Zebra® Xi4™ User Guide
© 2009 ZIH Corp. The copyrights in this manual and the software and/or firmware in the printer described therein are owned by ZIH Corp. Unauthorized reproduction of this manual or the software and/or firmware in the printer may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability. This product may contain ZPL®, ZPL II®, and ZebraLink™ programs; Element Energy Equalizer® Circuit; E3®; and Monotype Imaging fonts.
Declaration of Conformity Declaration of Conformity We have determined that the Zebra printers identified as the Xi4™ Series 110Xi4™, 140Xi4™, 170Xi4™, 220Xi4™ manufactured by: Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills, Illinois 60061-3109 U.S.A.
Declaration of Conformity Compliance Information Compliance Information FCC Compliance Statement This device complies with Part 15 rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference, and 2. This device must accept any interference received, including interference that may cause undesired operation.
Contents Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Compliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install Control Panel Keypad Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Overview. . . .
Contents 5 • Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Lubrication . . . . . . . . . . . .
Contents Print Specifications by Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Xi4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140Xi4, 170Xi4, and 220Xi4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Document This section provides you with contact information, document structure and organization, and additional reference documents. Contents Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Document Who Should Use This Document Who Should Use This Document This User Guide is intended for use by any person who needs to perform routine maintenance, upgrade, or troubleshoot problems with the printer. How This Document Is Organized The User Guide is set up as follows: P1009874-001 Section Description Introduction on page 15 This section provides a high-level overview of the printer and its components.
About This Document Contacts Contacts Technical Support via the Internet is available 24 hours per day, 365 days per year. Web Site: www.zebra.com E-mail Back Technical Library: E-mail address: emb@zebra.com Subject line: Emaillist Self Service Knowledge Base: www.zebra.com/knowledgebase Online Case Registration: www.zebra.
About This Document Document Conventions Document Conventions The following conventions are used throughout this document to convey certain information. Alternate Color (online only) Cross-references contain hot links to other sections in this guide. If you are viewing this guide online in .pdf format, you can click the cross-reference (blue text) to jump directly to its location. LCD Display Examples Text from a printer’s Liquid Crystal Display (LCD) appears in Bubbledot ICG font.
About This Document Document Conventions Illustration Callouts Callouts are used when an illustration contains information that needs to be labeled and described. A table that contains the labels and descriptions follows the graphic. Figure 1 provides an example.
About This Document Document Conventions Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ______________
1 Introduction This section provides a high-level overview of the printer and its components. Contents Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction Printer Components Printer Components Figure 2 shows the standard components inside the media compartment of your printer. Depending on printer model and the installed options, your printer may look slightly different. Familiarize yourself with these components before continuing with the printer setup procedure.
Introduction Control Panel Control Panel All controls and indicators for the printer are located on the control panel (Figure 3). • The control panel Liquid Crystal Display (LCD) shows the operating status and printer parameters. • The control panel buttons are used to control the printer operations and to set parameters. • The control panel lights (LEDs) show the printer’s operating status or indicate which control panel buttons are active.
Introduction Control Panel 5 LCD The control panel LCD functions differently in different printer modes. • In Operating mode, the LCD displays the printer’s status, sometimes in conjunction with a control panel light. • In Pause mode, the printer stops printing temporarily. • In Setup mode, you can use the control panel LCD to view or modify printer parameters (see Standard Control Panel Parameters on page 91).
2 Printer Setup This section provides the tasks that you must complete and the issues that you must consider before you load and configure your printer. Contents Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Setup Before You Begin Before You Begin Review this checklist, and resolve any issues before you set up or use your printer. Unpack and Inspect the Printer Have you unpacked the printer and inspected it for damage? If you have not, see Unpack and Inspect the Printer on page 21. Select a Site Have you selected an appropriate location for the printer? If you have not, see Select a Site for the Printer on page 22.
Printer Setup Handling the Printer Handling the Printer This section describes how to handle your printer. Unpack and Inspect the Printer When you receive the printer, immediately unpack it and inspect for shipping damage. • Save all packing materials. • Check all exterior surfaces for damage. • Raise the media door, and inspect the media compartment for damage to components. If you discover shipping damage upon inspection: • Immediately notify the shipping company and file a damage report.
Printer Setup Select a Site for the Printer Select a Site for the Printer Consider the following when selecting an appropriate location for your printer. Select a Surface Select a solid, level surface of sufficient size and strength to accommodate the printer and other equipment (such as a computer), if necessary. The choices include a table, countertop, desk, or cart. For the printer’s weight and dimensions, see General Specifications on page 158.
Printer Setup Select a Data Communication Interface Select a Data Communication Interface Table 3 provides basic information about data communication interfaces that you can use to connect your printer to a computer. You may send label formats to the printer through any data communication interface that is available. Select an interface that is supported by both your printer and your computer or your Local Area Network (LAN).
Printer Setup Select a Data Communication Interface Data Cables and Wireless Cards You must supply all data cables or wireless cards for your application. Data Cables Ethernet cables do not require shielding, but all other data cables must be fully shielded and fitted with metal or metallized connector shells. Unshielded data cables may increase radiated emissions above the regulated limits. To minimize electrical noise pickup in the cable: • Keep data cables as short as possible.
Printer Setup Select a Data Communication Interface Table 4 • Connecting the Printer to a Computer or Network 3/12/09 Interface Connection and Configuration RS-232 Serial The baud rate, number of data and stop bits, the parity, and the XON/XOFF or DTR control must match those of the host computer. See Standard Control Panel Parameters on page 91 to view or change these parameters. IEEE 1284 Bidirectional Parallel No additional configuration is necessary.
Printer Setup Select a Data Communication Interface Table 4 • Connecting the Printer to a Computer or Network (Continued) Interface Connection and Configuration USB No additional configuration is necessary. Caution • Be careful not to plug the USB cable into the wired Ethernet print server connector on the printer because doing so will damage the connector. Twinax/Coax P1009874-001 No additional configuration is necessary. To purchase this option, contact your authorized Zebra reseller.
Printer Setup Select a Data Communication Interface Table 4 • Connecting the Printer to a Computer or Network (Continued) 3/12/09 Interface Connection and Configuration Internal wired Ethernet print server Refer to the ZebraNet 10/100 Print Server User and Reference Guide for configuration instructions. A copy of this manual is available at http://www.zebra.com/manuals or on the user CD that came with your printer.
Printer Setup Connect the Printer to a Power Source Connect the Printer to a Power Source The AC power cord must have a three-prong female connector on one end that plugs into the mating AC power connector at the rear of the printer. If a power cable was not included with your printer, refer to Power Cord Specifications on page 29. Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation.
Printer Setup Connect the Printer to a Power Source Power Cord Specifications Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation. This cord must use an IEC 320 female connector and the appropriate region-specific, three-conductor grounded plug configuration. Depending on how your printer was ordered, a power cord may or may not be included.
Printer Setup Install Control Panel Keypad Cover Install Control Panel Keypad Cover A protective cover for the control panel keypad is provided with your printer (Figure 6). Install this optional cover if your printer will operate in a moist or dirty environment. This will help to protect the keypad from damage. Figure 6 • Control Panel Keypad Cover To install the control panel keypad cover, complete these steps: 1. Remove the paper backing from the control panel keypad cover to expose the adhesive.
