Zebra Technologies XiIII-Series User Manual

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Customer Order # 11992L Manufacturer Part # 11992LB Rev. 2

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This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and use of parties opera ti ng and maintaining the equipment desc rib ed 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.

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Continuous improvemen t of pro ducts is a policy of Zebra Technologies Corporation. All spec i fic at ions and signs are subject to change without notice.

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This equipment has been te sted and f ound to co mply with the limi ts for a Cla ss B digita l devi ce, pu rsu ant to Part 15 of the FCC Rules. The se limit s are des igned to pro vide re asonab le pro tectio n again st harmf ul inte rfere nce i n a reside nti al installation. This equipme nt ge ne ra te s, use s, a nd ca n radiate radio frequency en ergy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that the interfe re nc e w ill not occur in a particular installa t ion. If this equipment does cause harmful interference to radio or tele visi on reception, which can be determ ined by turning the equipment off and on, the user is encouraged to try to corre ct the interference by one or m o re of the following measures :

• Reorient or relocate the receiving antenna.

• Increase the separation be tween the equipment and the receiver.

• Connect the equipment into an outlet on a circuit different than that to which the receiver is connected.

• Consult the de aler or an experience d Radio/TV technician for help. NOTE: This unit was tested with shielded cables on the peripheral devices. Shielded cables must be used with the

unit to ensure compliance. “The user is cautioned tha t an y changes or modifications not expre ssly approved by Zebra Technologies Corporation

could void the user’s authority to operate the equipment.”

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This digital apparatus does not exc ee d the Cl ass A limi ts for ra di o noi s e em i s sions from digital apparatus as set out in the radio interference regulations of the Canadian Depart m en t of Communications.

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If the accompanying printer displays the CE mark, it also meets EMC directive 89/336/EEC, with amendments effective at the time of manufacture.

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Zebra Technologies Corporation takes steps to assure that its published Engineering Spe cifications and Manuals are correct; however, errors do occur. Zebra Technologies Corporation reserves the right to correct any such errors and disclaims liabilit y resu lting therefrom.

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In no event shall Zebra Technologies Corporation or anyone else involve d in the cre at ion, production, or delivery of the accompanying product (including hardware and software) be liable for any damages wha tso ever (including, without limitation, damages for loss of business pro fits, busine ss inter rupt io n, loss of bu sine ss information, or other pecuniary loss) arising out of th e use of or the results of use or inability to use such pro duct, even if Zebra Technologies Corporation has been advised of the po ssi bi lity of such damages. Because some states so not allow the exclusion or limitation of l iab ility for consequential or inci dental damages, the above limita ti on may not apply to you.

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This copyrighted manual and the label printer desc ribed herein are owned by Zebra Technologies Co rporation. All rights are reserved. Unauthorized reproduction of this manual or the software in the label 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.

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Hello! .......................................................................................................................1

Unpacking and Inspection............................................ ......... ......... ..........................2

Reporting Damage.............................................................................................. 2

Storage................................................................................................................2

Media and Ribbon Requirements.............................................................................3

Power Cord ..............................................................................................................3

Printer Anatomy 101................................................................................................4

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Purpose.....................................................................................................................5

Types of Media ....................................................................................... .................6

Non-Continuous Web Media..............................................................................6

Non-Continuous Black Mark Media ..................................................................7

Continuous Media...............................................................................................7

Choosing the Print Mode .........................................................................................8

Loading the Media...................................................................................................9

Positioning the Media Sensors...............................................................................10

Transmissive Sensor.........................................................................................10

Black Mark Sensor ...........................................................................................12

Loading the Ribbon................................................................................................13

Operator Controls...................................................................................................14

POWER Switch ................................................................................................ 14

Front Panel........................................................................................................14

Configuring the Printer..........................................................................................15

Configuring the Software or Printer Driver...........................................................16

Media and Ribbon Calibration...............................................................................17

Printing a Test Label ..............................................................................................19

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System Considerations .......................................................................................... 21

Interfaces..........................................................................................................2 1

Data Specifications...........................................................................................21

Cabling Requirements...........................................................................................22

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Operator Controls..................................................................................................23

POWER Switch ................................................................................................23

Front Panel Display..........................................................................................24

Front Panel Keys .............................................................................................25

Front Panel Lights............................................................................................ 26

Roll Media Loading............................................................................................... 27

Tear-Off Mode ................................................................................................. 27

Peel-Off Mode..................................................................................................28

Rewind Mode (for Printers Without the Cutter Option)..................................30

Cutter Mode......................................................................................................32

Rewind Mode (for Printers With the Cutter Option) ....................................... 33

Fanfold Media Loading............................................................... ......... .................35

Removing the Label Backing Material..................................................................37

Ribbon Loading.....................................................................................................38

Ribbon Removal....................................................................................................40

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Entering the Setup Mode....................................................................................... 41

Changing Password-Protected Parameters............................................................42

Leaving the Setup Mode........................................................................................43

Configuration and Calibration Sequence ..............................................................44

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Cleaning.................................................................................................................63

Cleaning the Exterior .......................................................................................64

Cleaning the Interior......................................................................................... 64

Cleaning the Printhead and Platen Roller ........................................................ 64

Cleaning the Sensors........................................................................................69

Cleaning the Snap Plate....................................................................................69

Cleaning the Cutter Module.............................................................................71

vi Zebra XiIII-Series User’s Guide

Lubrication.............................................................................................................71

Fuse Replacement..................................................................................................71

Adjustments ...........................................................................................................73

Toggle Positioning............................................................................................73

Printhead Pressure Adjustment.........................................................................74

Media Sensor Position Adjustment..................................................................74

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LED Error Conditions and Warnings ....................................................................75

Print Quality Problems...........................................................................................78

Wrinkled Ribbon....................................................................................................79

Communications....................................................................................................79

Printer Diagnostics.................................................................................................81

Power-On Self Test...........................................................................................81

Additional Printer Self Tests ............................................................................81

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Media Handling .....................................................................................................87

Options...................................................................................................................87

Zebra Programming Language (ZPL II®).............................................................88

Bar Codes...............................................................................................................88

General Specifications................................................. ......... .................................89

Printing Specifications...........................................................................................90

Ribbon Specifications............................................................................................90

Media Specifications..............................................................................................91

Power Line Cord Specifications ............................................................................92

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Printer Interface Technical Information.................................................................93

RS-232/RS-422/RS-485 Serial Data Port.........................................................93

Parallel Data Port ..............................................................................................97

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Thank you for purchasing this high-quality Zebra XiIII™-Series printer, manufactured by the indust ry leader in quali ty, servi ce, and valu e — Zebr a Technologies Corporation. For over 25 years, Zebra has provided customers with the highest caliber of products and support.

• This manual provides all of the information you need to operate your printer.

•The ZPL II 45540L) shows you how to create the perfect label format for your application. These books also explain how, through ZBI™, you can extend the power of ZPL II by allowing custom programs to be written that operate within the printer and directly interface with bar code scanners and keyboard display devices. In addition, the books contain information about the enhanced operating system features of your printer. There are three ways to obtain these books: on the accessory CD-ROM (supplied with the printer), on our web site (www.zebra.com), or printed manuals can be ordered from your distributor.

•The ZebraNet Guide (part # 45537L) explai ns how you ca n quickl y set up your pri nter on an IP network and experience ZebraLink™, our revolutionary real-time connectivity and control solution for Z ebra printers (optional ZebraNet

Programming Guide Volume I and Volume II (part #

Networking: PrintServer II™ Installation and User’s

PrintServer II required).

• There is also a main te nance manu al for th is pri nter. This manual (part # 48152L) contains the information you need to maintain your printer.

