Calibrate the Zebra ZT231: auto and manual calibration

Calibration sets the sensitivity of the ZT231's media and ribbon sensors and teaches the printer where each label starts. Without it, the printer may skip labels, let the print drift or stop with "Media Out" or "Ribbon Out" although supplies are loaded.

When to calibrate

• When you switch to labels or ribbon of a different size or type.
• When the printer skips labels, or the print drifts up, down or sideways.
• When the ribbon is not detected, either when it is loaded or when it runs out.
• When gap or black mark labels are handled as if they were continuous.

Know your labels

Set the label type under Print › Print Quality › Label Type and the sensor under Print › Sensors › Sensor Type. With continuous labels, the label length must come from your label format or driver.

The ZT231 detects gaps of 2–4 mm (3 mm is ideal). Black marks must be 2.5–11.5 mm long, at least 9.5 mm wide and reach to within 1 mm of the inner edge of the liner, the edge nearest the back wall of the printer.

Load labels and ribbon correctly

Most calibration failures start with loading. The labels must run through the slot in the media sensor, under the inner media guide, and touch the back of the sensor slot. The outer media guide should touch the label edge. Ribbon must run as far back as it can under the printhead. Our ZT231 setup guide shows the full path.

Use auto calibration

The quickest way is to let the printer calibrate itself. The Print wizard (Wizards › Print › Start Print) does it as part of setup. To calibrate automatically every time:

1. On the Home screen, touch System › Settings › Power Up Action or System › Settings › Head Close Action.
2. Choose CALIBRATE. It adjusts the sensor levels, measures the label length and feeds to the start of the next label.
3. Close the printhead or switch the printer on. It calibrates using about two to three labels.

SHORT CAL is a faster option: it sets the thresholds and measures the label length without adjusting the sensor gain. Zebra also lists a button shortcut: hold PAUSE + FEED + CANCEL for 2 seconds to start a calibration.

Video: Zebra Technologies

Run a manual calibration

Use manual calibration when auto calibration fails or labels still skip. The touch display guides you step by step with pictures. Follow the prompts exactly, touch Next after each one, and hold CANCEL at any point to stop.

1. With labels and ribbon loaded, touch Print › Sensors › Manual Calibration, then Start Calibration.
2. Follow the prompts. They take you through opening the printhead, taking out the ribbon, peeling labels off the backing (liner) and placing the bare backing under the media sensor for the media calibration.
3. For the ribbon sensor, reload the labels and the ribbon when asked and close the printhead assembly.
4. When calibration is complete, press PAUSE to leave pause mode.

Video: Zebra Technologies

Check the result

Press FEED once: the printer should feed exactly one label. Then print a test label from your software and check that it lands on the label, not across the gap. If the gap does not stop on the tear bar, adjust Print › Image Adjust › Tear Line Offset (−120 to +120): lower values move the labels in, higher values out.

Still unsure? Touch Print › Sensors › Print: Sensor Profile. On the printout, the spikes in the MEDIA line should be as far apart as the gaps or marks on your labels. If they are not, clean the sensors and calibrate again.

Skipped or blank labels: fixes

For lights and display alerts, see ZT231 alerts and lights.