🖨️ Direct Thermal & Thermal Transfer Troubleshooting

Your printer may print labels using Direct Thermal or/and Thermal Transfer methods

1. Direct Thermal - Uses heat to react with a special coating on the label.

   • No ribbon required

     Thermal Transfer - Uses heat to transfer ink from a ribbon onto the label.

   • Ribbon required

If the printer is set to the wrong method for the label type, the print may appear fuzzy, light, uneven, or missing.

Label Types Used

Thermal Transfer Labels

• 18500 – HCL® Class A Thermal Transfer Strip Labels
• Requires: Ribbon
• Printer setting: Thermal Transfer

Direct Thermal Labels

• 17295 – HCL® Class B Direct Thermal Labels
• Requires: No ribbon
• Printer setting: Direct Thermal

Step-by-Step Troubleshooting

1. Confirm the Label Type

Before making any adjustments, verify which labels are loaded:

• If a ribbon is required, labels are Thermal Transfer
• If no ribbon is required, labels are Direct Thermal

2. Verify Printer Print Method Setting

Check the printer menu, driver, or labeling software:

• For 18500 labels:
  • Print Method = Thermal Transfer

  • Ribbon = Installed

    For 17295 labels:

  • Print Method = Direct Thermal
  • Ribbon = Removed

⚠️ Using the wrong print method will cause poor print quality.

3. Ribbon Check (Thermal Transfer Only)

If using thermal transfer labels:

• Make sure a ribbon is installed

  Confirm ribbon is:

  • Facing the correct direction (ink side toward labels)
  • Smooth and properly tensioned
• Replace ribbon if print is faded or inconsistent

Quick test:

If the print scratches off easily, the ribbon may be installed backwards.

4. Adjust Print Quality Settings

If print is still unclear:

• Increase Darkness
• Reduce Print Speed
• Test print after each adjustment

5. Clean the Printer

Dirty printheads are a common cause of poor print quality.

• Clean the printhead with isopropyl alcohol

  Check for:

  • Adhesive residue
  • Dust or label debris
• Allow printhead to fully dry before printing

6. Calibrate the Printer

Calibration ensures the printer correctly detects label size and gaps.

• Run automatic calibration from the printer menu

  or

• Power-cycle the printer while holding the Feed button (method varies by model)

7. Verify Driver & Label Size Settings

• Confirm label dimensions in the printer driver match the physical labels

  Mismatched settings may cause:

  • Skipping labels
  • Misalignment
  • Uneven print density

Common Symptoms & Fixes

Printer Model Note

Some printers (such as the Zebra ZT230, which is discontinued) may still function normally but may have:

• Limited firmware updates
• Older driver requirements

Always confirm driver compatibility after system updates.