How do I resolve ribbon-related issues on the ZT410 and ZT420 printers?
How do I solve wrinkles on the ribbon and adjust the printhead pressure?
Applicable To
ZT410, ZT420, ZT411, ZT421
Resolution / Answer
Ribbon Detection
The printer uses an optical sensor and reflector plate to detect the ribbon by monitoring whether the ribbon blocks the sensor's light path. This system is used in Thermal Transfer applications to track the ribbon's state and issue a "Ribbon Out" warning when the ribbon runs out or is not installed. The ribbon can have a clear trailer (allowing light through) or a reflective chrome trailer (acting as a light reflector). In Direct Thermal applications, where no ribbon is required, the sensor alerts to a "Ribbon In" condition if a ribbon is detected. Proper cleaning, loading and configuration of the printer, driver, and software are essential to prevent ribbon errors.
Try loading Factory Defaults and allow the printer to run auto-calibration. Refer to Load Defaults.
If you are not using ribbon, ensure the printer, software, and driver are configured for Direct Thermal. Please, refer to article: Changing the Print Method.
If you are printing in Thermal Transfer, verify the ribbon is correctly loaded and fully pushed onto the Ribbon Supply spindle to ensure it passes over the Ribbon Reflector plate when the printhead is closed. Refer to Ribbon Loading.
Verify the ribbon sensor is calibrated correctly for the ribbon being used. Perform a manual calibration procedure. Refer to Manual Calibration.
Print a sensor profile to check the functionality of the ribbon sensor. Refer to Sensor Profile for more details then refer to Print Information. The ribbon out threshold is likely too high, above the line that indicates where the ribbon is detected.
Ribbon Not Expected The Supplies Light is Flashing Yellow
Try loading Factory Defaults and allow the printer to run auto-calibration. Refer to Load Defaults.
If you are using ribbon, ensure the printer, software, and driver are configured for Thermal Transfer, or remove the ribbon in the Direct Thermal Mode (no ribbon). Verify the driver and software settings match the printer settings. Please, refer to article: Changing the Print Method.
Verify the ribbon is loaded correctly. Refer to Load the Ribbon.
Reduce the darkness setting in the LCD and, driver and software. Refer to Print Darkness.
Verify ribbon composition (wax or Resin) and set recommended darkness level:
Wax ribbon: Darkness not higher than 23-25.
Resin ribbon: can handle darkness higher than 23.
Ribbon Stalling
Verify the inked side of the ribbon is facing the labels. Refer to Is Your Ribbon Inked on the Right Side?Note: There is a reverse-wound spindle available for the ZT410 P/N 79830M. Contact your Zebra Partner for details.
Decrease the Ribbon Supply Spindle tension, setting it to low. Refer to Adjust Ribbon Tension.
Increase the head pressure to ensure the pressure is balanced across the media. Refer to Adjust the Printhead Pressure.
Decrease the darkness and verify the media and ribbon combination are appropriate for the application:
Load the ribbon following the diagram printed on the supplies compartments inside the wall. This will ensure the ribbon sensor detects the presence of ribbon correctly. Improper loading can cause false ribbon-out errors and also lead to wrinkling.