Zebra XiIII-Series User’s Guide 1

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Carefully unpack and inspect the printer for possible damage incurred during shipment.

• Check all exterior surfaces.

• 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.

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If you discover shipping damage:

• Immediately noti fy and file a damage r eport with the shi pping company .

Zebra Technologies Corporation is not responsible for any damage incurred during shipment of the equipment and will not repair this damage under warranty.

• Keep the carton and all packing material for inspection.

• Notify your authorized Zebra reseller.

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If you are not placing the printer into operation immediately, repackage it using the original packing materials. The printer may be stored under the following conditions:

• Temperature: –4° to +140° F (–20° to +60° C)

• Relative humidity: 5% to 85% non-condensing

2Zebra XiIII-Series User’s Guide

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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 T ech nol ogi es 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.

• Continuous roll media, fanfold media, or card stock with optional perforations and registration holes may be used.

• Printhead life may be reduced by the abrasion of exposed paper fibers when using perforated media.

• The ribbon MUST be as wide as or wi der tha n the media being used. If the ribbon is narrower than the media, areas of the printhead are unprotected and subject to premature wear. (When printing in direct thermal mode, ribbon is not used and should not be loaded in the printer.)

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NOTE: Depending on how your printer was ordered, a power cord may

or may not be included. If one is not included, or if the one included is not suitable for your requirements, refer to “Power Line Cord Specifications” on page 92.

The power cord connector must be plugged into the mating connector on the rear of th e printer.

Make sure that the POWER on/off switch (located at the back of the printer) is in the off position before connecting the power cable to an electrical outlet.

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Figure 1 outlines the basic components of your printer. However, depending on the opti ons you have s elected, y our print er may look sl ightly different.

Figure 1

4Zebra XiIII-Series User’s Guide

This chapter of the user’s guide is so important that we’ve printed it on a different color paper! That way, it is easy for you to find when you must calibrate (set up) the printer for your particular application.

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• To calibrate the printer.

• 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

To calibrate the printer, you must perform the following procedures:

• Determine the type of media (labels) being used.

• Choose the print method.

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installed or when it cannot properly detect the top of the label.

• Position the media sensors (if necessary).

• Configure the prin ter and s oftware or driv er based o n the l abel bein g used.

• Perform a media and ribbon calibration.

•Print a test label.

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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.

Figure 2

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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).

Figure 3

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Continuous media (refer to Figure 4) is one uninterrupted roll of material that allows the image to be printed anywhere on the label.

Figure 4

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•In Tear-Off mode, each label (or a strip of labels) can be torn off after it

is printed.

•In Peel-Off mode, backing material is peel ed away from the label as it is

printed. After this label is removed from the printer, the next one is printed.

•In Cutter mode, t he pr int er a utoma tical ly c uts t he label afte r a s pec ifie d

number of labels has been printed.

•In Rewind mode, the media and backin g are rewou nd onto a cor e as the

labels are printed.

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Figure 5 illustrates one method of media loading. For more detailed instructions, as well as information about how to load the dif ferent type s of media and the various printing modes, refer to the instructions that begin on page 27.

Figure 5

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The correct positioning of the media sensors is important — it can make the difference between a perfect label and a call to Technical Support!

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The web or gap sensor, better known as the “transmissive sensor,” detects the gap between label s.

The transmissive sensor actually consists of two sections: a light source (the lower media sensor) an d a light sensor (the upper media sen sor ). The media passes between the two.

The upper media sensor must be positioned:

• Directly over the hole or notch, or

• Anywhere along the width of the media if there is a gap between labels. NOTE: If you are using continuous media, position the upper media

sensor over the media so that the printer can detect an out-of-paper condition.

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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 (use a

Phillips-head screwdriver).

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.

Figure 6

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Position the lower media sensor (refer to Figure 7) by sliding it in its slot until it is positioned under the upper media sensor.

Figure 7

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The black mark sen sor is in a fixed p osition and en abled via the fr ont panel (refer to “Configuring the Printer” on page 15 for details).

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T o load the ribbo n, refe r to Figure 8 (for the 90XiIII, 96XiIII, and 140XiIII) and Figure 9 (for the 170XiIII and 220XiIII). For more det ailed information, refer to the instructions that begin on page 38.

Figure 8

Figure 9

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The POWER switch is located at the back of the printer above the power cord and fuse. Turn on the printer.

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The step-by-step instru ctions in this section tell you which keys to press and what appears on the liq uid cr ystal displ ay (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.

Figure 10

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The configuration proce dure in the ne xt table con tains the information you need to get your prin ter up and runnin g, but it is not comprehensive. Refer to page 41 for more information.

• Enter the configuration mode by pressing the SETUP/EXIT key at the “PRINTER READY” display.

NOTE: You need to press the NEXT/SAVE key more than once to

advance to some of the displays.

• To increase the value, answer “yes,” indicate “on,” or move to the next selection, use the RIGHT BLACK OVAL key.

• To decrease the value, answer “no,” indicate “off,” or return to the previous selection, use the LEFT BLACK OVAL key.

NOTE: When changing parame te rs, an asterisk (*) in t he upper left-hand

corner of the display indicates that you have changed this setting from the setting that is currently stored in memory.

Zebra XiIII-Series User’s Guide 15

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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. Remove approximately 8" (200 mm) of labels

from the media roll, enough so that only the backing material is threaded b etween the media sensors when the media is loaded (refer to Figure 11).

Figure 11

Zebra XiIII-Series User’s Guide 17

5. Press the RIGHT BLACK OVAL key. The front panel display shows “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 shows “CALIBRATING PLEASE WAIT.”

9. When this part of the calibration process is completed, the display reads “RELOAD ALL CONTINUE.”

10. Open the printhead. Pull the backing material until a label is positioned between the media sensors.

11. Either load the ribbon or return the ribbon to its proper position.

12. Close the pr i nth ead. Press the RIGHT BLACK OVAL key to pe rf or m the next part of the calibration sequence. “MEDIA AND RIBBON CALIBRATE” displays. The pri nter is calibrated when the media stops feeding.

13. Press the SETUP/EXIT key to leave the programming mode. Choose “permanent” when SAVE CHANGES displays.

18 Zebra XiIII-Serie s User’s Guide

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To print a test label:

1. Turn of f the printer.

2. Press and hold the CANCEL key

while turning on the printer.

A configuration label prints showing the printer’s currently store d parameters (similar to the one shown in Figure 12).

Figure 12

If you encounter a ny problems while you ar e config uring or c alibrat ing the printer or printing a test label, refer to Troubleshooting, which starts on page 75. Otherwise, refer to Establishing Communication on page 21 to set up the communication parameters.

Zebra XiIII-Series User’s Guide 19

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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 se rial dat a port and a bi- directi onal paral lel port. The optional ZebraNet connected to 10Base-T Ethernet networks. In addition, the IBM or IBM Coax option is available for those applications that require them.

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When communicating via an asynchronous serial data port (refer to Figure 13), the baud rate, number of data and stop bits, parit y, and handshaking are user selectable. Parity only applies to data transmitted by the printer since the parity of received data is ignored.

PrintServer II enables pri n te rs to be

Twinax

Figure 13

Zebra XiIII-Series User’s Guide 21

When communicating via the parallel port (refer to Figure 14), the previously mentioned parameters are not considered. Refer to page 51 to configure the communication parameters for the printer. The values selected must be the sam e as those used by the host equipment connected to the print er.

For serial and parallel pinout and technical information, r efer to “Appendix” on page 93.

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Data cables must be fully shielded and fitted with metal or metalized connector shells. Shielded cables and connectors are required to prevent radiation and reception of electrical noise.

