ZT200 Series -- Loading the Ribbon and Resolving Ribbon Issues (With Video)

Details

Symptoms

This solution discusses resolving symptoms related to the following:

• Ribbon In error
• Ribbon Out error
• Not detecting a ribbon out condition
• Ribbon wrinkle causing random diagonal lines in print
• Ribbon stalling or sticking
• Ribbon breaking or tearing

Applies To

ZT Printers experiencing ribbon related problems or errors.

Overview

The printer can be used for a wide variety of printing applications. Printing can be done with and without ribbon and for each method the printer (and driver/software) must be properly configured. The most common term used when ribbon is required is ”Thermal Transfer” while “Direct Thermal” refers to applications that do not use ribbon. For non-ribbon applications a heat sensitive label must be used referred to as Direct Thermal labels.

The ribbon used in the printer consists of a 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 provides protection 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. Read More>>

Note: There is a reverse wound Ribbon Supply Spindle Optional P/N 79828M for the ZM400 that can support the inside inked ribbon

Common Issues and Resolutions
  

has calibrated correctly Read More&

Helpful Details

Click here to view video ->

Z220 Media and Ribbon Loading Video

Z230 Media and Ribbon Loading Video

Load the ribbon following the diagram that is printed on the inside wall of the supplies compartment. 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.

How it works

Ribbon Mechanics

There are two spindles, Ribbon Supply and Ribbon Take-up, that guide the ribbon during printing. The actual movement of ribbon is controlled by the printhead pressure at the print line. Back tension is applied from the Ribbon Supply spindle to help prevent wrinkle and take up slack during backfeed 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 to detect the ribbon as it blocks the ribbon sensor light path. The ribbon sensor is used in Thermal Transfer applications to detect 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 ribbon is not required) the sensor will warn if ribbon is detected by displaying a Ribbon In warning on the LCD Display or a Yellow Flashing Supplies Light. To avoid ribbon errors proper loading and configuration of the printer and driver/software is required.

Ribbon Sensor Reflective Plate view from the Front
(The Sensor is not viewed but is on the upper Printhead Mechanism)

Note: Labels go under the plate as shown and Ribbon goes over the reflector plate