Zebra ZT410/ZT420 Printer Calibration and Troubleshooting

Calibration and Diagnostic Tools

Tool	Description	Details
Media and Ribbon Sensor Calibration	Calibrates the printer to adjust the sensitivity of the media and ribbon sensors.	Accepted values: N/A Related ZPL command(s): ~JC SGD command used: ezpl.manual_calibration User menu item: MEDIA/RIBBON CAL (page 98) Control panel key(s): Hold PAUSE + CANCEL for 2 seconds to initiate calibration. Printer web page: Calibration procedure cannot be initiated via web pages. View and modify printer settings under Calibration.
Communication Diagnostics Mode	Outputs hexadecimal values for all data received by the printer.	Accepted values: DISABLED, ENABLED Related ZPL command(s): ~JD to enable, ~JE to disable SGD command used: device.diagnostic_print User menu item: DIAGNOSTIC MODE (page 99) Control panel key(s): Hold PAUSE + FEED for 2 seconds when the printer is in the Ready state. Printer web page: N/A

Printer Settings and Actions

Set the Head-Close Action

Configures the printer's action upon closing the printhead. Refer to Head-Close Action on page 73 for details.

Set the Head-Open Light Action

Adjusts the brightness of the light that activates when the printhead is open.

Set the Cover Open Light Action

Adjusts the brightness of the light that activates when the media door is open.

Load Printer Defaults

Restores all settings, except network settings, to factory defaults. Exercise caution as manually changed settings will need to be re-entered. See Load Defaults on page 74 for more information.

Calibrating the Media and Ribbon Sensors

This procedure calibrates the printer by adjusting the sensitivity of the media and ribbon sensors. It is recommended for resolving printing issues. See Printing Issues on page 148 for details.

Important: Follow the calibration procedure exactly. All steps must be completed, even if only one sensor requires adjustment. Press and hold CANCEL at any step to abort the process.

To perform sensor calibration:

With the printer in the Ready state, initiate media and ribbon calibration by one of the following methods:
- Press and hold PAUSE + CANCEL for 2 seconds.
- Send the ezpl.manual_calibration SGD command to the printer.
- Navigate to the MEDIA/RIBBON CAL menu item under TOOLS > SENSORS on the control panel display.
Press RIGHT SELECT to select START. The printer will indicate calibration is in progress with flashing lights and messages on the control panel.
Caution: The printhead may be hot. Allow it to cool. Open the printhead assembly by rotating the printhead-open lever.
Extend the media approximately 8 inches (203 mm) out of the printer.
Remove the exposed labels, leaving only the liner.
Pull the media into the printer so that only the backing is between the media sensors.
Remove the ribbon, if used.
Rotate the printhead-open lever downwards until it locks the printhead in place.
Press PAUSE to begin the media calibration process. The printer will display "CALIBRATING PLEASE WAIT".
When the process is complete, the control panel will display options to RELOAD ALL or CONTINUE.
Open the printhead assembly by rotating the printhead-open lever.
Pull the media forward until a label is positioned under the media sensors.
Reload the ribbon, if used.
Close the printhead.
Close the media door.
Press PAUSE to enable printing.

Troubleshooting Printing Issues

The following table outlines common printing issues, their potential causes, and recommended solutions.

