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Zebra Hardware Setup Guide

This guide covers the complete setup for integrating Zebra hardware with the Goods platform.

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Hardware Overview

DeviceModelPurpose
PrinterZebra ZD421Bag labels, tote labels, shelf labels
ScannerZebra TC58Barcode scanning, inventory, picking

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ZD421 Printer Setup

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1. Network Configuration

  1. Connect the printer to your local network via Ethernet
  2. Print a configuration label by pressing and holding the Feed button for 2 seconds
  3. Note the current IP address
Using the printer’s web interface:
  1. Navigate to http://{printer-ip} in a browser
  2. Go to Network Settings → Wired
  3. Set IP mode to Static
  4. Configure:
    • IP Address: 192.168.1.100 (or your preferred address)
    • Subnet Mask: 255.255.255.0
    • Gateway: 192.168.1.1
  5. Save and restart the printer

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2. Media Configuration

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Bag Labels (Fold-Over)

  • Size: 2.5” × 6”
  • Type: Direct Thermal
  • Gap/Mark: Black mark sensing (recommended) or gap sensing
  • Calibration: Press Feed button 2 times after loading media

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Tote Labels

  • Size: 3” × 3”
  • Type: Direct Thermal
  • Gap/Mark: Gap sensing

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Shelf Labels

  • Size: 2.5” × 1.25”
  • Type: Continuous roll (non-adhesive)
  • Gap/Mark: Continuous mode

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3. Test Printing

From the admin dashboard:
  1. Go to Settings → Hardware
  2. Click Check Printer Connection
  3. Click Print Test Label
Or via API: 
curl -X POST http://localhost:9000/admin/labels/test \
  -H "Authorization: Bearer $TOKEN"

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TC58 Scanner Setup

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1. Device Configuration

  1. Power on the TC58
  2. Complete initial Android setup
  3. Connect to your WiFi network
  4. Note the device IP address

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2. DataWedge Configuration

DataWedge broadcasts scanned barcodes as Android intents.

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Create Profile

  1. Open DataWedge app
  2. Tap Menu → New Profile
  3. Name: Goods Scanner
  4. Tap the new profile to configure

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Configure Profile

Associated Apps:
  • App name: com.goodsgrocery.scanner
  • Activity: *
Barcode Input:
  • Enabled: ✓
  • Scanner: Internal Imager (or your preferred)
Keystroke Output:
  • Enabled: ✗ (we use intents instead)
Intent Output:
  • Enabled: ✓
  • Intent Action: com.goodsgrocery.scanner.SCAN
  • Intent Category: android.intent.category.DEFAULT
  • Intent Delivery: Broadcast Intent
Data Formatting:
  • Basic data formatting: ✓
  • Enable new line at end: ✗

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3. Install Scanner App

# Build the APK
cd switchyard/apps/scanner-app
npm install
cd android
./gradlew assembleRelease

# Install via ADB
adb install app/build/outputs/apk/release/app-release.apk
Or install directly from your CI/CD pipeline.

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4. App Configuration

On first launch:
  1. Sign in with your Goods credentials
  2. Go to Settings
  3. Configure:
    • API URL: Your Switchyard backend URL
    • Printer IP: The ZD421’s static IP
    • Printer Port: 9100
  4. Tap Check Connection to verify printer
  5. Tap Print Test Label to confirm

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Label Specifications

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Bag Label (2.5” × 6”)

Fold-over design that displays on both sides of a sealed bag. 
┌─────────────────────────┐
│     (TOP HALF)          │  ← Upside down
│     Same as bottom      │
│                         │
├─────────────────────────┤  ← Fold line
│     (BOTTOM HALF)       │  ← Right-side up
│     Customer Name       │
│     • Item 1            │
│     • Item 2            │
│     Bag 1 of 3          │
│     [BARCODE]           │
└─────────────────────────┘

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Tote Label (3” × 3”)

Large QR code for tote identification. 
┌─────────────────────────────┐
│    ┌─────────────────┐      │
│    │    QR CODE      │      │
│    │   (2" × 2")     │      │
│    └─────────────────┘      │
│        TOTE #12345          │
└─────────────────────────────┘

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Shelf Label (2.5” × 1.25”)

Product identification for gondola shelves. 
┌─────────────────────────────────────────┐
│  Product Name                           │
│  |||||||||||||||||||||||||||||||        │
│  012345678901   Location: 3A-2          │
└─────────────────────────────────────────┘

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API Endpoints

EndpointMethodPurpose
/admin/labels/printer-statusGETCheck printer connection
/admin/labels/testPOSTPrint test label
/admin/labels/bagPOSTPrint single bag label
/admin/labels/bag/batchPOSTPrint multiple bag labels
/admin/labels/totePOSTPrint single tote label
/admin/labels/tote/batchPOSTPrint multiple tote labels
/admin/labels/shelfPOSTPrint single shelf label
/admin/labels/shelf/batchPOSTPrint multiple shelf labels
/admin/labels/preview/*POSTReturn ZPL without printing

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Scanner API

EndpointMethodPurpose
/scannerGETAPI status and features
/scanner/inventory/lookupGETLook up product by barcode
/scanner/inventory/scanPOSTProcess inventory scan
/scanner/ordersGETGet orders for picking
/scanner/orders/:idGETGet order details

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Troubleshooting

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Printer Not Connecting

  1. Verify network connectivity with ping {printer-ip}
  2. Check firewall allows port 9100
  3. Restart printer
  4. Confirm static IP hasn’t changed

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Labels Not Printing Correctly

  1. Calibrate media (press Feed 2x)
  2. Verify label size in ZPL (^PW and ^LL commands)
  3. Check darkness setting in printer web UI
  4. Use Labelary.com to preview ZPL

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Scanner Not Sending Barcodes

  1. Verify DataWedge profile is active
  2. Check intent action matches exactly
  3. Test with DataWedge Demo app first
  4. Review Android logs: adb logcat | grep DataWedge

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App Authentication Failing

  1. Verify Supabase credentials
  2. Check user has appropriate role
  3. Ensure API URL is correct
  4. Check network connectivity

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Environment Variables

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Backend (Switchyard)

ZEBRA_PRINTER_IP=192.168.1.100
ZEBRA_PRINTER_PORT=9100

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Scanner App

Create apps/scanner-app/.env: 
SUPABASE_URL=https://your-project.supabase.co
SUPABASE_ANON_KEY=your-anon-key
API_BASE_URL=http://your-backend:9000
PRINTER_IP=192.168.1.100
PRINTER_PORT=9100