Zebra XiIII-Series User's Guide Customer order # 48025L Manufacturer part # 48025LB Rev.
Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Corporation.
Table of Contents Introduction Hello! . . . . . . . . . . . . . . Unpacking and Inspection . . . . Reporting Damage . . . . . . Storage . . . . . . . . . . . . Media and Ribbon Requirements Power Cord . . . . . . . . . . . Printer Anatomy 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Establishing Communication System Considerations . Interfaces . . . . . . Data Specifications . Cabling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 21 21 22 Operator Controls . . . . . . . . . . . . . . . . . . . . POWER Switch . . . . . . . . . . . . . . . . . . .
Routine Care and Adjustment Cleaning . . . . . . . . . . . . . . . . . . . Cleaning the Exterior . . . . . . . . . . . Cleaning the Interior . . . . . . . . . . . Cleaning the Printhead and Platen Roller. Cleaning the Sensors . . . . . . . . . . . Cleaning the Snap Plate. . . . . . . . . . Cleaning the Cutter Module . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . Fuse Replacement . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . Toggle Positioning . . . . . . . . . . .
Specifications Media Handling . . . . . . . . . . . . . Options . . . . . . . . . . . . . . . . . . Zebra Programming Language (ZPL II®) Bar Codes. . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . Printing Specifications . . . . . . . . . . Ribbon Specification . . . . . . . . . . . Media Specifications . . . . . . . . . . . Power Line Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction Hello! Thank you for purchasing this high-quality Zebra XiIII-Series printer, manufactured by the industry leader in quality, service, and value -- Zebra Technologies Corporation. For over 25 years, Zebra has provided customers with the highest caliber of products and support. n n n n This manual provides all of the information you will need to operate your printer.
Unpacking and Inspection Inspect the printer for possible damage incurred during shipment. n Check all exterior surfaces. n Raise the media access door and inspect the media compartment. In case shipping is required, save the carton and all packing material. Contact your authorized Zebra reseller for instructions. Reporting Damage If you discover shipping damage: n Immediately notify and file a damage report with the shipping company.
Media and Ribbon Requirements Since print quality is affected by media and ribbon, printing speeds, and printer operating modes, it is very important to run tests for your applications. We STRONGLY RECOMMEND the use of Zebra Technologies Corporation-brand supplies for continuous high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the printing capabilities of the printer and to ensure against premature printhead wear.
Printer Anatomy 101 Depending on the options you have selected, your printer may look slightly different.
Calibrating the Printer This chapter of the user’s guide is so important that we’ve printed it on a different color paper! That way, it will be easy for you to find when you must calibrate (set up) the printer for your particular application. Purpose n To calibrate the printer. n To verify that the printer is properly set up by printing a test label. NOTE: This procedure must be performed when the printer is first installed or when it cannot properly detect the top of the label.
Types of Media Non-Continuous Web Media Non-continuous web media (refer to Figure 2) refers to individual labels that are separated by a gap, notch, or hole. When you look at the media, you can tell where one label ends and the next one begins.
Non-Continuous Black Mark Media Non-continuous black mark media has black marks printed on the back that indicate the start and end of each label (refer to Figure 3). Black mark Black mark Non-continuous media for black mark sensing Figure 3 Continuous Media Continuous media (refer to Figure 4) is one uninterrupted roll of material that allows the image to be printed anywhere on the label.
Choosing the Print Mode 8 n Tear-off mode allows you to tear off each label, or a strip of labels, after it is printed. n In Peel-off mode, backing material is peeled away from the label as it is printed. After this label is removed from the printer, the next one is printed. n When in cutter mode, the printer automatically cuts the label after it is printed. n In rewind mode, the media and backing are rewound onto a core as the labels are printed.
Loading the Media Figure 5 illustrates one method of media loading. For more detailed instructions, as well as information about how to load the different types of media and the various printing modes, refer to the instructions that begin on page 27.
Positioning the Media Sensors The correct positioning of the media sensors is important. It can make the difference between a perfect label and a call to Technical Support! Transmissive Sensor The web or gap sensor, better known as the “transmissive sensor,” detects the gap between labels. The transmissive sensor actually consists of two sections: a light source (the lower media sensor) and a light sensor (the upper media sensor). The media passes between the two.
Adjusting the Upper Media Sensor Refer to Figure 6. (For clarity, not all printer parts are shown.) 1. Remove the ribbon (if it is installed). 2. Locate the upper media sensor. The upper media sensor “eye” is directly below the adjustment screw head. 3. Slightly loosen the upper media sensor adjustment screw (Phillips head). 4. Using the tip of the screwdriver, slide the upper sensor along the slot to the desired position. 5. Secure the upper media sensor adjustment screw.
