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 and ZT420 Printers
Resolution / Answer
Overview
The printer can be used for a wide variety of printing applications. Printing can be done with and without ribbon, and the printer (driver or software) must be configured appropriately. Thermal Transfer is used when the ribbon is required, while Direct Thermal refers to applications that do not use ribbon. For non-ribbon applications, a heat-sensitive label referred to as a Direct Thermal label must be used. Refer to the article Identify Type of Media.
The ribbon used in the printer consists of wax or resin-based ink on a plastic film called the carrier that is rolled onto a cardboard core. The width of the roll varies based on the width of the labels and should always be slightly wider. This protects for the printhead to prevent wear. On Zebra printers, the ink is on the outside of the ribbon roll (see note), and this is the surface that should be facing the labels, so ink transfer is accomplished.
NOTE There is a reverse-wound spindle available for the ZT410 P/N 79830M. Contact your Zebra Reseller for details.
How It Works
Ribbon Mechanics Two spindles, Ribbon Supply and Ribbon Take-up, guide the ribbon during printing. The printhead pressure at the print line controls the actual movement of the ribbon. Back tension is applied from the Ribbon Supply spindle to help prevent wrinkles and take up slack during a back feed operation. Printhead pressure moves the ribbon, keeping it synchronized with the labels, and the Ribbon Take-up spindle removes the ribbon from the labels and rewinds the spent ribbon.
Ribbon Detection The printer uses a combination of an optical sensor and reflector plate (the silver plate under the print mech you load the labels under) to detect the ribbon as it blocks the ribbon sensor light path. The ribbon sensor is used in Thermal Transfer applications to see the state of the ribbon and will provide a Ribbon Out condition when the ribbon reaches the end of the roll or is not installed. A clear ribbon trailer allows the light to reach the reflector plate, or the ribbon has a reflective chrome trailer that acts as a light reflector for the ribbon sensor. For Direct Thermal applications (where the ribbon is not required), the sensor will warn if the ribbon is detected by displaying a Ribbon In a warning on the LCD (or yellow flashing supplies light). Proper loading and configuration of the printer, driver, and software are required to avoid ribbon errors.
If you are not using ribbon, ensure the printer, software, and driver are configured for Direct Thermal.
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.
Try loading Factory Defaults and allow the printer to run auto-calibration. Refer to Load Defaults.
Ribbon Not Expected The Supplies Light is Flashing Yellow
The printer is detecting ribbon but configured for Direct Thermal (no ribbon mode). Change the LCD Print Mode to Thermal Transfer if using ribbon, or remove the ribbon in the Direct Thermal Mode. Verify the driver and software settings match the printer settings.
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 your media and ribbon combination are compatible so the burn temperature does not have to be set too high.
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 Reseller 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.