Printer Setup Types of Media Types of Media Important • Your printer can use various types of media: • Standard media—Most standard media uses an adhesive backing that sticks individual labels or a continuous length of labels to a liner. • Tag stock—Tags are usually made from a heavy paper. Tag stock does not have adhesive or a liner, and it is typically perforated between tags.
Printer Setup Types of Media Table 5 • Roll and Fanfold Media Media Type Non-Continuous Roll Media How It Looks Description Roll media is wound on a 3-in. (76-mm) core. Individual labels are separated by one or more of the following methods: • Web media separates labels by gaps, holes, or notches. • Black mark media uses pre-printed black marks on the back side of the media to indicate label separations.
Printer Setup Ribbon Overview Ribbon Overview Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is transferred to the media during the thermal transfer process. The media determines whether you need to use ribbon and how wide the ribbon must be. When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is narrower than the media, areas of the printhead are unprotected and subject to premature wear.
Printer Setup Ribbon Overview Adhesive Test If you have labels available, perform the adhesive test to determine which side of a ribbon is coated. This method works well for ribbon that is already installed. To perform an adhesive test, complete these steps: 1. Peel a label from its liner. 2. Press a corner of the sticky side of the label to the outer surface of the roll of ribbon. 3. Peel the label off of the ribbon. 4. Observe the results.
3 Operations This section provides the procedures for loading and calibrating the printer. Note • Complete the tasks and resolve the issues in Printer Setup on page 19 before operating the printer. Contents Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mode Descriptions and Printer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operations Print Modes and Printer Options Print Modes and Printer Options The printer can use different print modes and options for label removal (Table 6). Use a print mode that matches the media being used and the printer options available. For more information on the types of media, see Types of Media on page 31. To select a print mode, see Select Print Mode on page 93.
Operations Print Modes and Printer Options Media Paths Table 7 shows the media paths for print mode and printer option combinations using roll media. Fanfold media uses the same print modes and printer options as roll media. RFID printers can use all of these printer options and have the same media paths.
Operations Print Modes and Printer Options Table 7 • Media Paths for Print Modes with Various Printer Options (Continued) Print Mode Printer Option Cutter Cutter Rewind Rewind (without Cutter option) Media Path Red solid lines = media, Blue dotted lines = backing only P1009874-001 Xi4 User Guide 3/12/09
Operations Prepare the Media for Loading Prepare the Media for Loading You can use roll media or fanfold media in your printer. Roll media hangs on and is loaded from the media supply hanger. Fanfold media is stored away from or in the bottom of the printer and can drape across the media supply hanger. Roll Media To place roll media on the media supply hanger, complete these steps: 1. Raise the media door. 2. Remove and discard any tags or labels that are dirty or that are held by adhesives or tape.
Operations Prepare the Media for Loading 3. Insert the media into the printer. 110Xi4 Other Xi4 Models a. Pull out the media supply guide as far as it goes. a. Slide out and flip down the media supply guide. b. Place the roll of media on the media supply hanger. Push the roll as far back as it will go. b. Place the roll of media on the media supply hanger. Push the roll back as far as it will go. c. Slide in the media supply guide until it touches the edge of the roll. c.
Operations Prepare the Media for Loading Fanfold Media You can store fanfold media behind the printer (rear feed) or under the printer (bottom feed). Using the media supply hanger is optional. To load fanfold media, complete these steps: 1. Raise the media door. 2. Thread the fanfold media through the rear access slot (1) or the bottom access slot (2). If using... Then use this access slot...
Operations Prepare the Media for Loading 3. Do you wish to use the media supply hanger? If… Then… No Continue with the media loading procedure for the desired print mode. Yes a. Slide out and flip down the media supply guide. b. Drape the media over the media supply hanger. 4. Flip up the media supply guide, and then slide it in until it touches the edge of the media.
Operations Load Media in Tear-Off Mode Load Media in Tear-Off Mode Follow these instructions to operate the printer in Tear-Off mode. Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead. You are not required to turn off the printer power when working near an open printhead, but Zebra recommends it as a precaution.
Operations Load Media in Tear-Off Mode 5. Slide the outer media guide (1) all the way out. 1 6. If your printer includes a media dancer assembly (1), thread the media under the media dancer assembly roller. For all printers, thread the media under the media guide roller (2) and then the upper media sensor (3). Important • Make sure that you thread the media under these components. If you thread the media over the them, the media obstructs the ribbon sensor and causes a false RIBBON OUT error.
Operations Load Media in Tear-Off Mode 7. Push the media forward until it passes under the printhead assembly (1), under the snap plate (2), and then over the platen roller (3). 1 2 3 8. Align the media with the inner media guide (1). Slide in the outer media guide (2) until it just touches the edge of the media.
Operations Load Media in Tear-Off Mode 9. Tighten the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 10. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) clockwise until it locks into place.
Operations Load Media in Peel-Off Mode Load Media in Peel-Off Mode Peel-Off mode (Figure 8) advances one label at a time. The printer does not print another label until the first label is removed. The TAKE LABEL light flashes until the label is removed. The backing is wound on the rewind spindle, but the rewind plate is not used.
Operations Load Media in Peel-Off Mode Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead. You are not required to turn off the printer power when working near an open printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose all temporary settings, such as label formats, and you must reload them before you resume printing.
Operations Load Media in Peel-Off Mode 4. Open the printhead assembly by rotating the printhead-open lever (1) counter-clockwise. 1 5. Loosen the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 6. Slide the outer media guide (1) all the way out.
Operations Load Media in Peel-Off Mode 7. If your printer includes a media dancer assembly (1), thread the media under the media dancer assembly roller. For all printers, thread the media under the media guide roller (2) and then the upper media sensor (3). Important • Make sure that you thread the media under these components. If you thread the media over the them, the media obstructs the ribbon sensor and causes a false RIBBON OUT error. 3 2 1 8.
Operations Load Media in Peel-Off Mode 9. Extend approximately 36 in. (920 mm) of media out of the printer. Remove and discard the labels from this exposed media. 10. Remove the hook from the rewind spindle. 11. If you are using a core, slide it onto the rewind spindle until it is flush against the guide plate. Note • A core is not required.
Operations Load Media in Peel-Off Mode 12. Wind the media liner counterclockwise around the rewind spindle. a. Reinstall the hook. Insert the short end of the hook into the hole in the center of the adjusting nut (1). Insert the long end of the hook into the small hole on the guide plate (2). 2 1 b. Rotate the spindle counterclockwise several turns to wind the media liner over the hook and remove any slack. 13. Align the media with the inner media guide (1).
Operations Load Media in Peel-Off Mode 14. Tighten the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 15. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) clockwise until it locks into place. 2 1 The backing winds on the rewind spindle or core. 16. For instructions for removing the backing from the rewind spindle, see Remove Media Liner from the Rewind Spindle on page 66.
Operations Load Media in Cutter Mode Load Media in Cutter Mode A cutter is a rotating knife with a self-sharpening blade that is attached to the front of the printer. The cutter is used to cut individual labels as they are printed. Figure 9 shows the printer loaded with labels in Cutter mode.
Operations Load Media in Cutter Mode 3. Open the printhead assembly by rotating the printhead-open lever (1) counter-clockwise. 1 4. Loosen the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 5. Slide the outer media guide (1) all the way out.