Adjusting the Lower Media Sensor Position the lower media sensor (refer to Figure 7) by sliding it in its slot until it is positioned under the upper media sensor. Lower media sensor Figure 7 Black Mark Sensor The black mark sensor is in a fixed position and enabled via the front panel (details in “Configuring the Printer” on page 15).
Loading the Ribbon To load ribbon, refer to Figure 8 (for the 90XiIII, 96XiIII, and 140XiIII) and Figure 9 (for the 170XiIII and 220XiIII). For more detailed information, refer to the instructions that begin on page 39.
Operator Controls POWER Switch The POWER switch is located at the back of the printer above the power cord and fuse. Turn on the printer. Front Panel The step-by-step instructions in this section tell you which keys to press and what appears on the liquid crystal display (LCD) during the calibration procedure. For a more detailed explanation of the front panel keys and lights (as shown in Figure 10), refer to the instructions that begin on page 24.
Configuring the Printer The configuration procedure in the next table contains the information you need to get your printer up and running, but it is not comprehensive. Refer to page 43 for more information. n Enter the configuration mode by pressing the SETUP/EXIT key at the “PRINTER READY” display. NOTE: You will need to press the NEXT/SAVE key more than once to advance to some of the displays.
Press - Display Shows Action/Explanation PRINTER READY Normal printer operation. DARKNESS Press the BLACK OVAL keys to increase or decrease the print darkness setting. (You may need to change this setting when you print your label.) PRINT MODE Press the BLACK OVAL keys to select tear-off, peel-off, cutter, or rewind mode. MEDIA TYPE Press the BLACK OVAL keys to select continuous or non-continuous media type.
Media and Ribbon Calibration NOTE: All steps must be performed in the following procedure, even if only one sensor needs to be adjusted. 1. Press the SETUP/EXIT key. 2. Press the NEXT/SAVE key until “MEDIA AND RIBBON CALIBRATE” displays. 3. To start the calibration procedure, press the RIGHT BLACK OVAL key. “LOAD BACKING CANCEL CONTINUE” displays. 4. Open the printhead.
5. Press the RIGHT BLACK OVAL key. The front panel display will show “REMOVE RIBBON CANCEL CONTINUE.” 6. Either remove the ribbon or slide it as far from the printer frame as possible. 7. Close the printhead, trapping the ribbon in this position. 8. Press the RIGHT BLACK OVAL key. The front panel will show “CALIBRATING PLEASE WAIT.” 9. When this part of the calibration process is completed, the display will read “RELOAD ALL CONTINUE.” 10. Open the printhead.
Printing a Test Label To print a test label: 1. Turn off the printer. 2. Press and hold the CANCEL key while turning on the printer. A configuration label, which shows the printer’s currently stored parameters, will print (similar to the one shown in Figure 12). Figure 12 If you encounter any problems while you are configuring or calibrating the printer or printing a test label, refer to Troubleshooting, which starts on page 75.
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Establishing Communication System Considerations Interfaces The method of interfacing this printer to a data source depends on the communication options installed in the printer. The standard interfaces are an RS-232/RS-422/RS-485 serial data port and a bi-directional parallel port. The optional ZebraNet PrintServer II enables printers to be connected to 10 BaseT Ethernet networks. In addition, the IBM® Twinax or IBM Coax option is available for those applications that require them.
When communicating via the parallel port (refer to Figure 14), the previously mentioned parameters are not considered. Refer to page 53 to configure the communication parameters for the printer. The values selected must be the same as those used by the host equipment connected to the printer. Printer Computer 36-pin male PC 25-pin female For serial and parallel pinout and technical information, refer to the Appendix on page 93.
Printer Basics Operator Controls This section discusses the functions of the various controls and indicators on the printer. The operator should become familiar with each of these functions. POWER Switch This switch is located at the back of the printer above the power cord and fuse. The POWER switch should be turned off before connecting or disconnecting any cables. External influences, such as lightning storms or noise on the power or data cables, may cause erratic printer behavior.
Front Panel Display The front panel display communicates operational status and programming modes and parameters.
Front Panel Keys Key Function Starts and stops the printing process. • If the printer is not printing: no printing can occur. • If the printer is printing: printing stops once the current label is complete. Press to remove error messages from the display. NOTE: Pause mode can also be activated via ZPL II (~PP, ^PP). Forces the printer to feed one blank label each time the key is pressed. • Printer not printing: one blank label immediately feeds.
Front Panel Lights NOTE: If two operating conditions occur simultaneously (for example, one that causes a light to be on constantly and one that causes the same light to flash), the light will flash. Light POWER Status The printer is off or power is not applied. On The printer is on. TAKE LABEL Off ERROR CHECK RIBBON PAPER OUT PAUSE DATA 26 Indication Off Normal operation. Flashing (Peel-off mode only.) The label is available. Printing is paused until the label is removed.
