Zebra Printer Calibration

My printer Won't print!

Zebra 140x, 105s, Xi series S series.

It is conceivable that you have the software working, the driver working, the correct cable and communications  and a modern operating system but you send the job to a Zebra printer, the data light flashes (as it should) and still nothing prints.  One of the most frequent tech support issues on a Zebra printer is improper calibration.

If your Zebra printer is not properly calibrated, the printer may not indicate any error condition but may still be confused.  To properly calibrate a Zebra printer you need to understand the sensors on your printer (a little), you need to understand your supplies and how they relate to each other. (see our support document on understanding your supplies).

Most of the time your Zebra printer is printing paper labels. If your machine "auto-calibrates" then it usually looks at the Gaps between your labels (at the difference in the transparency) and figures out how to advance the labels so that the printed image ends up in the correct position.  Then there is all the other cases.

A lot of the older machines don't "auto -calibrate". The newer machines could be set to not perform a calibration every time the printhead is opened.  The "transmissive" sensor in your printer needs to be in a physical position to allow it to see the gaps in your labels with absolute reliability.  If you hold up a 3 foot strip of your labels to the light you can see through the stock. Now you can see what the sensor sees.  If your transmissive sensor on your Zebra printer is not in a proper position to see the label gaps then you will experience skipping of labels, occasional  media out errors or print that crosses onto more than one label.

Media Loading

If your Zebra printer tech support person could see your printer the 2 things he would check first would be the cabling and the loading of the supplies. It's pretty easy for even the veteran user to accidentally load the machine incorrectly. Check the diagrams that are on the labels in your machine. (or if you went the cheap route, check your manual for loading instructions.)   Ask your tech person to walk you through loading the ribbon for the first time.

Tag Stock

Tag stock prints  great on a Zebra printer but the sensors must be in a position to see the notches in the tag stock.  Hopefully your tag supplier understands enough about your printer to supply the right stuff. You can slide the sensors into position to see the black marks on the back of your tag or to see the notches at the perf created to allow the printer to calibrate. Tags are tricky. If you have them and need help give us a call.

A word about Synthetic labels   (non paper materials)

Zebra printers do a great job printing onto synthetic stock. If you want to frequently switch between paper and synthetic stocks it is usually a good idea to calibrate your printer to be comfortable with the synthetic stock. Here's why...the high quality materials (poly materials) often use a carrier material that is less transparent. Therefore it is more difficult for your zebra printer to distinguish between gap and no-gap on the web of material running thru the Zebra printer. Adjust the sensors in your printer to print well with your synthetic label first. After that...the Zebra printer can usually handle the paper labels with no problems. 

General thoughts about Calibrating a printer

Every printer needs to now where to place the printed image into the media (paper, synthetic label, tag). Cut sheet laser printers use the sheets and rollers to figure out the top of form. Dot matrix impact printers often use the "pin feed" holes to know where the material is at all times. Many printing presses use timing marks to stay on track with print positioning. Thermal printers need to know the same thing. To eliminate accumulating error in the print location Zebra printer reset themselves on every page so that the accuracy of each printed image is the same as the last. The sensors in your printer generally use label gaps, tag notches or black marks to achieve accuracy in printing.