Thermal printheads for barcode label printers

Clean it first

Clean the printhead with isopropyl alcohol and run a test label. Zebra advises cleaning every one or two rolls of labels; dirt causes faded and patchy print.

Printhead maintenance guide: symptoms and tests

"Head Open" on the display

The printhead or cover is not fully closed. Close it until the latches snap shut. If the alert stays with the cover closed, the head-open switch or sensor needs service: log a service call.

Log a service call

Gaps in the print that stay after cleaning

Zebra's ZT411 guide describes long tracks of missing print on several labels as a damaged print element. Print the printer's self-test label: on TSC, Godex and TVS printers, missing dots in the test pattern point to a damaged printhead.

The printer says the printhead is worn

Some Zebra printers show "Head Element Out" or "Replace Printhead" near the end of the printhead's life. Order the replacement then, before the printer stops.

Faint print or a ribbon error

Check the print method (direct thermal or thermal transfer), the darkness setting and which side of the ribbon faces the label. These are settings, not a worn printhead.

Label printer setup steps

Model and resolution

A printhead matches one printer model and one resolution: 203, 300 or 600 dpi. On a Zebra printer, the digit before the dash in the printer's part number on its label shows the resolution: 2 is 203 dpi, 3 is 300 dpi, 6 is 600 dpi.

You cannot change the resolution on most printers

Printers take a printhead of their factory resolution. Zebra offers conversion kits only for some industrial models (ZT231, ZT411 and ZT421 and their older versions, and the ZE511 and ZE521 print engines), not for desktop printers or the ZT610 and ZT620.

Direct thermal or thermal transfer

Many models have different printheads for their direct thermal and thermal transfer versions, so tell us which version you have, or send a photo of the printer's label.

Send the serial number

With the printer's model and serial number we can confirm the exact printhead and whether the printer is still under warranty.

On site or in Chennai

If work has stopped, we can come to your site. If it can wait, bringing the printer to our Chennai office usually costs less.

Log a service call

Doing it yourself

On many desktop printers the user guide shows how to replace the printhead. Work in a static-safe area, switch off and unplug the printer, and let the printhead cool first. Calibrate the printer after fitting.

Heat and darkness

Zebra names heat and abrasion as the causes of printhead wear. Use the lowest darkness and printhead pressure that still print well.

Ribbon and labels

Use a ribbon at least as wide as the label, so the printhead never rubs bare label. Rough or poor-quality labels wear the printhead faster.

Cleaning

Clean every one or two rolls with isopropyl alcohol, never with sharp tools. Static and the wrong cleaning liquids also shorten printhead life.

How long does a printhead last?

Makers do not publish a fixed life for desktop label printers: it depends on labels, ribbon and darkness. For its industrial printers, Honeywell gives at least 1 million inches (25 km) in direct thermal and about 2 million inches on average in thermal transfer.

On a Zebra printer

Zebra's distributor in India has confirmed to us that Zebra covers printheads for 3 months or 30 km of printing; the ZD230A for one year. Send the serial number with your request so we can check.

On other makers' printers

Each maker sets its own printhead terms; TSC's ML241P datasheet, for example, gives 25 km or 12 months, whichever comes first. Ask us for the terms on a replacement printhead.

What is the price of a printhead in India?

Ask our team for today's competitive price. Send the printer model and resolution, and we will send a written quotation with current pricing and delivery time.

Do you have printheads in stock?

Many printheads are in stock in Chennai. Others are ordered in for you, which usually takes 2 to 3 weeks. Call us when a printer has stopped and we will check before you order.

Can I put a 300 dpi printhead in a 203 dpi printer?

Not on most printers: they take a printhead of their factory resolution. Zebra sells conversion kits only for some industrial models, such as the ZT231, ZT411 and ZT421.

Do you supply printheads for printers bought elsewhere?

Yes. We supply printheads for all the printers we sell and service, whoever sold you the printer.

Can you fit the printhead for us?

Yes, on site or at our Chennai office. We agree the way that suits your urgency and budget, and tell you any charge before we start.

Is a printhead covered by warranty?

Zebra covers printheads in India for 3 months or 30 km of printing (ZD230A: one year). Other makers set their own terms. Send the serial number and we will check.