Roll Media Loading NOTE: A calibration must be performed when media and ribbon (if used) are first installed in the printer, or when a different type of media or ribbon is being used. Tear-Off Mode Refer to Figure 16. 1. Open the printhead. 2. Slide the media guide and media supply guide as far from the printer frame as possible. Flip down the media supply guide. 3. Load media as shown. 4. Flip up the media supply guide.
Peel-Off Mode NOTE: Rewind option required. Refer to Figure 17. 1. Remove the rewind plate from the front of the printer (if installed). Store it on the two mounting screws on the inside of the front panel. 2. Open the printhead. 3. Slide the media guide and media supply guide as far from the printer frame as possible. Flip down the media supply guide. 4. Load media as shown. 5. When loading media, allow approximately 36” (914 mm) of media to extend past the tear-off/peel-off bar.
Printhead lever Media supply guide Open Media Label Closed Media guide Tear-off/ peel-off bar Label backing Rewind spindle Rewind plate Hook Guide plate Figure 17 Zebra XiIII-Series User’s Guide 29
Rewind Mode (for Printers Without the Cutter Option) NOTE: Rewind option required. Refer to Figure 18. 1. Remove the rewind plate from its storage location in front of the print mechanism inside the media compartment. 2. Invert the rewind plate so that the lip on the attached hook plate points down. 3. Insert the hook plate lip a short distance (½"/13 mm) into the lower opening in the side plate. 4. Align the upper end of the rewind plate with the corresponding opening in the side plate.
Before closing the printhead, make sure: n The media is positioned against the inside guides. n The media is taut and parallel with itself and the pathway when wound onto the rewind spindle/core. 12. Close the printhead.
Cutter Mode NOTE: Cutter option required. Refer to Figure 19. 1. Open the printhead. 2. Slide the media guide and media supply guide as far from the printer frame as possible. Flip down the media supply guide. 3. Load media as shown. 4. Flip up the media supply guide. Slide in the media guide and media supply guide so they just touch, but not restrict, the edge of the roll. 5. Close the printhead. 6. The printer will automatically feed out and cut one label when the printer is turned on.
Printhead lever Media supply guide Open Media Closed Media guide Cutter Figure 19 Zebra XiIII-Series User’s Guide 33
Rewind Mode (for Printers With the Cutter Option) NOTE: Cutter and rewind options required. Refer to Figure 20. 1. Remove the rewind plate from its storage location in front of the print mechanism inside the media compartment. 2. Invert the rewind plate so that the lip on the attached hook plate points down. 3. Insert the hook plate lip a short distance (½"/13 mm) into the lower opening in the side plate. Slide in the rewind plate so that it stops against the printer’s main frame. 4.
Before closing the printhead, make sure: n The media is positioned against the inside guides. n The media is taut and parallel with itself and the pathway when wound onto the rewind spindle/core. 12. Close the printhead.
Fanfold Media Loading NOTE: A calibration must be performed when media and ribbon (if used) are first installed in the printer, or when a different type of media or ribbon is being used. Fanfold media feeds through either the bottom or rear access slot from outside the printer. Refer to Figures 21 and 22. 1. Open the printhead. 2. Slide the media guide as far from the printer frame as possible. 3. Load media as shown. If in cutter mode, route media through the cutter. 4.
Bottom supply Printhead lever Open Closed Media guide Media Figure 21 Rear supply Printhead lever Open Closed Media guide Media Figure 22 Zebra XiIII-Series User’s Guide 37
Removing the Label Backing Material Since the rewind spindle holds the backing from a standard-size media roll, we recommend that you perform this procedure whenever you change the media. To remove the backing material from the rewind spindle, follow these steps (you don’t need to turn off the printer for this procedure). 1. Unwind approximately 36” (914 mm) of backing from the rewind spindle. Cut it off at the spindle. 2. Pull out the hook. Slide the backing material off of the rewind spindle and discard.
Ribbon Loading To load ribbon, refer to Figure 23 (for the 90XiIII, 96XiIII, and 140XiIII) and Figure 24 (for the 170XiIII and 220XiIII) and follow the procedure below. NOTE: Use ribbon that is at least as wide as the media. The smooth backing of the ribbon protects the printhead from wear and premature failure due to excessive abrasion. (For direct thermal print mode, ribbon is not used and should not be loaded in the printer.) 1. Align the segments of the ribbon supply spindle. 2.
7. Before wrapping the ribbon around the ribbon take-up spindle, ensure that the arrow on the knob aligns with the indented notch (see Figure 25 inset). 8. Place the ribbon (with leader, if used) around the ribbon take-up spindle and wind counterclockwise for several turns. 9. Close the printhead.
