Zebra ZQ610 Plus and ZQ630 Plus troubleshooting

CauseThe roll is empty, the printer can't see the media, or the media cover is not fully latched.

Fix

1. Press the latch release button on the side and swing the cover back.
2. Load a new roll between the media supports; the roll must turn freely.
3. Close the cover until it clicks. The media icon shows solid white when media is present.
4. If the alert stays, brush dust off the bar and gap sensor windows.

CauseThe media type set in the printer doesn't match the roll, the label length has not been calibrated, or the label format is larger than the printable area.

Fix

1. Open Settings › Media Type and choose the type that matches the roll: gaps, black marks or continuous receipt paper.
2. Run Tools › Label Length Cal, or Actions › Calibrate Media in the Printer Setup Utility app.
3. Make sure your label format fits the print width: 48 mm on the ZQ610 Plus, 104 mm on the ZQ630 Plus.

CauseDirt on the printhead, poor or wrong media, a darkness setting that is too low, or a roll loaded the wrong way round.

Fix

1. Check that the heat-sensitive side of the media faces the printhead. These printers print by heat only.
2. Switch the printer off and let the printhead cool. Clean the printhead with a Zebra cleaning pen, or a cotton swab with 90 % medical alcohol, from the centre to the edges.
3. Raise Settings › Darkness one step at a time. Zebra advises the lowest value that prints well.

Zebra advises cleaning the printhead after every five rolls, or after every roll of linerless media.

Video: Zebra Technologies

The video shows the earlier ZQ600 Series; Zebra describes the same printhead cleaning for the Plus models.

CauseIn peel-off mode the printer waits until you take the last label. An unlatched cover or a binding roll also stops feeding.

Fix

1. Take the last printed label. Check that nothing covers the label-present sensor.
2. Close and latch the media cover.
3. For a jam, open the cover, remove the media and load it again.

CauseThe battery is flat, not locked in, still has its tape insulator, or the printer is asleep.

Fix

1. Press POWER. After 20 minutes without use the printer sleeps with a blank display and wakes on any button.
2. Check that the battery is locked in and its tape insulator is removed.
3. Connect the Zebra AC adapter and let the battery charge.
4. If the display stays blank while the printer is on, contact us. Zebra notes that the printer software may need reloading.

CauseThe battery is low, worn out, or too hot or too cold. The PowerPrecision+ battery counts charge cycles: from 300 cycles Zebra rates it for replacement, and from 600 the printer shuts down after a 30-second warning.

Fix

1. Check Battery › Health and the cycle count on the display.
2. Charge at room temperature, between 5 and 40 °C, out of direct sunlight.
3. Use only Zebra chargers and genuine Zebra batteries.
4. A battery older than a year can lose capacity through normal ageing. Replace a battery whose health is no longer Good.

CauseThe printer is not in pairing mode, the phone holds an old pairing, or the phone is out of range.

Fix

1. Hold FEED for 5 seconds until the Bluetooth icon flashes, then search again. Zebra's app guide says pairing mode ends after 2 minutes.
2. Remove the printer from the phone's Bluetooth list and pair again. On an iPhone, pair in Settings › Bluetooth first.
3. For NFC pairing, hold the phone within 7.6 cm of the Print Touch icon on the side of the printer.

The full pairing steps are in our ZQ610 Plus and ZQ630 Plus setup guide.

CauseOn printers bought in Europe after 1 August 2025 Wi-Fi is disabled by default and protected settings need the Protected Mode password. A missing country setting or a weak signal also stops the connection.

Fix

1. Set up Protected Mode as described in the insert in the box and at zebra.com/asr, then enable Wi-Fi.
2. In the Printer Setup Utility, open Settings › Connectivity › Wireless and check the ESSID, security mode, band and country.
3. Apply network changes with Network › Reset Network.

CauseChanged settings no longer match your media or network.

Fix

1. Print a configuration label first as a record of your settings.
2. Open Tools › Load Defaults. Zebra states that this restores specific printer, print server and network settings to factory defaults.
3. Set the media type, calibrate again and re-enter your Wi-Fi settings.

Some menu items may ask for the menu password. Zebra cannot recover a forgotten Protected Mode password; contact us before you reset a printer that uses it.