug a battery pack into any one of the four charging bays asshown in Figure 3, noting the orientation of the battery pack.Slide the battery pack into the charging bay until it stops andthen rock the battery pack back until it snaps into place. Theamber indicator directly under the battery being charged willturn on if the battery is properly inserted.17ZQ500 Series User Guide

The indicators under the battery will allow you to monitor thecharging process per the table below:AmberOnGreenBattery StatusOffChargingOnFlashing80% charged (O.K.to use)OffOnCompletely ChargedFlashingOffFault-ReplaceBatteryImportant A fault condition is caused by a problem with the battery.The charger may indicate a fault because the battery is too hot or coldto charge reliably. Try to charge the battery again when it returns to theroom’s ambient temperature. If the amber indicator starts flashing onthe second attempt, the battery should be discarded. Always dispose ofbatteries in a proper manner as described in Appendix F.Figure 3: Quad Charger1. Slide Battery Packinto Charger bay.Power Supply2. Rock Battery Pack into place.AmberIndicatorGreenIndicatorCharger BayPower IndicatorQuad Charger Cycle Times :Battery StatusStandard PackExtended PackBattery 80% Charged 2 Hrs. 4 Hrs.Battery Fully Charged 3 Hrs. 5 Hrs.Note These times are for completely discharged batteries.18ZQ500 Series User Guide

Battery packs which are only partially discharged will take lesstime to reach their charged state. Batteries which have reached80% of their charge capacity may be used, however, it is recommended that you allow the batteries to reach a full charge tomaintain maximum battery life.The UCLI72-4 Quad Charger has a safety feature which stops charging abattery after six hours regardless of its charge state. If not fully charged,it might be indicative of a battery that needs to be replaced.Use care when installing the UCLI72-4 Quad Charger so that you do notblock the ventilating slots on the top and bottom covers. Ensure that thecharger is plugged into a power source which will not accidently beturned off if you will be charging batteries overnight.AC Power Adapter (p/n P1031365-024)Figure 4: Charging the Battery Pack with the AC Power AdapterAC AdapterAC Power Cord(varies withgeographiclocation)DC Input19ZQ500 Series User Guide

Open the protective cover on the printer to expose the DCinput charger jack. Connect the appropriate AC power cord for your location tothe adapter and then plug the power cord into an AC receptacle. Plug the barrel plug from the AC adapter into the chargerjack on the printer. The printer will power up and begin charging. The printercan be left on or turned off at this point. Charging will continue in either state.Note Batteries are shipped in sleep mode to preserve their maximumcapacity while in storage prior to initial use. Plug in the AC adapter (seePg. 19) or insert the battery into the Smart Charger 2 or Quad Charger (seePg. 17) to wake it up before using for the first time.While it’s possible to charge the battery when using the printer, chargetimes will increase under this condition.Vehicle CradleThe ZQ500 Series Vehicle Cradle provides a means to mount aZQ510 and ZQ520 printer in a vehicle while at the same time providing charging power to the battery. The Vehicle Cradle featuresUSB connectivity to allow the user to connect a laptop or tabletto the cradle.Battery Eliminator/Battery Eliminator Vehicle CradleThe ZQ500 Series Battery Eliminator allows a vehicle basedmobile printer user to operate the printer without the use of abattery. The Battery Elimnator Vehicle Cradle enables the userto mount a ZQ500 Series printer in a vehicle without the use of abattery.4-Bay Power StationThe ZQ500 4-Bay Power Station allows a total of four (4) ZQ510or ZQ520 printers to be docked and charged. The Power Stationprovides battery charging power while still maintaining all of theprinter’s functionality.Note For detailed information on accessories, refer to the ZQ500VCUser Guide (P1071204-001), the ZQ500 4-Bay Power Station User Guide(P1071266-001), the Battery Eliminator User Guide (P1071365-001), andthe Battery Eliminator Cradle User Guide (P1073631-001).20ZQ500 Series User Guide

Before docking the printer on either the Vehicle Cradle or the4-Bay Power Station, you must remove the docking contacts cover located on the bottom of the printer. To remove the cover, firstremove the battery, and then use a small screwdriver or coin todetach the cover and expose the docking contacts.XXXXXXXXXXXX MXXXXXXXXXXXX MFigure 5: Docking and Un-Docking the Vehicle Cradle2211Figure 6: Docking and Un-Docking the 4-Bay Power Station2121ZQ500 Series User Guide

Loading the Media in the ZQ500 Series PrintersThe ZQ500 Series printers are designed to print either continuous (receipt) media or label stock.Loading Media Procedure1. Open the printer (Refer to Figure 7). Press the Media Cover Button on the side of the printer asshown in “1” below. The Media Cover will open automatically. Rotate the Media Cover back completely as shown in “2”, exposing the media compartment and adjustable media supports.Figure 7: Opening the PrinterMedia CoverMediaCompartmentMedia SupportsMedia CoverButt

Zebra Technologies Corporation is not liable for any erroneous information or omissions. Zebra Technologies Corporation reserves the right to correct any such errors and disclaims liability resulting therefrom. No Liability for Consequential Damage In no event shall Zebra Technolo

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