Ribbon Removal 1. Break the ribbon as close to the ribbon take-up spindle as possible. 2. Refer to Figure 25. While holding the ribbon take-up spindle, turn the knob (1) clockwise until it stops. This will cause the ribbon release bars to pivot down (2), easing the spindle’s “grip” on the wound ribbon. 3. Slide the ribbon off of the ribbon take-up spindle.
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Configuration After you have installed the media and ribbon and the power-on self test (POST) is complete, the front panel display will show “PRINTER READY.” (If the printer fails its POST, refer to page 81.) You may now set printer parameters for your application using the front panel display and the five keys directly below it. NOTE: Printers that are operating on an IP network can be quickly configured via ZebraNet WebView (optional ZebraNet PrintServer II required).
Changing Password-Protected Parameters Certain parameters are password-protected by factory default. CAUTION: Do not change password-protected parameters unless you are sure you know what you are doing! If they are set incorrectly, these parameters could cause the printer to function in an unpredictable way. The first attempt to change one of these parameters (pressing one of the BLACK OVAL keys) will require you to enter a four-digit password. This is done via the “ENTER PASSWORD” display.
Leaving the Setup Mode You can leave the program mode at any time by pressing the SETUP/EXIT key. The “SAVE CHANGES” display will appear. There are five choices, described below. Pressing the LEFT or RIGHT BLACK OVAL key displays other choices and pressing the NEXT/SAVE key selects the displayed choice. n PERMANENT - Permanently saves the changes. Values are stored in the printer even when power is turned off. n TEMPORARY - Saves the changes until changed again or until power is turned off.
Configuration and Calibration Sequence Press ---- Display Shows PRINTER READY Action/Explanation Normal printer operation. Setting Print Parameters DARKNESS Adjusting Print Darkness Press the RIGHT BLACK OVAL key to increase darkness. Press the LEFT BLACK OVAL key to decrease darkness. Default: +10 Range: 0 to +30 Darkness settings are dependent upon a variety of factors including ribbon type, media, and the condition of the printhead. You may adjust the darkness for consistent high-quality printing.
Press Display Shows Action/Explanation MEDIA TYPE Setting Media Type Press the RIGHT or LEFT BLACK OVAL key to display other choices. Default: Continuous Selections: Continuous, non-continuous This parameter tells the printer the type of media you are using. Selecting continuous media requires that you include a label length instruction in your label format (^LLxxxx if you are using ZPL or ZPL II).
Press 48 Display Shows Action/Explanation PRINT WIDTH Setting Print Width Press the RIGHT BLACK OVAL key to increase the value, press the LEFT BLACK OVAL key to decrease the value. To change the unit of measurement, press the LEFT BLACK OVAL key until the unit of measurement is active, then press the RIGHT BLACK OVAL key to toggle to a different unit of measure (inches, mm, or dots). Default:, Range: The default and range of acceptable values vary depending on what printer you have.
Listing Printer Information Press Display Shows Action/Explanation LIST FONTS List Fonts Press the RIGHT BLACK OVAL key to print a label listing all of the available fonts. This selection is used to print a label that lists all of the fonts currently available in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM, FLASH memory, font EPROMs, or font cards.
Press 50 Display Shows Action/Explanation INITIALIZE CARD Initialize Memory Card CAUTION: Perform this operation only when it is necessary to erase all previously stored information from the optional memory card. Press the NEXT//SAVE key to bypass this function. 1. Press the RIGHT BLACK OVAL key to select “YES.” If your printer is set to require a password, you will now be prompted to enter the password. Enter the password and then press the NEXT/SAVE key. 2. The display will ask “INITIALIZE CARD?”.
Media and Ribbon Sensor Calibration NOTE: Before you begin this procedure, make sure that the maximum length is set to a value equal to or greater than the length of the labels you are using. If the maximum length is set to a lower value, the calibration process will assume that continuous media is in the printer. See page 48 for more information. There are two different types of calibration that can be performed by the printer: 1) Standard Calibration.
Press Display Shows MEDIA AND RIBBON CALIBRATE Action/Explanation Media and Ribbon Sensor Sensitivity Press NEXT/SAVE to skip the calibration procedure and continue with the host port selection parameters that follow. Press the RIGHT BLACK OVAL key to start the calibration procedure. This procedure is used to adjust the sensitivity of the media and ribbon sensors. NOTE: The procedure must be followed exactly as presented. All steps must be performed even if only one of the sensors requires adjustment.