Operations Load Media in Cutter Mode 6. If your printer includes a media dancer assembly (1), thread the media under the media dancer assembly roller. For all printers, thread the media under the media guide roller (2) and then the upper media sensor (3). Important • Make sure that you thread the media under these components. If you thread the media over the them, the media obstructs the ribbon sensor and causes a false RIBBON OUT error. 3 2 1 7. Caution • The cutter blade is sharp.
Operations Load Media in Cutter Mode 8. Align the media with the inner media guide (1). Slide in the outer media guide (2) until it just touches the edge of the media. 1 2 9. Tighten the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1).
Operations Load Media in Cutter Mode 10. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) clockwise until it locks into place.
Operations Load Media in Rewind Mode Load Media in Rewind Mode Rewind mode (Figure 10) allows the media to be wound on a core after printing. This section shows how to load media for Rewind mode in printers that do not have a Cutter option.
Operations Load Media in Rewind Mode Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead. You are not required to turn off the printer power when working near an open printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose all temporary settings, such as label formats, and you must reload them before you resume printing.
Operations Load Media in Rewind Mode 7. Insert media into the printer. See Prepare the Media for Loading on page 39 for instructions. 8. Open the printhead assembly by rotating the printhead-open lever (1) counter-clockwise. 1 9. Loosen the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 10. Slide the outer media guide (1) all the way out.
Operations Load Media in Rewind Mode 11. If your printer includes a media dancer assembly (1), thread the media under the media dancer assembly roller. For all printers, thread the media under the media guide roller (2) and then the upper media sensor (3). Important • Make sure that you thread the media under these components. If you thread the media over the them, the media obstructs the ribbon sensor and causes a false RIBBON OUT error. 3 2 1 12.
Operations Load Media in Rewind Mode 13. Extend approximately 36 in. (920 mm) of media out of the printer. Remove and discard the labels from this exposed media. 14. Remove the hook from the rewind spindle. 15. If you are using a core, slide it onto the rewind spindle until it is flush against the guide plate. Note • A core is not required. 16. Wind the media liner counterclockwise around the rewind spindle. 17. Reinstall the hook.
Operations Load Media in Rewind Mode 2 1 18. Rotate the spindle counterclockwise several turns to wind the media liner over the hook and remove any slack. 19. Align the media with the inner media guide (1). Slide in the outer media guide (2) until it just touches the edge of the media.
Operations Load Media in Rewind Mode 20. Tighten the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 21. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) clockwise until it locks into place. 2 1 The labels wind on the rewind spindle or core.
Operations Load Media in Rewind Mode Remove Media Liner from the Rewind Spindle Rewind mode uses the rewind spindle to wind media, while Peel-Off mode uses the rewind spindle to wind used liner. Remove the media or the liner from the rewind spindle each time that you change media. Important • It is not necessary to turn off the power to remove media or liner from the rewind spindle.
Operations Load Media in Rewind Mode 2. Pull out the spindle hook. 3. Slide the media or liner off of the rewind spindle.
Operations Load Ribbon Load Ribbon Use the instructions in this section to load ribbon for use with thermal transfer labels. For direct thermal labels, do not load ribbon in the printer. The ribbon path is slightly different for printers with ribbon dancers (Figure 11). Important • Use ribbon that is wider than the media to protect the printhead from wear. Ribbon must be coated on the outside.
Operations Load Ribbon 2. Align the segments of the ribbon supply spindle. 3. Orient the ribbon with the loose end unrolling clockwise. 4. Place the roll of ribbon on the ribbon supply spindle. Push the roll back as far as it will go. 5. A ribbon leader makes ribbon loading and unloading easier. Does your roll of ribbon have paper or something else attached to the end to serve as a ribbon leader? If… Then… Yes Continue with the next step. No a.
Operations Load Ribbon 6. Open the printhead assembly by rotating the printhead-open lever counter-clockwise. 7. Does your printer contain a ribbon dancer assembly? (See Figure 11 on page 68 for the ribbon dancer location.) If... Then... No Thread the ribbon over the media dancer assembly (1) and under the ribbon guide roller (2).
Operations Load Ribbon If... Then... Yes a. Thread the ribbon through the ribbon dancer. The ribbon must go under the upper roller (1) and then over the lower roller (2). b. Thread the ribbon under the ribbon guide roller (3). 3 2 1 8. Push the ribbon leader forward until it passes under the printhead assembly (1), over the snap plate (2), and then over the platen roller (3).
Operations Load Ribbon 9. Bring the ribbon leader over the upper ribbon roller (1) and then toward the ribbon take-up spindle (2). 1 2 10. Wind the ribbon leader and attached ribbon counterclockwise around the ribbon take-up spindle. 11. Rotate the spindle counterclockwise several turns to wind the ribbon and remove any slack.
Operations Load Ribbon 12. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) clockwise until it locks into place. 2 1 Remove Used Ribbon Remove used ribbon from the ribbon take-up spindle each time you change the roll of ribbon. To remove used ribbon, complete these steps: 1. Has the ribbon run out? 3/12/09 If the ribbon... Then Ran out Continue with the next step. Did not run out Cut or break the ribbon before the ribbon take-up spindle.
Operations Load Ribbon 2. While holding the ribbon take-up spindle, turn the ribbon release knob clockwise until it stops. The ribbon release bars pivot down, easing the spindle’s grip on the used ribbon. 3. Slide the used ribbon off of the ribbon take-up spindle and discard.
Operations Calibrate the Printer Calibrate the Printer Calibrate the printer when it is first put into service. Calibration allows the printer to establish the proper settings for the specific media and ribbon used in your application. You may calibrate the printer at other times as needed. Table 8 shows the different methods for calibration.
Operations Calibrate the Printer Table 8 • Types of Calibration (Continued) Type of Calibration Description When/How It Occurs Sensor Profile Calibration The printer auto-calibrates and prints a media sensor profile. Select the SENSOR PROFILE option on the control panel. See Print Sensor Profile on page 100 for instructions. Media and Ribbon Sensor Sensitivity Calibration One of the most common adjustments to printer settings.
Operations Adjust Transmissive Media Sensors Adjust Transmissive Media Sensors The transmissive media sensor assembly consists of two parts: a light source and a light sensor. The lower media sensor is the light source, and the upper media sensor is the light sensor. The media passes between the two parts. Adjust these sensors only when the printer cannot detect the top of the labels.
Operations Adjust Transmissive Media Sensors 3. Using a thin, flat-blade screwdriver, loosen the upper media sensor adjustment screw. Z X Y 4. Slide the upper media sensor along the slot to the desired position.
Operations Adjust Transmissive Media Sensors 5. Tighten the adjustment screw to secure the upper media sensor in its new position. Z X Y 6. Adjust the lower media sensor to match the new position of the upper media sensor. See Lower Media Sensor on page 80.
Operations Adjust Transmissive Media Sensors Lower Media Sensor After you adjust the upper media sensor, adjust the lower media sensor to match its new position. To adjust the lower media sensor, complete these steps: 1. Locate the lower media sensor assembly under the rear roller. The sensor is a spring clip holding a circuit board. 2. Slide the lower sensor until it is under the upper media sensor. Use the light that shines from the lower sensor to help align it with the upper sensor.