Figure 14

To minimize electrical noise pickup in the cable:

• Keep data cables as short as possible.

• Do not bundle the data cables tightly with the power cords.

• Do not tie the data cables to power wire conduits.

NOTE: Zebra printers comply with FCC “Rules and Regulations”,

Part 15, Subpart J, for Class A Equipment, using fully shielded 6' data cables. Use of longer cables or unshielded cables may increase radiated emissions above the Class A limits.

RS-422 and RS-485 applications should use twisted shielded pairs as recommended in the Appendix of the TIA/EIA.-485 Specification.

22 Zebra XiIII-Serie s User’s Guide

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This section discusses the functions of the various controls and indicators on the printer. Become familiar with each of these functions before operating the printer.

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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 a s lig htn ing st orms or noise o n the p ower or dat a cables, may cause erratic printer behavior. Turning the printer’s power off and back on may re-establish proper printer operation.

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Zebra XiIII-Series User’s Guide 23

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The front panel d ispla y (as shown in Fi gure 15 ) communic ates operat ional status and programming modes and parameters.

Figure 15

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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.

• Printing: one blank label feeds after the current batch of labels is complete. NOTE: Equivalent to the Slew to Home Position (~PH, ^PH) ZPL II instruction.

When in the pause mode, this key cancels print jobs.

• Print job in queue: press once for each print job to be deleted.

• Press and hold for several seconds to cancel all print jobs in the printer’s memory. The DATA light turns off.

When in the pause mode, this key calibrates the printer for:

• Media length.

• Media type (continuous or non-continuous).

• Print mode (direct thermal or thermal transfer).

• Sensor values.

NOTE: The keys below are used only when configuring the printer. Specific uses of these keys are explained in “Configuration”, beginning on page 41.

• Scrolls back to the previous parameter.

• Press and hold to quickly go backward through parameter sets.

• Scrolls forward to the next parameter. (Saves any changes you’ve made in the configuration and calibration sequence.)

• Press and hold to quickly advance through parameter sets. Enters and exits the configuration mode.

These keys change the parameter values. They are used in different ways depending on the parameter displayed. Common uses are: to increase/decrease a value; answer “yes” or “no”; indicate “on” or “off”; scroll through several choices; input the password; or set up the printer for a firmware download.

Zebra XiIII-Series User’s Guide 25

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NOTE: If two operating conditions occur simultaneously (for example,

one that causes a l ight t o be on constantly and one tha t causes the same light to flash), the light flashes.

Light Status Indication

POWER

Off The printer is off or power is not applied. On The printer is on.

TAKE LABEL

ERROR

CHECK

RIBBON

PAPER OUT

PAUSE

DATA

Off Normal operation. Flashing (Peel-off mode only .) The label is available. Printing is paused until the

label is removed.

Off Normal operation — no printer errors. Flashing A printer error exists. Check the display screen for more information.

Off Normal operation — ribbon (if used) is properly loaded. On Printing is paused, the front panel displays a warning message, and the

PAUSE light is on.

• If the printer is in direct thermal mode: Ribbon is loaded.

• If the printer is in thermal transfer mode: No ribbon is loaded.

Off Normal operation — media is properly loaded. On No media is under the media sensor. Printing is paused, the display

shows an error message, and the PAUSE light is on.

Off Normal operation. On The printer has stopped all printing operations. Either the PAUSE key

was pressed, a pause command was included in the label format, the on-line verifier detected an error, or a printer error was detected. Refer to the display screen for more information.

Off Normal operation. No data being received or processed. On Data processing or printing is taking place. No data is being received. Flashing The printer is receiving data from or sending status information to the

host computer. Flashing slows when the printer cannot accept more data, but returns to normal once data is again being received.

26 Zebra XiIII-Serie s User’s Guide

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NOTE: A calibration must be perf ormed when media and ribbo n (if used)

are first installed in the printer, or when a different type of media or ribbon is being used.

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Refer to Figu re 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. Slide in the media guide and media

supply guide so they just touch, but don’t restrict, the edge of the roll.

5. Close the printhead.

Figure 16

Zebra XiIII-Series User’s Guide 27

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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" (915 mm) of media to extend past the tear-off/peel-off bar. Remove all labels from this portion to create a leader.

6. Remove the hook from the rewind spindle. If you are using a core, slide it onto the rewind spindle until it is flush against the guide plate.

7. Wind the label backing around either the 3" (76 mm) core or the rewind spindle and reinstall the hook.

8. Flip up the media supply guide. Slide in the media guide and media supply guide so they just touch, but don’t restrict, the edge of the roll.

Before closing the printhead, make sure:

• The media is positioned against the inside guides.

• The media is taut and parallel with itself and the pathway when wound

onto the rewind spindle/core.

9. Close the printhead.

10. To discard the label backing from the rewind spindle, refer to “Removing the Label Backing Material” on page 37.

28 Zebra XiIII-Serie s User’s Guide

Figure 17

Zebra XiIII-Series User’s Guide 29

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NOTE: Rewind option required. Refer to Figure 18.

1. Remove the rewind plate from its stora ge loca ti on in fro n t of the print mechanism inside the media compartment.

2. Invert the rewind plat e so that the li p on the at tache d hook plate po ints 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 th e side plate. Slide in the rewind plate so that it stops against the printer’s main frame.

5. Open the printhead.

6. Slide the media guide and media supply guide as far from the printer frame as possible. Flip down the media supply guide.

7. Load media as shown.

8. When loading media, allow approximately 36" (915 mm) of media to extend past the printhead. Remove all labels from this portion to create a leader.

9. Remove the hook from the rewind spindle. If you are using a core, slide it onto the rewind spindle until it is flush against the guide plate.

10. Wind the label backing around either the 3" (76 mm) core or the rewind spindle and reinstall the hook.

11. Flip up the media supply guide. Slide in the media guide and media supply guide so they just touch, but don’t restrict, the edge of the roll.

30 Zebra XiIII-Serie s User’s Guide

Before closing the printhe ad, make sure:

• The media is positioned against the inside guides.

• The media is taut and parallel with itself and the pathway when wound

onto the rewind spindle/core.

12. Close the printhead.

Figure 18

Zebra XiIII-Series User’s Guide 31

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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

3. Load media as shown.

4. Flip up the media supply guide. Slide in the media guide and media

5. Close the printhead.

6. The printer automatically feeds out and cuts one label when the printer

frame as possible. Flip down the media supply guide.

supply guide so they just touch, but don’t restrict, the edge of the roll.

is turned on.

Figure 19

32 Zebra XiIII-Serie s User’s Guide

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NOTE: Cutter and rewind options required. Refer to Figu re 20.

1. Remove the rewind plate from its storage location in front of the print

mechanism inside the media compartment.

2. Invert the rewind plat e so that the li p on the at tache d hook plate po ints

down.

3. Insert the hook plate lip a short distance (½"/13 mm) into the lower

opening in th e side plate. Slide in the rewind plate so that it stops against the printer’s main frame.

4. Insert the two small tabs on the rewind plate into the corresponding

slots in the cutter support bracket. (The rewind plate should spring into the proper position.)

5. Open the printhead.

6. Slide the media guide and media supply guide as far from the printer

frame as possible. Flip down the media supply guide.

7. Load media as shown.

8. When loading media, allow approximately 36" (915 mm) of media to

extend past the printhead. Remove all labels from this portion to create a leader.

9. Remove the hook from the rewind spindle. If you are using a core,

slide it onto the rewind spindle until it is flush against the guide plate.

10. Wind the label backing around either the 3" (76 mm) core or the

rewind spindle and reinstall the hook.