Setting Communication Parameters Communication parameters must be set correctly for the printer to communicate with the host. These parameters make sure that the printer and host are “speaking the same language.” All communications parameters are password protected. Press Display Shows Action/Explanation PARALLEL COMM Setting Parallel Communications Press the RIGHT or LEFT BLACK OVAL key to display other choices.
Press 54 Display Shows Action/Explanation PARITY Setting Parity Press the RIGHT or LEFT BLACK OVAL key to display other choices. Default: Even Selections: Even, odd, none The parity of the printer must match the parity of the host for accurate communications to take place. Select the parity that matches the one being used by the host. STOP BITS Setting Stop Bits Press the RIGHT or LEFT BLACK OVAL key to display other choices.
Press Display Shows Action/Explanation NETWORK ID Setting Network ID Press the LEFT BLACK OVAL key to move to the next digit position, press the RIGHT BLACK OVAL key to increase the value of the digit. Default: 000 Range: 000 - 999 Network ID is used to assign a unique number to a printer used in an RS-422/RS-485 network. This gives the host the means to address a specific printer. If the printer is used in a network, you must select a network ID number. This does not affect TCP/IP or IPX networks.
Selecting Prefix and Delimiter Characters Prefix and delimiter characters are 2-digit hex values used within the ZPL/ZPL II formats sent to the printer. The printer uses the last prefix and delimiter characters sent to it, whether from a ZPL II instruction or from the front panel. NOTE: DO NOT use the same hex value for the control, format, and delimiter character. The printer needs to see different characters to function properly.
Selecting ZPL Mode Press Display Shows ZPL MODE Action/Explanation Selecting ZPL Mode Press the RIGHT or LEFT BLACK OVAL key to display other choices. Default: ZPL II Selections: ZPL II, ZPL The printer will remain in the selected mode until it is changed by this front panel instruction or by using a ZPL/ZPL II command. The printer accepts label formats written in either ZPL or ZPL II. This eliminates the need to rewrite any ZPL formats you already have.
Label Positioning Parameters Press 58 Display Shows Action/Explanation BACKFEED Backfeed Sequence Press the RIGHT or LEFT BLACK OVAL key to display other choices. Default: Default (90%) Selections: Default, after, before, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, off This parameter establishes when and how much label backfeed occurs after a label is removed or cut in the peel-off, cutter, and applicator modes. It has no effect in rewind or tear-off modes.
Press Display Shows Action/Explanation HEAD TEST COUNT Setting the Head Test Count Press the LEFT BLACK OVAL key to move to the next digit position, press the RIGHT BLACK OVAL key to change the value of the digit. Default: 0000 (disables the test) Range: 0000 to 9999 The printer periodically performs a test of the printhead functionality, called a “printhead test” or “head test.” This parameter establishes how many labels are printed between these internal tests.
Press Display Shows APPLICATOR PORT Action/Explanation Setting the Applicator Port Press the RIGHT or LEFT BLACK OVAL key to display other choices. Default: Off Selections: Off, mode 1, mode 2, mode 3, mode 4 Determines the action of the verifier port. • Off: The applicator port is off. • Mode 1: Asserts the ~END_PRINT signal low while the printer is moving the label forward. • Mode 2: Asserts the ~END_PRINT signal high while the printer is moving the label forward.
Press Display Shows Action/Explanation LCD ADJUST LCD Display Adjustment Press the LEFT BLACK OVAL key to decrease the value (reduce brightness), press the RIGHT BLACK OVAL key to increase the value (increase brightness). Range: 00 to 19 This parameter allows you to adjust the brightness of your display if your display is difficult to read. FORMAT CONVERT Format Convert Press the RIGHT or LEFT BLACK OVAL key to display other choices.
Press Display Shows Action/Explanation IP RESOLUTION* IP Resolution Press the RIGHT or LEFT BLACK OVAL key to display other choices. Default: Dynamic Selections: Dynamic, permanent Depending on the selection, allows either the user (”permanent”) or the server (”dynamic”) to select the IP address. For more information, refer to ZebraNet Networking: PrintServer II Installation and User’s Guide. IP PROTOCOLS* IP Protocols Press the RIGHT or LEFT BLACK OVAL key to display other choices.
Press Display Shows LANGUAGE Action/Explanation Selecting the Display Language Press the RIGHT or LEFT BLACK OVAL key to display other choices. Default: English Selections: English, Spanish, French, German, Italian, Norwegian, Portuguese, Swedish, Danish, Spanish 2, Dutch, Finnish, Custom This parameter allows you to change the language used on the front panel display. You have now completed the entire configuration and calibration sequence. You may either press the NEXT/SAVE key or the SETUP/EXIT key.
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Routine Care and Adjustment Cleaning The following table provides a brief cleaning schedule. Specific cleaning procedures are provided on the following pages.