Operations Adjust Printhead Pressure and Toggle Position Adjust Printhead Pressure and Toggle Position Print quality depends on the labels and ribbon used as well as the toggle pressure and position. Make sure that your labels and ribbon are acceptable for your application. If they are, check the toggle position and then the printhead pressure. Toggle Position Adjustment You may need to adjust the toggles if printing is too light on one side or if thick labels are used.
Operations Adjust Printhead Pressure and Toggle Position Printhead Pressure Adjustment If positioning the toggles properly does not solve a print quality problem, try adjusting the printhead pressure. Maximize printhead life by using the lowest pressure that produces the desired print quality. Caution • Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads. To adjust printhead pressure, complete these steps: 1.
Operations Adjust Printhead Pressure and Toggle Position 4. Some media types require higher pressure to print well. For these media types, increase or decrease pressure using the lower knurled nuts (1) until the left and right edges of the printed area are equally dark. 1 5. Using the control panel, increase the darkness to the desired level. 6. Tighten the upper knurled nuts.
Operations Adjust Printhead Pressure and Toggle Position Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _________________________________________________________________________
4 Configuration This section describes the control panel parameters that are used to configure the printer for operation. Contents Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Enter and Use Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration Setup Mode Setup Mode After you have installed the media and ribbon and the Power-On Self Test (POST) is complete, the control panel displays PRINTER READY. You may now set printer parameters for your application using the control panel display and the buttons directly below it. If it becomes necessary to restore the initial printer defaults, see FEED and PAUSE Self Test on page 152.
Configuration Setup Mode Exit Setup Mode When you exit setup mode, you have several options for saving, changing, or not changing parameters. To leave Setup mode, complete these steps: 1. Press SETUP/EXIT. The LCD displays SAVE CHANGES. 2. Press PLUS (+) or MINUS (-) to display the save options: LCD Description PERMANENT Stores values in the printer even when power is turned off. TEMPORARY Saves the changes until power is turned off.
Configuration Change Password-Protected Parameters Change Password-Protected Parameters Certain parameters, including the communication parameters, are password-protected by factory default. Caution • Do not change password-protected parameters unless you have a complete understanding of the parameters’ functions. If the parameters are set incorrectly, the printer may function unpredictably. The first time that you attempt to change a password-protected parameter, the printer displays ENTER PASSWORD.
Configuration Print a Configuration Label Print a Configuration Label A configuration label lists the printer settings that are stored in configuration memory. After you load the media and ribbon (if necessary), print a configuration label as a record of your printer’s current settings. Keep the label to use when troubleshooting printing problems. To print a configuration label, complete these steps: 1. On the control panel, press SETUP/EXIT. 2.
Configuration Print a Network Configuration Label Print a Network Configuration Label If you are using a print server, you can print a network configuration label after the printer is connected to the network. To print a network configuration label, complete these steps: 1. On the control panel, press SETUP/EXIT. 2. Press NEXT/SAVE or PREVIOUS to scroll through the parameters until you reach LIST NETWORK. 3. Press PLUS (+) to confirm printing. A network configuration label prints (Figure 13).
Configuration Standard Control Panel Parameters Standard Control Panel Parameters Table 9 shows parameters in the order in which they are displayed when you press NEXT/SAVE after entering Setup mode. For parameters that do not appear in this table, see Additional Control Panel Parameters on page 113. Note • Your label preparation software or the printer driver may override adjustments made through the control panel. Refer to the software or driver documentation for more information.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 2 of 22) Language/Parameter Action/Explanation Adjust the Tear-Off Position This parameter establishes the position of the media over the tear-off/peel-off bar after printing. See Figure 14. Higher numbers move the media out (the tear line moves closer to the leading edge of the next label), and lower numbers move the media in (the tear line moves closer to the edge of the label just printed).
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 3 of 22) Language/Parameter Action/Explanation Select Print Mode This parameter tells the printer how printed labels will be removed. Make sure that you select a print mode that is compatible with your printer and printer options. For information about how the print modes work with different printer options, see Print Modes and Printer Options on page 36.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 4 of 22) Language/Parameter Action/Explanation Select Print Method The print method parameter tells the printer the method of printing that you want to use: direct thermal (no ribbon) or thermal transfer (using thermal transfer media and ribbon). Default Value: THERMAL-TRANS. Selections: THERMAL-TRANS., DIRECT THERMAL To change the value shown: 1. Press PLUS (+) or MINUS (-) to scroll through the options.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 5 of 22) Language/Parameter Action/Explanation Set Maximum Label Length This parameter is used during the media portion of the calibration process. Always set maximum label length to a value that is at least 1.0 in. (25.4 mm) greater than the actual label length (Figure 15). If the value is set to a smaller value than the label length, the printer assumes that continuous media is loaded, and the printer cannot calibrate.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 6 of 22) Language/Parameter Action/Explanation Set Early Warning for Maintenance When this feature is enabled, the printer provides warnings when the printhead needs to be cleaned. Default Value: MAINT. OFF Selections: MAINT. OFF, MAINTENANCE ON To change the Early Warning settings: When the LCD displays EARLY WARNING MAINTENANCE, press PLUS (+) or MINUS (-) to toggle between OFF and ON.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 7 of 22) Language/Parameter Action/Explanation Set Printhead Life for Early Warning This parameter appears only when Early Warning for Maintenance is enabled. Set this value to the number of inches of media that the printhead is expected to print. Default Value: 1,000,000 inches Range: 100 to 1,000,000 inches To change the value shown: Press MINUS (-) to move the cursor. 2.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 8 of 22) Language/Parameter Action/Explanation Print Counter Readings Prints a label that lists the odometer readings for the following: • the non-resettable counter • the two user-controlled counters • the Early Warning for Maintenance counters, which indicate when the printhead was last cleaned and the printhead life If the Early Warning for Maintenance feature is disabled, the counters related to it do not print.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 9 of 22) Language/Parameter Action/Explanation List Network Settings This option prints a network configuration label (see Figure 13 on page 90), which lists the settings for any print server that is installed. To print a network configuration label: 1. Press PLUS (+) to select PRINT.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 10 of 22) Language/Parameter Action/Explanation Print Sensor Profile A sensor profile shows sensor settings compared to actual sensor readings. This label (which will extend across several actual labels or tags) can be used to troubleshoot printing problems. To interpret the results of the sensor profile, see Sensor Profile on page 154.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 11 of 22) Language/Parameter Action/Explanation Calibrate Media and Ribbon Sensor Sensitivity Use this procedure to adjust sensitivity of media and ribbon sensors. Important • Follow this procedure exactly as presented. All of the steps must be performed even if only one of the sensors requires adjustment. You may press MINUS (-) at any step in this procedure to cancel the process.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 12 of 22) Language/Parameter Action/Explanation Set Serial Communications Select the communications port that matches the one being used by the host computer. This setting applies only when the serial port is used. Note • Select RS232 if you are using an external adapter to enable RS422/485 operation. Default Value: RS232 Selections: RS232, RS422/485, RS485 MULTIDROP To change the value shown: 1.