11. 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.

Zebra XiIII-Series User’s Guide 33

Before closing the printhead, make sure:

• The media is positioned against the inside guides.

• The media is taut and parallel with itself and the pathway when wound

onto the rewind spindle/core.

12. Close the printhead.

Figure 20

34 Zebra XiIII-Serie s User’s Guide

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NOTE: A calibration must be perf ormed when media and ribbo n (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 Figure 21 and Figure 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. Slide in the media guide so it just touches, but doesn’t restrict, the

edge of the roll.

5. Close the printhead.

Zebra XiIII-Series User’s Guide 35

Figure 21

Figure 22

36 Zebra XiIII-Serie s User’s Guide

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Since the rewind spindle holds the backing from a standard-size media roll, we recommend that you perfor m this proce dure 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" (915 mm) of backing from the rewind

spindle. Cu t it off at the spind le.

2. Pull out the hook. Slid e the bac king mate rial of f of t he rewin d spindl e

and discard.

3. Wind the media around the rewind spindle once or twice and reinstall

the hook. Continue winding to remove any slack in the media.

Zebra XiIII-Series User’s Guide 37

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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 therm al

print mode, ribbon is not used and should not be loaded in the printer.)

1. Align the segments of the ribbon supply spindle.

2. Place the ribbon roll on the ribbon supply spindle.

NOTE: Make sure t hat the core is pushed up against

the stop on the ribbon supply spindle and that the ribbon is aligned squarely with i ts cor e. If this is not done, the ribbon may not cover the printhead entirely on the inside, exposing print elements to potentially damaging contact with the media.

3. Open the printhead.

4. (Optional) To make ribbon loading and unloading easier, make a leader for your ribbon roll.

5. Tear off a strip of media (labels and backing) about 6"-12" (150 mm- 300 mm) long from the roll. Peel off a label from this strip. Apply half of this label to the end of the st rip and the oth er half to the end of the ribbon. This acts as a ribbon leader.

6. Thread the ribbon (with leader, if used) as shown without creasing or wrinkling it.

38 Zebra XiIII-Serie s User’s Guide

7. Before wrapping the ri bbon aroun d the t ake-up sp indle, ens ure th at the

arrow on the knob aligns wit h the indented notch (see Fi gur e 25 i ns et) .

8. Place the ribbon (with leader, if used) around the ribbon take-up

spindle and wind counterclockwise for several turns.

9. Close the printhead.

Figure 23

Figure 24

Zebra XiIII-Series User’s Guide 39

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Refer to Figure 25.

1. Break the ribbon as close to the ribbon take-up spindle as possible.

2. While holding the ribbon take-up spindle, turn the knob (1) clockwise until it stops. This causes 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. Once the spent ribbon has been removed, ensure that the arrow on the knob aligns with the indented notch in the ribbon take-up spindle (see Figure 25 inset).

4. Remove the core from the ribbon supply spindle.

5. Follow the ribbon loading procedure on page 38 to load the new ribbon.

Figure 25

40 Zebra XiIII-Serie s User’s Guide

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After you have installed the media and ribbon and the Power-On Self Test (POST) is complete, the front panel display show s “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 ZebraLink PrintServer II required). For information, refer to ZebraNet Networking: PrintServer II Installation and User’s Guide.

If it becomes necessary to restore the initial printer defaults, see “FEED Key and PAUSE Key Self Test” on page 85.

NOTE: Unless otherwise noted, all parameters are listed in the order they

are displayed, starting with “DARKNESS.”

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T o en ter t he prog ramming mode , press the SETUP/ EXIT key. Press either the NEXT/SAVE key or PREVIOUS key to scroll to the parameter you wish to set.

NOTE: You may also press and hold the NEXT/SAVE and PREVIOUS

keys to quickly advance through the configuration parameters.

Parameters in this section are shown in the order displayed when pressing the NEXT/SAVE key. Throughout this process, press the NEXT/SAVE key to continue to the next parameter, or press the PREVIOUS key to return to the previous parameter in t he cycle.



WebView (optional ZebraNet

An asterisk (*) in the upper left-hand corner of the display indicates that the value di splayed is different than the currently stored value.

Zebra XiIII-Series User’s Guide 41

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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 the parameters are set incorrectly, they could cause the printer to function in an unpredictable way.

The first at tempt to chang e one of these parameters ( pressing one of the BLACK OVAL keys) requires you to enter a four-digit password. This is done via the “ENTER PASSWORD” display. The LEFT BLACK OVAL key changes the selected digit position; the RIGHT BLACK OVAL key increases the selected digit value. After entering the password, press the NEXT/SAVE key. The parameter you wish to change is displayed. If the password was entered correctly, you can now change the value.

The default password value is 1234. The password can be changed using the ^KP (Define Password) ZPL II instruction or through ZebraLink WebView (optional ZebraNet

NOTE: Once the password has been ent ered cor rectly, it does not have to

be entered again unless you leave and re-enter the programming mode using the SETUP/EXIT key, or if you power the printer down and then re-enter the programming mode.

You can disable the password protection feature so that it no longer prompts you for a password by setting the password to ØØØØ via the ^KPØ ZPL/ZPL II command. To re-enable the password-protection feature, send the ZPL/ZPL II command ^KPx, where “x” can be any number, one to four digits in length, except Ø.

PrintServer II required).



42 Zebra XiIII-Serie s User’s Guide

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You can leave the program mode at any time by pressi ng the SETUP/ EXIT key. The “SAVE CHANGES” display appears. There are five choi ces , as described below. Pressing the LEFT displays other choices and pressing the NEXT/SAVE key selects the displayed choice.

• PERMANE NT — Permanen tly saves the ch anges. Values are stored in

the printer even when power is turned off.

• TEMPORARY — Saves the changes until you change them again or

until power is turned off.

• CANCEL — Cancels all changes from the time you pressed the

SETUP/EXIT key except th e darkness and tear -of f s ettings (if they were changed).

• LOAD DEFAULTS — Loads factory d efa ul ts . The f act or y def aul t s ar e

shown on the following pages.

NOTE: Loading factory defaul ts requires printer calibration.

• LOAD LAST SAVE — Loads values from the last permanent save.

or RIGHT BLACK OVAL key

Zebra XiIII-Series User’s Guide 43

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Press Display Shows Action/Explanation

— PRINTER READY Normal printer operation.

Setting Print Parameters

Adjusting Print Darkness: Pres s the RIGH T BLA CK 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. If printing is too light, or if there are voids in printed areas, you

DARKNESS

TEAR OFF

PRINT MODE

should increase the darkness. If printing is too dark, or if there is spreading or bleeding of printed areas, you should decrease the darkness. The FEED Key Self Test on page 84 can also be used to determine the best darkness setting. Since the darkness setting takes effect immediately, you can see the results on labels that are currently printing. CAUTION: Set the darkness to the lowest setting that provides good print quality . Darkness set too high may cause ink smearing and/or it may burn through the ribbon. Darkness settings also may be changed by the driver or software settings.

Adjusting the Tear-Off Position: Press the RIGHT BLACK OVAL key to increase the value, press the LEFT BLACK OVAL key to decrease the value. Each press of the key adjusts the tearoff position by four dot rows.

Default: +0 Range: –120 to +120

This parameter establishes the position of the media over the tear-off/peel-off bar after printing.

Selecting Print Mode: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Tear-off Selections: Tear-off, peel-off, cutter, rewind, applicator

Print mode settings tell the printer the method of media delivery that you wish to use. Be sure to select a print mode that your hardware configuration supports since some selections displayed are for optional printer features.