Cleaning the Exterior The exterior surfaces of the printer may be cleaned with a lint-free cloth. Do not use harsh or abrasive cleaning agents or solvents. If necessary, a mild detergent solution or desktop cleaner may be used sparingly. Cleaning the Interior Inspect this area after every four rolls of media. Remove any dirt and lint from the interior of the printer using a soft bristle brush and/or vacuum cleaner.
4. Rotate the platen roller and clean thoroughly with solvent and an applicator. 5. Brush/vacuum any accumulated paper lint and dust away from the rollers. 6. Reload ribbon and/or media, and close and the printhead. Printhead lever Printhead Black mark sensor Ribbon sensor Label available sensors Platen roller Tear-off/peel-off bar Figure 27 Cleaning the Sensors The media, ribbon, and label available sensors should be cleaned on a regular basis to ensure proper operation of the printer.
Cleaning the Snap Plate Clean the snap plate to remove label adhesive or a label that has adhered to the underside of the snap plate. Refer to Figure 28. 1. Insert a small-blade screwdriver or similar tool into the loop on the left side of the snap plate. Lift the snap plate. CAUTION: Use care to not bend, twist, or otherwise deform the loops! 2. Repeat step one on the right side of the snap plate. 3. Remove the snap plate from the printer. 4. Clean the snap plate with cleaning solvent and a soft cloth.
Loop Loop Snap plate Figure 28 Loop Slot Tab Loop Slot Tab Figure 29 Zebra XiIII-Series User’s Guide 69
Cleaning the Cutter Module (For printers equipped with the optional cutter.) If labels are not being cut properly or if the cutter jams with labels, turn off the printer power and unplug the printer. Then, clean the stationary cutter blade with cleaning solvent. This will remove label adhesive and/or paper debris. If further cutter cleaning is necessary, or if the cutter continues to perform unsatisfactorily, contact an authorized service technician.
4. Snap the fuse holder back into position. 5. Reconnect the power cord. If the new fuse fails right away, the printer has an internal component failure and must be repaired.
Adjustments Toggle Positioning Both toggles should be positioned so that they provide even pressure on the media. The toggles are positioned by sliding them to the desired location. On media too narrow to accommodate both toggles, or if you are using a 90 or 96 XiIII printer, position one toggle over the center of the media and decrease the pressure on the unused toggle. NOTE: Make sure that the toggle pressure is even across the width of the media. Otherwise, the media and/or ribbon may “drift.
Printhead Pressure Adjustment This adjustment may be necessary if printing is too light on one side or if thick media is used. Refer to Figure 32. 1. Perform the toggle positioning procedure. If the problem is solved, you may stop here; otherwise, continue with the rest of this procedure. 2. Print some labels at 2.4"/61 mm per second (1”/25.4 mm for the 96 XiIII) by running the PAUSE key self test (see page 83). 3. While printing labels, lower the darkness setting until a gray level of printing is seen. 4.
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Troubleshooting LED Error Conditions and Warnings Error Condition Ribbon Out Problem Solution In thermal transfer mode, the ribbon is not loaded or loaded incorrectly. Load the ribbon correctly. See “Ribbon Loading” on page 39. In thermal transfer mode, the ribbon sensor is not sensing correctly loaded ribbon. Perform the media and ribbon sensor calibration (see page 17).
Error Condition Head Open Problem The printhead is not fully closed. Solution Close the printhead. Error Condition Head Element Bad Problem Solution If the failed elements impact your printing application, One or more of the printhead elements replace the printhead. To override this error, disable have failed the printhead element test. the head test count feature on the front panel by defaulting the value to “0000.” See page 59. Warning Ribbon In Problem The ribbon is loaded.
Warning Head Cold Problem The printhead is under temperature. Solution Continue printing while the printhead reaches the correct operating temperature. If the error remains, the environment may be too cold for proper printing. Relocate the printer to a warmer area. Warning Cutter Jammed Problem Cutter blade is in the media path. Solution Turn off the printer power and unplug the printer. Inspect the cutter module for debris and clean as needed following the cleaning instructions on page 70.
Print Quality Problems General Print Quality Issues Problem Solution You are using an incorrect media and Consult your authorized Zebra reseller/distributor for ribbon combination for your application. information and advice. The printer is set at the incorrect print speed. For optimal print quality, set the print speed to the lowest possible setting via ZPL II, the driver, or the software. The printer is set at the incorrect darkness level.
Wrinkled Ribbon Problem Solution The ribbon is not loaded correctly. Load the ribbon correctly. See “Ribbon Loading” on page 39. The darkness setting is incorrect. Set the darkness to the lowest possible setting for good print quality. See “Darkness” on page 46. Set the pressure to the minimum required for good Incorrect printhead pressure or balance. print quality. See “Printhead Pressure Adjustment” on page 73. The media is not feeding correctly. It is “walking” from side to side.