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 13 of 22) Language/Parameter Action/Explanation Set Host Handshake This setting applies only when the serial port is used. The handshake protocol of the printer must match the handshake protocol of the host computer for communication to take place. Select the handshake protocol that matches the one being used by the host computer. Default Value: XON/XOFF Selections: XON/XOFF, DSR/DTR, RTS/CTS To change the value shown: 1.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 14 of 22) Language/Parameter Action/Explanation Set Control Prefix Character The printer looks for this two-digit hex character to indicate the start of a ZPL/ZPL II control instruction. Note • Do not use the same hex value for the control, format, and delimiter character. The printer must see different characters to work properly.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 15 of 22) Language/Parameter Action/Explanation Select ZPL Mode The printer remains in the selected mode until it is changed by this parameter or by using a ZPL/ZPL II command. The printer accepts label formats written in either ZPL or ZPL II, eliminating the need to rewrite any ZPL formats that already exist. See the ZPL Programming Guide for more information on the differences between ZPL and ZPL II.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 16 of 22) Language/Parameter Action/Explanation Select Head Close Option This parameter sets the action of the media when you close the printhead. Default Value (non-RFID printers): CALIBRATION Default Value (RFID printers): FEED Selections: CALIBRATION, LENGTH, SHORT CAL, NO MOTION, FEED • Calibration adjusts sensor levels and thresholds, determines length, and feeds the media to the next web.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 17 of 22) Language/Parameter Action/Explanation Adjust Left Position This parameter adjusts the print position horizontally on the label. Positive numbers adjust printing to the left by the specified number of dots. Negative numbers shift printing to the right. Default Value: 0000 Range: –9999 to +9999 dots To change the value shown: Press MINUS (-) to move the cursor. 2.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 18 of 22) Language/Parameter Action/Explanation Set the Verifier Port The auxiliary port is used to determine how the printer reacts to an online verifier. For more information on the operation of the optional verifier, refer to the documentation provided with that option. Default: OFF Selections: OFF, VER-RPRNT ERR, VER-THRUPUT • OFF: The verifier port is off.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 19 of 22) Language/Parameter Action/Explanation Set Applicator Error Signal When Printer Pauses When this option is enabled and the printer is paused, the printer sets the applicator error state. Default: ENABLED Selections: ENABLED, DISABLED To change the value shown: 1. Press PLUS (+) or MINUS (-) to toggle between the options.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 20 of 22) Language/Parameter Action/Explanation Set Reprint Mode When reprint mode is enabled, you can reprint the last label printed either by issuing the ~PR ZPL command or by pressing MINUS (-) on the control panel. Default Value: DISABLED Selections: ENABLED, DISABLED To change the value shown: 1. See next column Press PLUS (+) or MINUS (-) to toggle between the options.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 21 of 22) Language/Parameter Action/Explanation Select Format Convert Selects the bitmap scaling factor. The first number is the original dots per inch (dpi) value; the second, the dpi to which you would like to scale. Default Value: NONE Selections: NONE, 150 → 300, 150 → 600, 200 → 600, 300 → 600 To change the value shown: 1. Press PLUS (+) or MINUS (-) to scroll through the options.
Configuration Standard Control Panel Parameters Table 9 • Printer Parameters (Sheet 22 of 22) Language/Parameter Action/Explanation Select the Display Language This parameter changes the language displayed on the LCD. Each language selection is displayed in the language itself.
Configuration Additional Control Panel Parameters Additional Control Panel Parameters Additional parameters appear in the following situations. • When a Radio Frequency Identification (RFID) reader is installed. The 110Xi4 is RFID-ready, but it does not come with an RFID reader installed. For more information about purchasing the RFID option for these printers, contact your authorized Zebra reseller. • When a wired print server is installed in the printer.
Configuration Additional Control Panel Parameters Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ____
5 Routine Maintenance This section provides routine cleaning and maintenance procedures. Contents Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routine Maintenance Replacing Printer Components Replacing Printer Components Some printer components, such as the printhead and platen roller, may wear out over time and can be replaced easily. Regular cleaning may extend the life of some of these components. See Cleaning Schedule and Procedures on page 117 for the recommended cleaning intervals.
Routine Maintenance Cleaning Schedule and Procedures Cleaning Schedule and Procedures Cleaning your printer regularly maintains print quality and may extend the life of the printer. The recommended cleaning schedule is shown in Table 11. See the following pages for specific procedures. Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead.
Routine Maintenance Cleaning Schedule and Procedures Clean the Printhead and Platen Roller If print quality does not improve after you perform this procedure, clean the printhead with Save-a-Printhead cleaning film. This specially coated material removes contamination buildup without damaging the printhead. Call your authorized Zebra reseller or distributor for more information.
Routine Maintenance Cleaning Schedule and Procedures Caution • The printhead may be hot and can cause severe burns. Allow the printhead to cool. Caution • Before touching the printhead assembly, discharge any built-up static electricity by touching the metal printer frame or by using an anti-static wriststrap and mat. Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead.
Routine Maintenance Cleaning Schedule and Procedures 3. Using the swab from the Preventive Maintenance Kit (part number 47362), wipe along the brown strip on the printhead assembly from end to end. In place of the Preventive Maintenance Kit, you may use a clean swab dipped in a solution of isopropyl alcohol (minimum 90%) and deionized water (maximum 10%). Allow the solvent to evaporate. 3 4 1 2 1 2 3 4 Swab Platen roller Printhead print elements Printhead-open lever 4.
Routine Maintenance Cleaning Schedule and Procedures Clean the Sensors Brush or vacuum any accumulated paper lint and dust off the sensors. Clean the sensors according to the recommendations in Cleaning Schedule and Procedures on page 117. Ribbon and Label-Available Sensor Locations The ribbon sensor and optional label-available sensor are shown in Figure 16.
Routine Maintenance Cleaning Schedule and Procedures Transmissive Media Sensor Locations The locations of the upper and lower transmissive media sensors are shown in Figure 17 and Figure 18.
Routine Maintenance Cleaning Schedule and Procedures Media Out Sensor Location The location of the media out sensor is shown in Figure 19.
Routine Maintenance Cleaning Schedule and Procedures Clean the Snap Plate Clean the snap plate when label adhesive or a label is stuck to the underside. Figure 20 shows the location of the snap plate. Figure 20 • Snap Plate Location 1 1 2 3 2 3 Left loop Snap plate Right loop To clean the snap plate, complete these steps: 1. See Figure 20. Insert a small-blade screwdriver or similar tool into the loop on the left side of the snap plate. 2. Gently lift the left side of the snap plate. 3.
Routine Maintenance Cleaning Schedule and Procedures 7. To reinstall the snap plate, insert the two tabs on the bottom of the snap plate into the two slots of the media path. 8. Slide the snap plate toward you. 9. Press down on the loops to lock the snap plate into place. Clean the Cutter If the cutter is not cutting the labels cleanly or if it jams with labels, clean the cutter. Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers.
Routine Maintenance Replace the Fuse Replace the Fuse The instructions that follow are for the 140Xi4, 170Xi4, and 220Xi4 printers only. Fuses are not user-replaceable in the 110Xi4. Caution • Turn the AC power switch off (O) and remove the power cord before performing this procedure. The printer uses a metric-style fuse (5 × 20 mm IEC) rated at F5A, 250 V. The AC power entry module comes with two approved fuses in the fuse holder: one is in-circuit, and the second is provided as a spare.