44 Zebra XiIII-Serie s User’s Guide

Press Display Shows Action/Explanation

Setting Media Type: Press the RIGHT or LEFT BLACK OVAL

key to display other choices.

Default: Continuous Selections: Continuous, non-continuous

MEDIA TYPE

SENSOR TYPE

PRINT METHOD

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). When non-continuous media is selected, the printer feeds media to calculate label length (the distance between two recognized registration points of the inter-label gap, webbing, or alignment notch or hole).

Setting the Sensor Type: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Web Selections: Web, mark

This parameter tells the printe r whether you are using media with a web (gap/space between labels, notch, or hole) to indicate the separations between labels or if you are using media with a black mark printed on the back. If your media does not have black marks for registration on the back, leave your printer at the default (web).

Selecting Print Method : Press the RIGHT BLACK OVAL key for the next value; press the LEFT BLACK OVAL key for the previous value.

Default: Thermal transfer Selections: Thermal transfer, direct thermal

The print method parameter tells the printer the method of printing you wish to use: direct thermal (no ribbon) or thermal transfer (using thermal transfer media and ribbon). NOTE: Selecting direct thermal when using thermal transfer media and ribbon creates a warning condition, but printing continues.

Zebra XiIII-Series User’s Guide 45

Press Display Shows Action/Explanation

Setting Print Width: Press the RIGHT BLACK O VAL 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

PRINT WIDTH

MAXIMUM LENGTH

active, then press the RIGHT BLACK OVAL key to toggle to a different unit of measure (mm, inches, or dots). Default; Range: The default and range of acceptable values vary depending on what printer you have. Refer to “Printing Specifications” on page 90 for further information about the ranges available for your model. Print width determines the printable area across the width of the label. NOTE: The printer does not accept any value larger than the

maximum print width listed on page 90.

Setting Maximum Length: Press the LEFT BLACK OVAL key to decrease the value, press the RIGHT BLACK OVAL key to increase the value. Default; Range: The default and range of acceptable values vary depending on your printer’s configuration. Values are adjustable in 1" (25.4 mm) increments. Maximum length is used in conjunction with the calibration procedure. The value of this setting is the maximum label length that is used during the media portion of the calibration process. Only a few labels are required to set media sensors. Always set the value that is at least 1" longer than the longest label to be used on the printer.

46 Zebra XiIII-Serie s User’s Guide

Listing Printer Information

Press Display Shows Action/Explanation

List Fonts: Press the RIGHT BLACK OVAL key to print a label

LIST FONTS

LIST BAR CODES

LIST IMAGES

LIST FORMATS

LIST SETUP

LIST ALL

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.

List Bar Codes: Press the RIGHT BLACK OVAL key to print a label listing all of the available bar codes. This selection is used to print a label that lists all of the bar codes currently available in the printer.

List Images: Press the RIGHT BLACK OVAL key to print a label listing all of the available images. This selection is used to print a label that lists all of the images currently stored in the printer’s RAM, FLASH memory, optional EPROM, or optional memory card.

List Formats: Press the RIGHT BLACK OV AL key to print a label listing all of the available formats. This selection is used to print a label that lists all of the formats currently stored in the printer’s RAM, FLASH memory, optional EPROM, or optional memory card.

List Setup: Press the RIGHT BLACK OVAL key to print a label listing the current printer configuration. This selection is used to print a label that lists the current printer configuration information. (Same as the CANCEL key self test.)

List All: Press the RIGHT BLACK OVAL key to print a label listing all of the available fonts, bar codes, images, formats, and the current printer configuration. This selection is used to print a label that lists the five previous selections, as described.

Zebra XiIII-Series User’s Guide 47

Press Display

Shows

INITIALIZE CARD

INIT FLASH MEM

Action/Explanation

Initialize Memory Card CAUTION: Perform this operation only when it is necessary to erase all

previously stored information from the optional memory card (for printers with a PCMCIA slot [part # 32091]). 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 are now prompted to enter the password. Enter the password and then press the NEXT/ SAVE key.

2. The display asks “INITIALIZE CARD?”. Press the RIGHT BLACK OVAL key “YES.”

3. The front panel LCD asks “ARE YOU SURE?”.

4. Press the RIGHT BLACK OVAL key “YES” to begin initialization.

or Press the LEFT BLACK OVAL key “NO” to cancel the request and return to the “INITIALIZE CARD” prompt.

5. Press the SE T U P/ EXIT key followe d b y th e N EXT/SAVE key. If initialization is still in process, the front panel display flashes back and forth between the two phrases “CHECKING B: MEMORY” and “PRINTER IDLE.” When initialization is complete, the printer automatically exits the

configuration mode and the front panel displays “PRINTER READY.”

NOTE: Depending on the amount of memory in the memory

card, initialization may take up to five minutes to complete.

Initialize Flash Memory CAUTION: Perform this operation only when it is necessary to erase all

previously stored information from the FLASH memory. 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 are now prompted to enter the password. Enter the password and then press the NEXT/ SAVE key.

2. The display asks “INITIALIZE FLASH?”. Press the RIGHT BLACK OVAL

key “YES.”

3. The front panel LCD asks “ARE YOU SURE?”.

4. Press the RIGHT BLACK OVAL key “YES” to begin initialization.

or Press the LEFT BLACK OVAL key “NO” to cancel the request and return to the “INITIALIZE FLASH” prompt.

48 Zebra XiIII-Serie s User’s Guide

Media and Ribbon Sensor Calibration

NOTE: Before you begin this procedure, make sure that the maximum length is set to a value 1" greater

than the length of the labels you are using. If the maximum length is set to a lower value, the calibration process assumes that continuous media is in the printer. See page46 for more information. There are two different types of calibration that can be performed by the printer:

1) Standard Calibration. When the printer is first powered up and after the print head has been closed, the printer feeds media and automatically sets the value it detects for media, media backing material (the spaces between labels), and media out. This type of calibration also occurs as part of the sensor profile and media and ribbon calibration procedures.

2) Media and Ribbon Sensor Sensitivity Calibration. Performing the media and ribbon calibration procedure first resets the sensitivity of the sensors to better detect the media and ribbon you are using. With the sensors at their new sensitivity, the printer then performs the standard calibration. Changing the type of ribbon and/or media may require resetting the sensitivity of the media and ribbon sensors. Indications that the sensitivity may need to be reset would be a CHECK RIBBON light on with the ribbon properly installed or non-continuous media being treated as continuous media.

Press Display Shows Action/Explanation

Sensor Profile : Press NEXT/SAVE to skip this standard calibration

procedure and continue with the media and ribbon calibration parameter which follows. Press the RIGHT BLACK OVAL key to initiate this standard calibration procedure and print a media sensor

SENSOR PROFILE

profile. See Figure 26. The media sensor profile may be used to troubleshoot registration problems that may be caused when the media sensor detects preprinted areas on the media or experiences difficulty in determining web location. If the sensitivity of the media and/or ribbon sensors MUST be adjusted, use the media and ribbon sensor sensitivity procedure.

Figure 26

Zebra XiIII-Series User’s Guide 49

Press Display Shows Action/Explanation

Media and Ribbon Sensor Sensitivity: Press NEXT/SAVE to

skip the calibration procedure and continue with the host port

MEDIA AND RIBBON CALIBRATE

Media and Ribbon Calibration Procedure

LOAD BACKING

REMOVE RIBBON

CALIBRATING PLEASE WAIT

— RELOAD ALL

MEDIA AND RIBBON CALIBRATE

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.

Press the LEFT BLACK OVAL key to cancel the operation, or do the following:

1) Open the printhead.