A label format was sent to the printer. Several labels print, then the printer skips, misplaces, misses, or distorts the image on the label. Problem The host is set to EPP parallel communications. Solution Change the settings on the computer host to standard parallel communications. Ensure that the flow control settings match. The serial communication settings are incorrect. Check the communication cable length. See page 22 for requirements.
Printer Diagnostics Power-On Self Test A power-on self test (POST) is performed automatically each time the printer is turned on. During this test sequence, the front panel lights and liquid crystal display monitor the progress of the POST. If the printer fails any of these tests, the word “FAILED” will be added to the display. If this occurs, notify an authorized Zebra reseller.
CANCEL Key Self Test This self test prints a listing of the configuration parameters currently stored in the printer’s memory. See Figure 33 (depending on the options ordered, your label may look different). 1. Turn the printer off. 2. Press and hold the CANCEL key while turning on the power. The configuration may be changed either temporarily (for specific label formats or ribbon and label stock) or permanently (by saving the new parameters in memory).
PAUSE Key Self Test This self test can be used to provide the test labels required when making adjustments to the printer’s mechanical assemblies. See the sample printout in Figure 34. 1. Turn off the printer. 2. Press and hold the PAUSE key while turning on the power. n The initial self test prints 15 labels at 2.4"/61 mm per second (1”/25.4 mm for the 96 XiIII) per second, then automatically pauses the printer. Each time the PAUSE key is pressed, an additional 15 labels print.
FEED Key Self Test See Figure 35. 1. Turn off the printer. 2. Press and hold the FEED key while turning on the power. The FEED key self test prints out at various darkness settings above and below that of the darkness value shown on the configuration label. Look at these labels and determine which one has the best darkness setting for your application. This value can be entered into the printer by setting the darkness during the configuration procedure. Refer to page 46 for more information.
FEED Key and PAUSE Key Self Test 1. Turn off the printer. 2. Press and hold the FEED and PAUSE keys while turning on the power. Performing this self test temporarily resets the printer configuration to the factory default values. These values will be active only until power is turned off unless you save them permanently in memory. Communications Diagnostics Test This test is controlled from the front panel display. Refer to page 55. A typical printout from this test is shown in Figure 36.
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Specifications NOTE: Printer specifications are subject to change without notice. Media Handling n Tear-off mode: Labels are produced in strips. n Peel-off mode: Labels are dispensed and peeled from the liner as needed. n Cutter mode: Labels are printed and individually cut. n Rewind mode: Labels are rewound internally. Options n n n n n n n n n n n Cutter Rewind Cutter-rewind Cutter tray Media supply spindle (1.
Zebra Programming Language (ZPL II®) n n n n n n n n n n Downloadable graphics, scalable and bitmap fonts, and label formats Object copying between memory areas (RAM, memory card, and internal FLASH) Code Page 850 character set Adjustable print cache Data compression Automatic virtual input buffer management Automatic memory allocation Format inversion Mirror image printing Four-position field rotation (0º, 90º, 180º, and 270º) n n n n n n n n n n Slew command Programmable quantity with print, paus
General Specifications General Specifications Height 90/96XiIII 140XiIII 170XiIII 220XiIII 15.5" 393.7 mm 15.5" 393.7 mm 15.5" 393.7 mm 15.5" 393.7 mm Width 9.15" 232.4 mm 11.15" 283.2 mm 13.15" 334.4 mm 15.65" 397.5 mm Depth 19.5" 495.3 mm 19.5" 495.3 mm 19.5" 495.3 mm 19.5" 495.3 mm Weight (without options) 50 lb 22.7 kg General (auto adjusting) Electrical Printing PAUSE test label at Power consumption slowest speed Printer idle 67 lb 30.5 kg 72 lb 32.
Printing Specifications Printing Specifications Resolution 90XiIII 96XiIII 140XiIII 170XiIII 220XiIII 300 dots/inch (12 dots/mm) 600 dots/inch (23.5 dots/mm) 203 dots/inch (8 dots/mm) 300 dots/inch (12 dots/mm) 203 dots/inch (8 dots/mm) 0.0033” x 0.0039” (.084 x .100 mm) 0.0016” x 0.0016” (.042 x .042 mm) 0.0049” x 0.0049” (.125 x .125 mm) 0.0033” x 0.0039” (.084 x .100 mm) 0.0049” x 0.0049” (.125 x .125 mm) 0.12" ± .035" (3 mm ± .89 mm) 0.12" ± .035" (3 mm ± .89 mm) 0.10" ± .035" (2.