Routine Maintenance Replace the Fuse Figure 22 • Fuse Locations 1 2 3 1 2 3 In-circuit fuse Fuse holder Spare fuse 3. Snap the fuse holder back into the AC power entry module. 4. Reconnect the power cord, and turn the printer on (I). Note • If the printer does not power on, an internal component failure may have occurred, and the printer requires servicing by an authorized service technician.
Routine Maintenance Replace the Fuse Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _________________
6 Troubleshooting This section provides information about errors that you might need to troubleshoot. Assorted diagnostic tests are included. Contents Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Troubleshooting Checklists Troubleshooting Checklists If an error condition exists with the printer, review this checklist: Is there an error message on the LCD? If yes, see LCD Error Messages on page 131. Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media and Ribbon Sensor Sensitivity on page 101. Is the CHECK RIBBON light on when ribbon is loaded properly? If yes, see Calibrate Media and Ribbon Sensor Sensitivity on page 101.
Troubleshooting LCD Error Messages LCD Error Messages The LCD displays messages when there is an error. See Table 12 for LCD errors, the possible causes, and the recommended solutions. Table 12 • LCD Error Messages LCD Display/ Printer Condition Possible Cause Recommended Solution The printhead was replaced with one that is not a genuine Zebra™ printhead. Install a genuine Zebra™ printhead. In thermal transfer mode, ribbon is not loaded or incorrectly loaded. Load ribbon correctly.
Troubleshooting LCD Error Messages Table 12 • LCD Error Messages (Continued) LCD Display/ Printer Condition Possible Cause Recommended Solution Ribbon is loaded, but the printer is set for direct thermal mode. Ribbon is not required with direct thermal media. If you are using direct thermal media, remove the ribbon. This error message will not affect printing. If you are using thermal transfer media, which requires ribbon, set the printer for Thermal Transfer mode.
Troubleshooting LCD Error Messages Table 12 • LCD Error Messages (Continued) LCD Display/ Printer Condition Possible Cause Recommended Solution Caution • An improperly connected printhead data or power cable can cause these error messages. The printhead may be hot enough to cause severe burns. Allow the printhead to cool. The printhead data cable is not properly connected. Caution • Turn off (O) the printer before performing this procedure. Failure to do so can damage the printhead.
Troubleshooting LCD Error Messages Table 12 • LCD Error Messages (Continued) LCD Display/ Printer Condition Possible Cause Recommended Solution Caution • An improperly connected printhead data or power cable can cause this error message. The printhead may be hot enough to cause severe burns. Allow the printhead to cool. The printer prints while the ERROR light flashes. The printhead temperature is approaching its lower operating limit. The printhead data cable is not properly connected.
Troubleshooting LCD Error Messages Table 12 • LCD Error Messages (Continued) LCD Display/ Printer Condition Possible Cause The printer is defragmenting memory. Recommended Solution Caution • Do NOT turn off the printer power during defragmenting. Doing so can damage the printer. Allow the printer to finish defragmenting. If you get this error message frequently, check your label formats. Formats that write to and erase memory frequently may cause the printer to defragment often.
Troubleshooting LCD Error Messages Table 12 • LCD Error Messages (Continued) LCD Display/ Printer Condition Possible Cause Recommended Solution There is not enough memory to perform the function specified on the second line of the error message. Free up some of the printer’s memory by adjusting the label format or printer parameters. One way to free up memory is to adjust the print width to the actual width of the label instead of leaving the print width set to the default.
Troubleshooting Print Quality Problems Print Quality Problems Table 13 identifies problems with print quality, the possible causes, and the recommended solutions. Table 13 • Print Quality Problems Problem Possible Cause Recommended Solution General print quality issues The printer is set at the incorrect print speed. For optimal print quality, set the print speed to the lowest possible setting for your application via control panel, the driver, or the software. See Adjust Print Speed on page 91.
Troubleshooting Print Quality Problems Table 13 • Print Quality Problems (Continued) Problem Possible Cause Recommended Solution Wrinkled ribbon Ribbon was fed through the ribbon system incorrectly. Load the ribbon correctly. See Load Ribbon on page 68. Incorrect burn temperature. Set the darkness to the lowest possible setting for good print quality. See Adjust Print Darkness on page 91. Incorrect or uneven printhead pressure.
Troubleshooting Print Quality Problems Table 13 • Print Quality Problems (Continued) Problem Possible Cause Recommended Solution Misregistration/skips labels The printer is not calibrated. Recalibrate the printer. The media sensor is not positioned correctly. Perform media sensor position adjustment. Improper label format. Use correct label format. The platen roller is dirty. See Clean the Printhead and Platen Roller on page 118. The media sensor is not positioned correctly.
Troubleshooting Print Quality Problems Table 13 • Print Quality Problems (Continued) Problem Possible Cause Recommended Solution The bar code printed on a label does not scan. The bar code is not within specifications because the print is too light or too dark. Perform the FEED Self Test on page 149. Adjust the darkness or print speed settings as necessary. Not enough blank space around the bar code. Leave at least 1/8 in. (3.
Troubleshooting Calibration Problems Calibration Problems Table 14 identifies problems with calibration, the possible causes, and the recommended solutions. Table 14 • Calibration Problems Problem Possible Cause Recommended Solution Loss of printing registration on labels. Excessive vertical drift in top-of-form registration. The platen roller is dirty. Clean the platen roller according to the instructions in Clean the Printhead and Platen Roller on page 118. Media guides are positioned improperly.
Troubleshooting Communications Problems Communications Problems Table 15 identifies problems with communications, the possible causes, and the recommended solutions. Table 15 • Communications Problems Problem Possible Cause Recommended Solution A label format was sent to the printer but was not recognized. The DATA light does not flash. The communication parameters are incorrect. Check the printer driver or software communications settings (if applicable).
Troubleshooting Ribbon Problems Ribbon Problems Table 16 identifies problems that may occur with ribbon, the possible causes, and the recommended solutions. Table 16 • Ribbon Problems Problem Possible Cause Recommended Solution Broken or melted ribbon Darkness setting too high. 1. The printer does not detect when the ribbon runs out. The printer was calibrated without ribbon. Later, ribbon was inserted without the user recalibrating the printer or loading printer defaults.
Troubleshooting Miscellaneous Printer Problems Miscellaneous Printer Problems Table 17 identifies miscellaneous problems with the printer, the possible causes, and the recommended solutions. Table 17 • Miscellaneous Printer Problems Problem Possible Cause Recommended Solution The LCD displays a language that I cannot read The language parameter was changed through the control panel or a firmware command. 1. Press SETUP/EXIT to enter configuration mode. 2. Press MINUS (-).
Troubleshooting Miscellaneous Printer Problems Table 17 • Miscellaneous Printer Problems (Continued) Problem Possible Cause Recommended Solution The printer fails to calibrate or detect the top of the label. The printer was not calibrated for the label being used. Perform the calibration procedure in Calibrate Media and Ribbon Sensor Sensitivity on page 101. The printer is configured for continuous media. Set the media type to noncontinuous media. See Set Media Type on page 93.
Troubleshooting Printer Diagnostics Printer Diagnostics Self tests and other diagnostics provide specific information about the condition of the printer. The self tests produce sample printouts and provide specific information that helps determine the operating conditions for the printer. The most commonly used are the Power-On and the CANCEL self tests. Important • Use full-width media when performing self tests. If your media is not wide enough, the test labels may print on the platen roller.