2) Remove approximately 8" (203 mm) of labels from the media roll, and pull the backing into the printer so that only the backing is between the media sensors.

3) Press the RIGHT BLACK OVAL key to continue.

Press the LEFT BLACK OVAL key to cancel the operation or do the following:

1) Remove the ribbon.

2) Close the printhead.

3) Press the RIGHT BLACK OVAL key to continue.

The printer automatically adjusts the scale (gain) of the signals it receives from the media and ribbon sensors. On the sensor profile, this essentially corresponds to moving the peak of the graph up or down to optimize the readings for your application.

When “RELOAD ALL” is displayed:

1) Open the printhead and pull the media forward until a label is

positioned under the media sensor.

2) Reload the ribbon back into to its proper position.

3) Close the printhead.

4) Press the RIGHT BLACK OVAL key to continue.

Now that the scale has changed, the printer performs a calibration equivalent to pressing the CALIBRA TE key; during thi s process, the printer determines the label length. The process is now complete! To see the new readings on the new scale, print a sensor profile.

50 Zebra XiIII-Serie s User’s Guide

Setting Communication Parameters

Communication parameters must be set correctly for the printer to communicate with the host computer. These parameters make sure that the printer and host computer are “speaking the same language.” All communications parameters are password protected.

Press Display Shows Action/Explanation

Setting Parallel Communications: Press the RIGHT or LEFT

PARALLEL COMM

SERIAL COMM

BAUD

DATA BITS

BLACK OVAL key to display other choices.

Default: Parallel Selections: Parallel, twinax/coax

Select the communications port that matches the one being used by the host computer.

Setting Serial Communications: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: RS-232 Selections: RS-232, RS-422/485, RS-485 multidrop

Select the communications port that matches the one being used by the host computer.

Setting Baud: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: 9600 Selections: 110, 300, 600, 1200, 2400, 4800, 9600, 14400,

19200, 28800, 38400, 57600 The baud setting of the printer must match the baud setting of the host computer for accurate communications to take place. Select the value that matches the one being used by the host computer.

Setting Data Bits: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: 7-bits Selections: 7-bits, 8-bits

The data bits of the printer must match the data bits of the host computer for accurate communications to take place. Set the data bits to match the setting being used by the host computer. NOTE: Must be set to 8 data bits to use Code Page 850.

Zebra XiIII-Series User’s Guide 51

Press Display Shows Action/Explanation

Setting Parity: Press the RIGHT or LEFT BLACK OVAL key to

display other choices.

PARITY

STOP BITS

HOST HANDSHAKE

PROTOCOL

Default: Even Selections: Even, odd, none

The parity of the printer must match the parity of the host computer for accurate communications to take place. Select the parity that matches the one being used by the host computer.

Setting Stop Bits: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: 1 stop bit Selections: 1 stop bit, 2 stop bits

The stop bits of the printer must match the stop bits of the host computer for accurate communications to take place. Select the stop bits that match the one being used by the host computer.

Setting Host Handshake: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: XON/XOFF Selections: XON/XOFF, DTR/DSR

The handshake protocol of the printer must match the handshake protocol of the host computer for proper communications to take place. Select the handshake protocol that matches the one being used by the host computer.

Setting Protocol: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: None Selections: None, Zebra, ACK/NACK

Protocol is a type of error checking system. Depending on the selection, an indicator may be sent from the printer to the host computer signifying that data has been received. Select the protocol that is requested by the host computer. Further details on protocol can be found in the ZPL II Programming Guide. NOTE: Zebra is the same as ACK/NACK except that with Zebra

the response messages are sequenced. If Zebra is selected, printer must use “DTR/DSR” host handshake protocol.

52 Zebra XiIII-Serie s User’s Guide

Press Display Shows Action/Explanation

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

NETWORK ID

COMMUNICATIONS

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 computer the means to address a specific printer. If the printer is used in a RS-422/RS-485 network, you must select a network ID number. This does not affect TCP/IP or IPX networks.

Setting Communications Mode: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Normal mode Selections: Normal mode, diagnostics

The communication diagnostics mode is a troubleshooting tool for checking the interconnection between the printer and the host computer. When “diagnostics” is selected, all data sent from the host computer to the printer is printed as straight ASCII characters, with the hex value below the ASCII text. The printer prints all characters received including control codes, like CR (carriage return). A sample printout is shown in Figure 36 on page 85. NOTES on diagnostic printouts:

• FE indicates a framing error.

• OE indicates an overrun error.

• PE indicates a parity error.

• NE indicates noise. For any errors, check that your communication parameters are correct. Set the print width equal to or less than the label width used for the test. See page 46 for more information.

Zebra XiIII-Series User’s Guide 53

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.

Press Display Shows Action/Explanation

Control Prefix Character: Press the LEFT BLACK OVAL key

to move to the next digit position, press the RIGHT BLACK

CONTROL PREFIX

FORMAT PRE FIX

DELIMITER CHAR

OVAL key to increase the value of the digit.

Default: 7E (tilde - displayed as a black square) Range: 00-FF

The printer looks for this 2-digit hex character to indicate the start of a ZPL/ZPL II control instruction.

Format Prefix Character: 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: 5E (caret) Range: 00 - FF

The printer looks for this 2-digit hex character to indicate the start of a ZPL/ZPL II format instruction.

Delimiter Character: 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: 2C (comma) Range: 00 - FF

The delimiter character is a 2-digit hex value used as a parameter place marker in ZPL/ZPL II format instructions. Refer to th e ZPL II Programming Guide Volume I for more information.

54 Zebra XiIII-Serie s User’s Guide

Selecting ZPL Mode

Press Display Shows Action/Explanation

Selecting ZPL Mode: Press the RIGHT or LEFT BLACK OVAL

key to display other choices.

Default: ZPL II Selections: ZPL II, ZPL

ZPL MODE

Power-Up and Head Close Parameters

MEDIA POWER UP

HEAD CLOSE

The printer remains 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. Refer to the ZPL II Programming Guide for more information on the differences between ZPL and ZPL II.

Media Power-Up: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Calibration Selections: Feed, calibration, length, and no motion

This parameter establishes the action of the media when the printer is turned on.

• Calibration: Determines the length of the label.

• Feed: Feeds the label to the first registration point.

• Length: Used in continuous mode to feed the last stored label

length.

• No Motion: Media does not move. Head Close: Press the RIGHT or LEFT BLACK OVAL key to

display other choices.

Default: Calibration Selections: Feed, calibration, length, no motion

Determines the action of the media after the printhead has been opened and then closed.

• Calibration: Determines the length of the label.

• Feed: Feeds the label to the first registration point.

• Length: Used in continuous mode to feed the last stored label

length.

• No Motion: Media does not move.

Zebra XiIII-Series User’s Guide 55

Label Positioning Parameters

Press Display Shows Action/Explanation

Backfeed Sequence: Press the RIGHT or LEFT BLACK OVAL

key to display other choices. Default: Default (90%)

BACKFEED

LABEL TOP

LEFT POSITION

Selections: Default, after, before, 10%, 20%, 30%, 40%, 50%,

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. This parameter setting can be superseded by the ~JS instruction when received as part of a label format (refer to the ZPL II Programming Guide).

NOTE: The difference between the value entered and 100%

Adjusting Label Top Position: Press the RIGHT BLACK OVAL

key to increase the value, press the LEFT BLACK OVAL key to decrease the value. The displayed value represents dots.

Default: +0 Range: –120 to +120 dot rows

The label top position adjusts the print position vertically on the label. Positive numbers adjust the label top position further down the label (away from the printhead), negative numbers adjust the position up the label (toward the printhead).