Media Specifications Media Specifications Tear-off Minimum label length* 90/96XiIII 0.7" (18 mm) 140XiIII 170XiIII 220XiIII 0.7" (18 mm) 0.7" (18 mm) 0.7" (18 mm) Peel-off 0.5" (13 mm) 0.5" (13 mm) 0.5" (13 mm) 0.5" (13 mm) Cutter 1.5" (38 mm) 1.5" (38 mm) 1.5" (38 mm) 1.5" (38 mm) Rewind 0.25" (6 mm) 0.25" (6 mm) 0.25" (6 mm) 0.25" (6 mm) Total media width (label + liner, if any) Minimum 0.79" (20 mm) 1.57” (40 mm) 2.00” (51 mm) 4.25” (108 mm) Maximum 3.54" (90 mm) 5.
Power Line Cord Specifications n The overall length must be less than 9.8 feet (3.0 meters). n It must be rated for at least 5 A, 250 V. n The chassis ground (earth) MUST be connected to assure safety and reduce electromagnetic interference. The ground connection is handled by the third wire (earth) in the power line cord. See Figure 37. n The AC power plug and IEC 320 connector must bear the certification mark of at least one of the known international safety organizations shown in Figure 38.
Appendix Printer Interface Technical Information RS-232/RS-422/RS-485 Serial Data Port The connections for these standard interfaces are made through the DB25S connector on the rear panel. For all RS-232 input and output signals, the printer follows both the Electronics Industries Association’s (EIA) RS-232 specifications and the Consultative Committee for International Telegraph and Telephone (CCITT) V.24 standard signal level specifications.
RS-232 connector (DTE) rear panel DB-25S +5 V F1 1 Amp 1 FG (frame ground) 2 TXD (transmit data) output 3 RXD (receive data) input 4 RTS (request to send) output 6 DSR (data set ready) input 7 SG (signal ground) 9 +5 VDC source 20 DTR (data terminal ready) output Figure 39 RS-232 Interconnections The printer is configured as Data Terminal Equipment (DTE). Figure 39 illustrates the internal connections of the printer’s RS-232 connector.
DB-9S connector to computer DB-25P connector to printer DCD FG RXD TXD TXD DTR RXD SG RTS DSR DSR RTS SG CTS DTR RI Figure 40 When the printer is connected via its RS-232 interface to Data Communication Equipment (DCE) such as a modem, use a standard RS-232 (straight-through) interface cable. Figure 41 illustrates the connections required for this cable.
Male DB-25 to printer Frame ground Signal ground ref. Data input B(-) Data output B(-) Data input A(+) Data output A(+) 1 11 13 14 16 19 Figure 42 RS-422/RS-485 Interconnections The printer may be connected to a host by either an RS-422 or an RS-485 interface. The DB-25 connector on the rear of the printer uses specific pins for this purpose. Figure 42 illustrates the required cable wiring for interconnecting to the printer’s DB-25 connector.
Parallel Data Port A standard 36-pin parallel connector is available at the rear of the printer for connection to the data source. Under normal circumstances, data sent from the printer to the host in response to a “Printer Status Request” command is sent through the RS-232 serial port. However, if the host has a properly configured IEEE-1284 parallel port that is recognized by the printer, status information will be returned through the parallel port.
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Index A D Adjustments Media sensor position . . . . . . . . 73 Printhead pressure . . . . . . . . . . 73 Toggle positioning . . . . . . . . . . 72 Damage, reporting . . . . . . . . . . . . 2 Data specifications. . . . . . . . . . . . 21 F B FEED key and PAUSE key self test. . . 85 Bar codes . . . . . . . . . . . . . . . . 88 FEED key self test . . . . . . . . . . . . 84 Black mark media sensor . . . . . . . . 12 Front panel display . . . . . . . . . . . 24 Front panel keys . . . . . . . . . . . . .
M P Maintenance manual . . . . . . . . . . . 1 Parallel port technical information . . . 97 Media handling . . . . . . . . . . . . . 87 Passwords . . . . . . . . . . . . . . . . 44 Media loading Cutter . . . . . . . . . Peel-off . . . . . . . . Rewind (with cutter) . . Rewind (without cutter) Tear-off . . . . . . . . PAUSE key self test . . . . . . . . . . . 83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 28 34 30 27 Media loading, fanfold . . . . . . . . .
Power-on. . . . . . . . . . . . . . . 81 Serial port technical information . . . . 93 Software configuration . . . . . . . . . 16 Specifications Bar codes . . . General. . . . . Media . . . . . Media handling Options. . . . . Power line cord Printing . . . . Ribbon . . . . . ZPL II . . . . . U Unpacking and inspection . . . . . . . . 2 Upper media sensor adjustment . . . . . 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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