Troubleshooting Printer Diagnostics CANCEL Self Test The CANCEL self test prints a configuration label (Figure 23). To perform the CANCEL Self Test, complete these steps: 1. Turn off (O) the printer. 2. Press and hold CANCEL while turning on (I) the printer. Hold CANCEL until the first control panel light turns off. A printer configuration label prints (Figure 23).
Troubleshooting Printer Diagnostics PAUSE Self Test This self test can be used to provide the test labels required when making adjustments to the printer’s mechanical assemblies or to determine if any printhead elements are not working. Figure 24 shows a sample printout. To perform a PAUSE self test, complete these steps: 1. Turn off (O) the printer. 2. Press and hold PAUSE while turning on (I) the printer. Hold PAUSE until the first control panel light turns off.
Troubleshooting Printer Diagnostics FEED Self Test Different types of media may require different darkness settings. This section contains a simple but effective method for determining the ideal darkness for printing bar codes that are within specifications. During the FEED self test, labels are printed at different darkness settings at two different print speeds. The relative darkness and the print speed are printed on each label. The bar codes on these labels may be ANSI-graded to check print quality.
Troubleshooting Printer Diagnostics 4. See Figure 26 and Table 18. Inspect the test labels and determine which one has the best print quality for your application. If you have a bar code verifier, use it to measure bars/spaces and calculate the print contrast. If you do not have a bar code verifier, use your eyes or the system scanner to choose the optimal darkness setting based on the labels printed in this self test.
Troubleshooting Printer Diagnostics Table 18 • Judging Bar Code Quality Print Quality Description Too dark Labels that are too dark are fairly obvious. They may be readable but not “in-spec.” • The normal bar code bars increase in size. • The openings in small alphanumeric characters may fill in with ink. • Rotated bar code bars and spaces run together. Slightly dark Slightly dark labels are not as obvious. • The normal bar code will be “in-spec.
Troubleshooting Printer Diagnostics FEED and PAUSE Self Test Performing this self test temporarily resets the printer configuration to the factory default values. These values are active only until power is turned off unless you save them permanently in memory. If the factory default values are permanently saved, a media calibration procedure must be performed. To perform a FEED and PAUSE self test, complete these steps: 1. Turn off (O) the printer. 2.
Troubleshooting Printer Diagnostics Communications Diagnostics Test The communication diagnostics test is a troubleshooting tool for checking the interconnection between the printer and the host computer. When the printer is in diagnostics mode, it prints all data received from the host computer as straight ASCII characters with the hex values below the ASCII text. The printer prints all characters received, including control codes such as CR (carriage return).
Troubleshooting Printer Diagnostics Sensor Profile Use the sensor profile label to troubleshoot the following types of problems: • If the media sensor experiences difficulty in determining gaps (web) between labels. • If the media sensor incorrectly identifies preprinted areas on a label as gaps (web). For instructions on printing a sensor profile, see Print Sensor Profile on page 100.
7 Specifications This section provides the features of and specifications for this printer. Contents Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Modes . . . . . . . . . . . . .
Specifications Features Features This section lists the standard and optional features for the printer. Standard Features Note • Printer specifications are subject to change without notice. • Thermal transfer and direct thermal printing • 16 MB SDRAM (12 MB user-available) • USB 2.0 Port • Real-time Clock • Advanced Counter • RS-232 serial port • bidirectional parallel port • USB 2.
Specifications Features Zebra Programming Language (ZPL) ZPL II features include: • 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 • Data compression • Automatic virtual input buffer management • Format inversion • Mirror image printing • Four-position field rotation (0°, 90°, 180°, 270°) • Slew command • Controlled via mainframe, minicomputer, PC, portable data terminal • Prog
Specifications General Specifications General Specifications Physical Specifications Dimensions 110Xi4 140Xi4 170Xi4 220Xi4 Height 15.5 in (393.7 mm) 15.5 in. (393.7 mm) 15.5 in. (393.7 mm) 15.5 in (393.7 mm) Width 10.31 in. (261.9 mm) 11.31 in. (287.3 mm) Depth 20.38 in. (517.5 mm) 20.38 in. (517.5 mm) 20.38 in. (517.5 mm) 20.38 in. (517.5 mm) Weight without 50 lb. (22.7 kg) options 55 lb. (25 kg) 13.31 in. (338.1 mm) 15.81 in. (401.6 mm) 67 lb. (30.5 kg) 72 lb. (32.
Specifications Print Specifications by Model Print Specifications by Model Refer to the key and the tables that follow for printer specifications. Specifications Key Non-Continuous printing (gap, notch, or hole between labels). Continuous printing (no gap, notch or hole). Ladder (rotated) orientation. Picket fence (nonrotated) orientation.
Specifications Print Specifications by Model 140Xi4, 170Xi4, and 220Xi4 Print Specifications 140Xi4 170Xi4 200 dpi 170Xi4 300 dpi 220Xi4 200 dpi 220Xi4 300 dpi Printhead resolution 203 dots/inch (8 dots/mm) 203 dots/inch (8 dots/mm) 300 dots/inch (12 dots/mm) 203 dots/inch (8 dots/mm) 300 dots/inch (12 dots/mm) Dot size (width×length) 0.0049×0.0049 in. (0.125×0.125 mm) 0.0049×0.0049 in. (0.125×0.125 mm) 0.0033×0.0033 in. (0.084×0.084 mm) 0.0049×0.0049 in. (0.125×0.125 mm) 0.0033×0.
Specifications Ribbon Specifications Ribbon Specifications Refer to the following tables for ribbon specifications. Note • Consider the following when using ribbon: • Match the ribbon to the label width and printhead width that you are using. The ribbon should be at least as wide as the labels to protect the printhead from excessive wear. • Ribbon must be wound with the coated side out.
Specifications Media Specifications Media Specifications Use the correct size and type of labels for best performance. Refer to the tables that follow for specifications. Important • Media registration and minimum label length are affected by label type and width, ribbon type, print speed, and printer mode of operation. Performance improves as these factors are optimized. Zebra recommends qualifying any application with thorough testing.
Specifications Media Specifications 110Xi4 Black Mark Sensing Only Media Specifications 110Xi4 200 dpi 110Xi4 300 dpi 110Xi4 600 dpi Mark length (measuring parallel Minimum to label/tag edge) Maximum 0.12 in. (3 mm) 0.12 in. (3 mm) 0.12 in. (3 mm) 0.43 in. (11 mm) 0.43 in. (11 mm) 0.43 in. (11 mm) Minimum 0.43 in. (11 mm) 0.43 in. (11 mm) 0.43 in. (11 mm) Maximum Full media width Full media width Full media width Mark location within 0.040 in. (1 mm) of the inside media edge within 0.
Specifications Media Specifications 140Xi4, 170Xi4, and 220Xi4 Black Mark Sensing Only Media Specifications 140Xi4 170Xi4 220Xi4 Mark length (measuring parallel to label or tag edge) Minimum 0.12 in. (3 mm) 0.12 in. (3 mm) 0.12 in. (3 mm) Maximum 0.43 in. (11 mm) 0.43 in. (11 mm) 0.43 in. (11 mm) Mark width (measuring to perpendicular label or tag edge) Minimum 0.43 in. (11 mm) 0.43 in. (11 mm) 0.43 in.