Adjusting Left P os ition: Press the LEFT BLACK OVAL key to move the cursor, press the RIGHT BLACK OVAL key to change between + and – and to increase the value of the digit. The displayed value represents dots.

Default: 0000 Range: –9999 to +9999 NOTE: For a negative value, enter the value before changing to

This parameter establishes how far from the left edge of a label the format begins to print by adjusting horizontal positioning on the label. Positive numbers adjust the printing to the left by the number of dots selected, negative numbers shift printing to the right.

60%, 70%, 80%, off

establishes how much backfeed occurs before the next label is printed. For example, a value of 40 means that 40% of the backfeed takes place after the label is removed or cut. The remaining 60% takes place before the next label is printed. A value of “before” means that all backfeed takes place before the next label is printed.

the minus sign.

56 Zebra XiIII-Serie s User’s Guide

Press Display Shows Action/Explanation

Setting the Head Test Count: Press the LEFT BLACK OVAL

key to move the cursor, press the RIGHT BLACK OVAL key to change the value of the digit. Default: 0000 (disables the test)

HEAD TEST COUNT

HEAD RESISTOR

VERIFIER POR T

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.

Setting the Head Resistor Value: Press the LEFT BLACK OVAL key to move the cursor , press the RIGHT BLACK OV AL key to increase the value of the digit. CAUTION: This parameter should only be changed by qualified

personnel! Initial V a lue: Factory-set to match the printhead shipped with your printer.

Default Value: 0500 Range: 0500 to 1175

This value has been pre-set at the factory to match the resistance value of the printhead. It does not need to be changed unless the printhead is replaced or the main logic board is replaced. CAUTION: DO NOT set the value higher than that shown on the

printhead. Setting a higher value may damage the

printhead! Before replacing a printhead, look on the printhead for the label that shows the resistance value (ohm value).

Setting the Verifier Port: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Off Selections: Off, 1 VER-RPRNT, 2 VER-THRUPUT

The auxiliary port is used to determine how the printer reacts to the on-line verifier. There are currently three operating conditions for this port:

• Off: The verif i e r p o rt i s o ff.

• 1 VER-RPRNT ERR: Label reprinted if verifier detects an error.

If a bar code is near the upper edge of the label, the label is fed out far enough to be verified and then backfed to allow the next label to be printed and verified.

• 2 VER-THRUPUT : Allows greatest throughput but may not

indicate a verification error immediately upon detection. May print from one to three labels before an error is recognized and

printing stops. For more information on the operation of the optional verifier, refer to the documentation provided with that option.

Zebra XiIII-Series User’s Guide 57

Press Display Shows Action/Explanation

Setting the Applicat or 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

APPLICATOR PORT

WEB S.

MEDIA S.

RIBBON S.

printer is moving the label forward.

• Mode 2: Asserts the ~END_PRINT signal high while the printer is moving the label forward.

• Mode 3: Asserts the ~END_PRINT signal low for 20 milliseconds when a label has been completed and positioned. Not asserted during continuous printing modes.

• Mode 4: Asserts the ~END_PRINT signal high for 20 milliseconds when a label has been completed and positioned. Not asserted during continuous printing modes.

NOTE: Set as suggested by the applicator manufacturer.

MARK S.

MARK MED S.

MEDIA LED

RIBBON LED

MARK LED

These parameters are automatically set during the calibration procedure. They should only be changed by a qualified service technician. Refer to the maintenance manual for more information on these parameters. Press the NEXT/SAVE key repeatedly to skip these parameters.

58 Zebra XiIII-Serie s User’s Guide

Press Display Shows Action/Explanation

Start Print Signal: Press the RIGHT or LEFT BLACK OVAL

key to display other choices.

Default: Pulse Mode Selections: Pulse Mode, Level Mode

This parameter determines how the printer reacts to the Start Print Signal input on pin 3 of the applicator interface connector at the rear of the printer.

START PRINT SIG

RESYNCH MODE

• In Pulse Mode, labels print when the signal transitions from HIGH to LOW.

• In Level Mode, labels print as long as the signal is asserted LOW.

CAUTION: Start Print Signal is set by the applicator

manufacturer and should not be changed unless the factory defaults have been reloaded. Please make a note of it! While other choices are valid, the printer must be returned to its designated setting in order for it to work properly.

Resynch Mode: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Feed Mode Selections: Feed Mode, Error Mode

This parameter determines how the printer reacts if the label synchronization is lost and the label top is not where expected. FEED MODE — If the label top is not where expected, the printer feeds a blank label to find the label top position. ERROR MODE — If the label top is not where expected, the printer stops, enters the PAUSE mode, displays the message “Error Condition Feed Label”, flashes the ERROR LED, and asserts the “Service Required” signal (pin 10 on the Applicator Interface Connector). To resynch the media to the top of the label in this mode, press the PAUSE key to exit the PAUSE state. The ERROR LED stops flashing and the “Service Required” signal is deactivated. The action of the printer is determined by the “Head Close” configuration selection:

• “Calibration” — determines the length of the label.

• “Feed” — feeds the labels to the first registration point.

• “Length” — used in continuous mode to feed the last stored

label length.

• “No Motion” — the media does not move. The user must

press the FEED key to cause the printer to resynch to the start of the next label.

Zebra XiIII-Series User’s Guide 59

Press Display

Shows

LCD ADJUST

FORMAT CONVERT

IDLE DISPLAY*

RTC DATE*

RTC TIME*

Action/Explanation

LCD Display Adjustment: Press the LEFT BLACK OVAL key to

decrease the value (reduce contrast), press the RIGHT BLACK OVAL key to increase the value (increase contrast). Range: 00 to 19 This parameter allows you to adjust the contrast of your display if your display is difficult to read.

Format Convert: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: None Selections: None, 150 → 300, 150 → 600, 200 → 600, 300 → 600

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.

NOTE: Not applicable on all printers. Idle Display: Press the RIGHT or LEFT BLACK OVAL key to

display other choices.

Default: Firmware version Selections: mm/dd/yy (24 hour), mm/dd/yy (12 hour),

dd/mm/yy (24 hour), dd/mm/yy (12 hour) This parameter selects the LCD display options for the real time clock (if installed). NOTE: If the default value is not selected, pressing either BLACK OVAL key briefly displays the firmware version of the printer.

RTC (Real Time Clock) Date: 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. This parameter allows you to set the date following the convention selected in “IDLE DISPLAY.”

RTC (Real Time Clock) Time: 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. This parameter allows you to set the time following the convention selected in “IDLE DISPLAY.”

* Real Time Clock option required

60 Zebra XiIII-Serie s User’s Guide

Press Display

Shows

IP RESOLUTION*

IP PROTOCOLS*

IP ADDRESS*

SUBNET MASK*

DEFAULT GATEWAY*

Action/Explanation

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: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: All Selections: All, gleaning only, RARP, BOOTP, DHCP,

DHCP/BOOTP If “dynamic” was chosen in the previous parameter, this selection determines the method(s) by which the PrintServer II receives the IP address from the server. For more information, refer to ZebraNet Networking: PrintServer II Installation and User’s Guide.

IP Address: 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. This parameter allows you to select the IP address if “permanent” was chosen in “IP RESOLUTION.” (If “dynamic” was chosen, the user cannot select the address.) For more information, refer to ZebraNet Networking: PrintServer II Installation and User’s Guide.

Subnet Mask: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Permanent (user must set) Selections: Dynamic (user may set, but server can assign),

permanent This parameter selects the part of the IP address that is considered to be part of the local network. It can be reached without going through the default gateway.

Default Gateway: 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. This parameter allows you to select the IP address that the network traffic is routed through if the destination address is not part of the local network.