Issue	Possible Cause	Recommended Solution
General print quality issues	Incorrect print speed setting.	Set print speed to the lowest possible setting for your application. Perform FEED Self Test (page 162) to find optimal settings. See Print Speed (page 67).
	Incorrect media/ribbon combination.	Try different media or ribbon types. Consult Zebra reseller or distributor for advice.
	Incorrect darkness level.	Set darkness to the lowest possible setting. Perform FEED Self Test (page 162) to find ideal settings. See Print Darkness (page 67).
	Dirty printhead.	Clean the printhead and platen roller. See Clean the Printhead and Platen Roller (page 132).
	Incorrect or uneven printhead pressure.	Set printhead pressure to the minimum needed for good print quality. See Adjust the Printhead Pressure (page 124).
Loss of printing registration on labels. Excessive vertical drift in top-of-form registration.	Dirty platen roller.	Clean the printhead and platen roller. See Clean the Printhead and Platen Roller (page 132).
	Improperly positioned media guides.	Ensure media guides are properly positioned. See Load the Media (page 34).
	Incorrect media type setting.	Set the printer for the correct media type (gap/notch, continuous, or mark). See Media Type (page 67).
	Incorrectly loaded media.	Load media correctly. See Load the Media (page 34).
Long tracks of missing print on several labels	Damaged print element.	Call a service technician.
	Wrinkled ribbon.	See Ribbon Problems (page 151) for causes and solutions.
Fine, angular gray lines on blank labels	Wrinkled ribbon.	See Ribbon Problems (page 151) for causes and solutions.
Printing too light or too dark over the entire label	Media or ribbon not designed for high-speed operation.	Replace supplies with those recommended for high-speed operation.
	Incorrect media/ribbon combination.	Try different media or ribbon types. Consult Zebra reseller or distributor for advice.
	Using ribbon with direct thermal media.	Direct thermal media does not require ribbon. Perform the label scratch test in When to Use Ribbon (page 18).
	Incorrect or uneven printhead pressure.	Set printhead pressure to the minimum needed for good print quality. See Adjust the Printhead Pressure (page 124).
Smudge marks on labels	Media or ribbon not designed for high-speed operation.	Replace supplies with those recommended for high-speed operation.
Misregistration/skips labels	Printer not calibrated.	Calibrate the printer. See Calibrate the Ribbon and Media Sensors (page 119).
	Improper label format.	Check and correct label format as necessary.
Misregistration and misprint of one to three labels	Dirty platen roller.	Clean the printhead and platen roller. See Clean the Printhead and Platen Roller (page 132).
	Media does not meet specifications.	Use media that meets specifications. See Media Specifications (page 172).
Vertical drift in top-of-form position	Printer out of calibration.	Calibrate the printer. See Calibrate the Ribbon and Media Sensors (page 119).
	Dirty platen roller.	Clean the printhead and platen roller. See Clean the Printhead and Platen Roller (page 132).
Vertical image or label drift	Using non-continuous labels but configured in continuous mode.	Set printer for correct media type (gap/notch, continuous, or mark) and calibrate if necessary. See Media Type (page 67) and Calibrate the Ribbon and Media Sensors (page 119).
	Improperly calibrated media sensor.	Calibrate the printer. See Calibrate the Ribbon and Media Sensors (page 119).
	Dirty platen roller.	Clean the printhead and platen roller. See Clean the Printhead and Platen Roller (page 132).
	Improper printhead pressure settings.	Adjust printhead pressure for proper functionality. See Adjust the Printhead Pressure (page 124).
	Incorrectly loaded media or ribbon.	Ensure media and ribbon are loaded correctly. See Load the Ribbon (page 60) and Load the Media (page 34).
	Incompatible media.	Use media meeting printer specifications. Ensure interlabel gaps or notches are 2 to 4 mm and consistently placed. See Media Specifications (page 172).
The bar code printed on a label does not scan.	Barcode not within specifications (print too light or too dark).	Perform FEED Self Test (page 162). Adjust darkness or print speed settings.
	Insufficient blank space around the barcode.	Leave at least 1/8 in. (3.2 mm) between the barcode and other printed areas or label edges.
Auto Calibrate failed.	Incorrectly loaded media or ribbon.	Ensure media and ribbon are loaded correctly. See Load the Ribbon (page 60) and Load the Media (page 34).
	Sensors could not detect media or ribbon.	Calibrate the printer. See Calibrate the Ribbon and Media Sensors (page 119).
	Dirty or improperly positioned sensors.	Ensure sensors are clean and properly positioned.
	Incorrect media type setting.	Set the printer for the correct media type (gap/notch, continuous, or mark). See Media Type (page 67).

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