End User License Agreement Please read the terms of this “End User License Agreement” (the “Agreement”) carefully. The Agreement is a legal agreement between you (either an individual or a single entity) and Zebra Technologies International, LLC (“Zebra”) for the Zebra computer software and/or firmware accompanying this End User License Agreement, and any associated media, printed materials and any “online” or electronic documentation (collectively, “Software”).
End User License Agreement 3. Documentation. If the Software contains documentation which is provided only in electronic form, you may print one copy of such electronic documentation. You may not copy the printed materials accompanying the Software. 4. Limitations of Reverse Engineering, Decompilation and Disassembly. You may not reverse engineer, decompile, or disassemble the Software, except and only to the extent that such activity is permitted by applicable law notwithstanding this limitation. 5.
End User License Agreement 10. Export Restrictions. You agree that you will not export or re-export the Software, any part thereof, or any process or service that is the direct product of the Software (the foregoing collectively referred to as the “Restricted Components”), to any country, person or entity subject to U.S. export restrictions. You specifically agree not to export or re-export any of the Restricted Components: (i) to any country to which the U.S.
End User License Agreement IMPLIED WARRANTIES ARE NOT ALLOWED TO BE EXCLUDED IN THEIR ENTIRETY, THEY WILL BE LIMITED TO THE DURATION OF NINETY (90) DAYS. WITHOUT LIMITING THE GENERALITY OF THE FOREGOING, ZEBRA DOES NOT WARRANT THAT THE OPERATION OF THE SOFTWARE WILL BE UNINTERRUPTED OR ERROR FREE.
End User License Agreement 16. Governing Law. To the maximum extent permitted by law, the laws of the State of Illinois, U.S.A., without reference to its conflict of laws provisions, will apply to this Agreement. You irrevocably agree to submit to the exclusive jurisdiction and venue of the state or federal courts in the State of Illinois in the event of any litigation involving this Agreement or the Software.
End User License Agreement 22. QUESTIONS. Should you have any questions, or if you desire to contact Zebra for any reason, please contact the Zebra subsidiary serving your country, or write: Zebra Technologies International, LLC 333 Corporate Woods Parkway Vernon Hills, Illinois 60061 REVISED MARCH 2008.
Glossary alphanumeric Indicating letters, numerals, and characters such as punctuation marks. backfeed When the printer pulls the media and ribbon (if used) backward into the printer so that the beginning of the label to be printed is properly positioned behind the printhead. Backfeed occurs when operating the printer in Tear-Off and Applicator modes. bar code A code by which alphanumeric characters can be represented by a series of adjacent stripes of different widths.
Glossary continuous media Label or tag-stock media that has no notch, gap, or web (media liner only) to separate the labels or tags. The media is one long piece of material. core diameter The inside diameter of the cardboard core at the center of a roll of media or ribbon. diagnostics Information about which printer functions are not working that is used for troubleshooting printer problems. die-cut media A type of label stock that has individual labels stuck to a media liner.
Glossary label backing (liner) The material on which labels are affixed during manufacture and which is discarded or recycled by the end-users. light emitting diode (LED) Indicators of specific printer status conditions. Each LED is either off, on, or blinking depending on the feature being monitored. liquid crystal display (LCD) The LCD is a back-lit display that provides the user with either operating status during normal operation or option menus when configuring the printer to a specific application.
Glossary ribbon A band of material consisting of a base film coated with wax or resin “ink.” The inked side of the material is pressed by the printhead against the media. The ribbon transfers ink onto the media when heated by the small elements within the printhead. Zebra ribbons have a coating on the back that protects the printhead from wear. ribbon wrinkle A wrinkling of the ribbon caused by improper alignment or improper printhead pressure.
Index Numerics B 110Xi4 black mark specifications, 163 label specifications, 162 print specifications, 159 ribbon specifications, 161 140Xi4 black mark specifications, 164 label specifications, 163 print specifications, 160 ribbon specifications, 161 170Xi4 black mark specifications, 164 label specifications, 163 print specifications, 160 ribbon specifications, 161 220Xi4 label specifications, 163 print specifications, 160 ribbon specifications, 161 black mark specifications, 164 backfeed setting, 106 b
Index cleaning cutter, 125 exterior of printer, 117 media compartment, 117 printhead and platen roller, 118 recommended schedule, 117 sensors, 121 snap plate, 124 coax option characteristics of coax connection, 23 connection and configuration, 26 communication interfaces, 23 communications diagnostics test overview, 153 selecting, 103 communications problems, 142 configuration changing parameters, 91 enter and use Setup mode, 86 exit Setup mode, 87 software or printer driver, 91 configuration label pr
Index F factory defaults reload parameters, 87 restore network settings, 87 fanfold media described, 32 FCC compliance, 4 features, 156 FEED button FEED and PAUSE self test, 152 FEED self test, 149 function, 18 Flash memory, 99 font list, 98 format convert setting, 111 format list, 98 format prefix setting, 104 H head test setting, 107 host handshake setting, 103 humidity requirements, 22 I idle display setting, 111 images list, 98 initialize Flash memory, 99 inspect for shipping damage, 21 international
Index N network configuration label printing, 90 printing using List Network command, 99 network ID setting, 103 NEXT/SAVE button function, 18 non-continuous media described, 32 setting media type, 93 O odometer, 98 operating conditions, 22 Operating mode, 18 optional features, 156 ordering replacement parts, 116 ordering ribbon and media, 11 P parallel port characteristics of parallel connection, 23 connection and configuration, 25 setting parallel communications, 101 parity setting, 102 passwords
Index printer settings (continued) saving, 87 sensor type, 93 serial communications, 102 setting through control panel, 86 start print signal, 109 time, 111 verifier port, 108 wired print server, 113 wireless print server, 113 ZPL mode, 105 printhead cleaning, 118 head close setting, 106 head test count setting, 107 pressure adjustment, 81 when to clean, 117 protocol setting, 103 R recycling printer parts, 116 registration problems, 141 relative humidity requirements, 22 remove media liner from rewind spi
Index Setup mode defined, 18 enter and use Setup mode, 86 exit Setup mode, 87 LCD messages, 91 passwords, 88 SETUP/EXIT button function, 18 shipping report damage, 21 reshipping the printer, 21 short calibration, 75 “smart” labels, 31 snap plate cleaning, 124 when to clean, 117 spacing requirements, 22 specifications by model number, 159 electrical, 158 environmental, 158 physical, 158 power cord, 29 ribbon, 161 standard features, 156 start print signal setting, 109 storing the printer, 21 supplies lo
Zebra Technologies International, LLC 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.A T: +1 847 793 2600 Toll-free +1 800 423 0422 F: +1 847 913 8766 Zebra Technologies Europe Limited Dukes Meadow Millboard Road Bourne End Buckinghamshire, SL8 5XF, UK T: +44 (0)1628 556000 F: +44 (0)1628 556001 Zebra Technologies Asia Pacific, LLC 120 Robinson Road #06-01 Parakou Building Singapore 068913 T: +65 6858 0722 F: +65 6885 0838 http://www.zebra.com © 2009 ZIH Corp.
