How to Resolve Zebra ZT230 Media Out Error

June 1, 2023

The Zebra ZT230 printer is a reliable and widely used printing solution that plays a crucial role in various industries, from manufacturing and logistics to healthcare and retail. When it comes to printing labels, tags, or receipts, the ZT230 excels in providing high-quality and efficient output. However, like any technology, it is not immune to occasional issues that may disrupt its performance. One common challenge that users encounter is the Media Out error on the Zebra ZT230.

Media handling is a critical aspect of the printing process, and any error related to it can lead to delays, downtime, and decreased productivity. In this comprehensive guide, we will delve into the Media Out error on the Zebra ZT230 and provide you with practical troubleshooting steps to resolve it effectively. 

What is the Zebra ZT230 Media Out Error?

When the ZT230 printer encounters a Media Out error, it means that there is a lack of media or the printer’s sensors cannot detect or properly sense the media (such as labels or tags) needed for printing.

The Media Out error can have several possible causes:

1. Insufficient media in the printer: If there is not enough media loaded in the printer, the printer’s sensors may fail to detect it, triggering the Media Out error.
2. Incorrect media configuration settings: If the printer’s settings are not correctly configured to match the loaded media, such as label size or media type, the printer may not recognize the media and display the Media Out error.
3. Faulty media sensors: Issues with the printer’s media sensors, such as dirt or damage, can result in inaccurate detection of media presence and trigger the Media Out error.
4. Printer firmware issues: Outdated or incompatible firmware on the ZT230 printer can cause communication issues with the media sensors, leading to the Media Out error.

Troubleshooting the Media Out Error

Check the Media Supply 

An adequate amount of media can vary depending on your printing requirements and the nature of your printing tasks. Here are a few factors to consider when determining what constitutes an adequate amount of media:

1. Printing Volume: Consider the volume of printing you expect to perform. If you have a high volume of printing tasks, you will need a larger supply of media to ensure uninterrupted printing without frequently reloading the printer. Conversely, for lower printing volumes, a smaller supply may be sufficient.
2. Projected Duration: Estimate the duration for which you will be printing continuously or the time between planned maintenance or media replacements. This will help determine how much media you need to load into the printer to cover that time period.
3. Media Size and Format: Take into account the size and format of the media you are using. Different media sizes or formats may require different amounts of media to complete specific tasks. Consider the dimensions and specifications of your labels, tags, or receipts to determine how much media is needed to fulfill your printing requirements.
4. Printing Environment: Evaluate the working conditions and constraints of your printing environment. If your printer is located in a remote area or difficult-to-access location, you may need to load a larger amount of media to minimize the need for frequent replacements.

Check Media and Ribbon Loading

Properly loading the media and ribbon ensures that the printer can accurately print labels or documents. Incorrect loading can lead to misaligned printing, poor print quality, or even printing on the wrong side of the media.

Refer to User Guide: Load Media

Refer to User Guide: Load Ribbon

Update or reinstall printer drivers

Outdated or corrupted printer drivers can also cause errors. Visit the Zebra website and download the latest drivers for your ZT230 printer model. Install the updated drivers or reinstall the existing ones to ensure compatibility and proper functionality.

Verify the correct media sensor is selected. 

This Zebra printer comes with different sensors for label tracking based on the Media Type used. For the Zebra ZT230 printer, the default and commonly used sensor is the Reflective Sensor, which is suitable for most media types. 

However, depending on the specific requirements of your media, you may need to select a different sensor option. Here are the available sensor options and when to use:

1. Reflective Sensor (Default): This sensor is typically used for most media types, including barcode labels, tags, and receipt paper. It detects the presence of media based on the reflection of light.
2. Transmissive Sensor: The transmissive sensor is specifically designed for transparent or non-reflective media, such as clear labels or perforated tags. It works by transmitting light through the media and detecting changes in the light transmission.
3. Fixed Position Inter-Label Gap: It is typically used when the media has a specific arrangement with gaps, and the sensor needs to accurately detect the presence or absence of labels based on these gaps. This sensor is often used for media with a dark preprint on the backing that can interfere with the Reflective Sensor’s functionality.

Verify the moveable Reflective Sensor is correctly positioned. 

Verifying the correct positioning of the moveable Reflective Sensor is essential for accurate media detection, print quality, and reliable printing operations. Reference this article on positioning the label sensor for unique labels on Zebra printers for more information. 

Try to default the printer and allow it to run auto-calibration. 

Refer to User Guide: Changing Printer Settings for more information.

Perform Manual Calibration

By fine-tuning the sensors, manual calibration helps in achieving accurate media detection, improving print alignment, enhancing print quality, and preventing errors such as jams or misfeeds. It allows the printer to optimize its settings based on the calibrated sensors, resulting in better overall performance. 

Refer to: ZT230 Manual Calibration Procedure

Verify the Maximum Length is set longer than the labels used. 

Set the maximum label length to a value at least 1.0 in. (25.4 mm) greater than the actual label length plus the interlabel gap. If you set the value to one smaller than the label length, the printer assumes that continuous media is loaded, and the printer cannot calibrate. 

For example, if the label length is 6.0 inches (152 mm) including the interlabel gap, set the parameter for at least 7.0 inches (178 mm).

Refer to User Guide: Maximum Label Length for more information.

Inspect and clean media sensors

Inspecting and cleaning the media sensors is an important troubleshooting step to resolve issues related to the Media Out error on your printer. Here’s how you can perform this task:

1. Brush, air blow, or vacuum any accumulated paper lint and dust away from media and ribbon tabs 
2. Brush, air blow, or vacuum sensors 
3. Move the empty ribbon supply core to the ribbon take up spindle 

Tips for preventing the Media Out error 

To prevent the Media Out error and ensure smooth printing operations, consider implementing the following tips:

1. Maintain an adequate supply of media: Always keep a sufficient quantity of media, such as labels or paper, in the printer. Regularly monitor the media level and replenish it as needed to avoid running out during print jobs.
2. Calibrate media sensors: Perform regular calibration of the media sensors according to the manufacturer’s instructions. Calibration helps the printer accurately detect the gaps, notches, or marks on the media, reducing the chances of a Media Out error.
3. Keep printer firmware up to date: Stay updated with the latest firmware releases for your printer model. Firmware updates often include bug fixes and performance improvements, which can help prevent errors and enhance the printer’s overall functionality.
4. Follow recommended media specifications: Use media that complies with the printer’s specifications. Ensure the media type, size, and thickness are within the recommended range. Using incompatible or improper media can lead to media detection errors, including the Media Out error.
5. Handle media with care: Properly handle the media when loading it into the printer. Ensure it is aligned correctly, without any wrinkles or misfeeds. Avoid rough handling or forcing the media into the printer, as it can damage the media sensors or cause other issues.
6. Regular maintenance with professional assistance: Consider a reliable maintenance provider, like Lexicon Tech Solutions, for routine maintenance and inspections on your printer. Technicians can identify potential issues, clean the printer components, and ensure optimal performance, reducing the risk of errors like the Media Out error.

By combining these troubleshooting steps and preventive measures, you can try to resolve the media out error and create a more reliable Zebra ZT230 printer. If further assistance is needed, reach out to Lexicon Tech Solutions for expert support and maintenance.