* ZebraNet® PrintServer II option required

Zebra XiIII-Series User’s Guide 61

Press Display Shows Action/Explanation

Selecting the Display Language: Press the RIGHT or LEFT

BLACK OVAL key to display other choices.

LANGUAGE

You have now completed the entire configuration and calibration sequence. You may either press the NEXT/SAVE key or the SETUP/EXIT key.

Default: English Selections: English, Spanish, French, German, Italian,

Norwegian, Portuguese, Swedish, Danish, Spanish

2, Dutch, Finnish, Japanese This parameter allows you to change the language used on the front panel display.

You are now back at the first parameter in the configuration sequence.

DARKNESS

SAVE SETTINGS

— PRINTER READY You have exited the configuration and calibration sequence and

NOTE: If you pressed the NEXT/SAVE key but are through programming the printer configuration, you may press the SETUP/EXIT key and continue with the “SAVE SETTINGS” function.

Save Settings: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Permanent Selections: Permanent, temporary, cancel, load defaults, load

last save. This display appears when you attempt to exit the configuration mode.

• Permanent: Permanently saves the changes, even when

printer power is turned off.

• Temporary: Saves the changes until changed again or until

power is turned off.

• Cancel: Cancels all changes since you entered the

configuration mode except for darkness and tear-off position (if they were changed).

• Load defaults: Loads factory defaults. NOTE: Loading factory defaults requires calibration.

• Load last save: Loads the values from the last permanent

save.

are now ready for normal printer operation.

62 Zebra XiIII-Serie s User’s Guide

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The following table provides a brief cleaning schedule. Specific cleaning procedures are provided on the following pages.

Area Method Interval

Printhead Solvent* Direct thermal print mode: Platen roller Solvent* Transmissive sensor Air blow Black mark sensor Air blow Media path Solvent* Ribbon sensor Air blow Label available sensors Air blow Monthly Tear-off/peel-off bar Solvent* Snap plate Solvent* Cutter Solvent* * Zebra recommends using isopropyl alcohol.

CAUTION: Use only the cleaning agents indicated. Zebra

Technologies Corporation is not responsible for damage caused by any other fluids being used on thi s printer.

After every roll of media (or 500’/152 m of fanfold media).

Thermal transfer print mode: After every roll of ribbon.

As needed

Zebra XiIII-Series User’s Guide 63

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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.

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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.

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Inconsistent print quality, such as voids in the bar code or graphics, may indicate a dirty printhead. For best results, perform the following cleaning procedure after every roll of ribbon.

NOTE: You do not need to turn off the printer before cleaning the

printhead. If power is turned off, all label f or mats and images, as well as any temporarily saved parameter settings stored in the printer’s internal memory, are lost. When power is turned back on, you need to reload these items.

To clean the printhead, refer to Figure 27 and follow these steps:

1. Open the printhead.

2. Remove the media and ribbon (if loaded).

3. Moisten an applicator tip with solvent and wipe along the print elements from end to end. (The print elements are on the brown strip just behind the chrome strip on the printhead.) Allow a few seconds for the solv ent to evapor ate.

64 Zebra XiIII-Serie s User’s Guide

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 the printhead. NOTE: If print quality has not impr oved afte r perfo rming thi s procedu re,

try cleaning the printhead with Save-a-Printhead cleaning film. This specially-coated material removes contamination buildup without damaging the printhead. Call your authorized Zebra reseller/distributor for more information.

Figure 27

Zebra XiIII-Series User’s Guide 65

Extend the Life of Y our Printhead

With Save-A-Printhead Cleaning Film

Challenge

The printhead is the most critical component in your printer, and possibly the most delicate. It is a consumable item just like the brakes on your car, which eventually wears over time. However, with ongoing careful attention and maintenance, you can extend the life of the printhead!

Below are photographs of three printheads. The first printhead is brand new. The second has print ed over 1 million li near i nches of thermal transfer labels and ha s b een properly maintained. The third printhead has printed far fewer labels, but without proper care and maintenance, signs of abrasion and contamination build-up are evident.

Preventive Maintenance

For optimum performance, clean the printhead regularly after every roll of thermal transfer ribbon or afte r eve ry rol l of dir ect ther mal la bels. Take care when handling or cleaning the printhead by removing any jewelry that may scratch the printhead and use a grounding strap or anti-static mat to discharge static electricity that could damage the printhead.

To start, only use the pre-soaked (isopropyl alcohol) cleaning swabs provided in the preventive maintenance kit. First, turn off the printer and open the printhead. Lightly blow or brush away any loose dust and lint particles within the print mechanism (i.e., rollers, media/ribbon sensors, and printhead). NEVER use any hard, metallic, or abrasive objects — such as a screwdriver — to remove adhesives or other contaminants that may have built up on the printhead.

Next, press the swab tip agains t the printhea d and swipe the print elements from end to end. Then, turn the platen rollers while wiping them from side to side. Repeat this step until the swab no longer shows dirt.

66 Zebra XiIII-Serie s User’s Guide

Avoid the Contributing Factors to Premature Printhead Failure

Abrasion through the protective ceramic coating, exposing and eventually damaging the print elements ( dots).

In order to avoid abrasion:

• Clean your printhead frequently and use well-lubricated thermal transfer ribbons

• Minimize printhead pressure and burn temperature settings by optimizing the

• En sur e that the thermal transf er rib bon i s as wi de or wide r than the label media to

Ribbon Backcoating and Buildup or thermal transfe r ribbon may occu r in a pplic at ions r equir ing hi gh bu rn se ttin gs, hig h head pressure, high speed, or high volume. This contamination builds up on the printhead elements, creating a barrier to the heat transformation required to produce high quality images. Contaminant buildup occurs gradually and results in poor print quality that may look like faded print or failed print element(s). This build up is very resistant to cleaning wi th the pre-soaked swabs an d is difficult to remove.

In order to avoid ribbon backcoating and buildup:

• Use thermal transfer ribbons that have been specially cured to provide backcoat

• Follow the recommended Printhead Preventive Maintenance procedures.

• Use our Save-a-Printhead cleaning film to remove printhead contamination

- Over time, the movement of media/ribbon across the printhead wears

with backcoatings optimiz ed to redu ce fr ict i on. balance between the two. prevent exposing the elements to the m ore abrasive label material.

- Printhead contamina tion from dire ct thermal media

protection for high deman d appl i cat ions. These ribbons — sometimes refer re d to as anti-stick ribbons — also dissipate static and provide more lubrication.

buildup quickly and easily.

Save-a-Printhead Cleaning Film

What is contamination buildup without damaging the printhead.

What are the benefits of

• Extends the life of your printhead.

• Reduces maintenance downtime and the cost of replacing a printhead.

• An inexpensive, easy and quick way to remove contaminants without having to

When should you use quality that looks like faded print or a failed print element(s) that cannot be corrected by cleaning with the pre-soaked cleaning swabs.

Zebra XiIII-Series User’s Guide 67

Save-a-Printhead cleaning film? A specially c oated film that removes

Save-a-Printhead cleaning film?

remove the printhead.

Save-a-Printhead cl eaning fil m? When you see de grading pri nt

How to Use Save-a-Printhead Cleaning Film

1. Remove power from the printer.

2. Open the printhead, remove media and ribbon from the print mechanism.

3. Clean the printhead per the recommended Preventive Maintenance procedures.

4. Position the Save-a-Printhead film in the pri nt path, placing the glossy s ide down away from th e printhead (matte side up).

5. Close and latch the printhead.

6. Slowly pull the full length of the film through the print mechanism.

7. Again, clean the printhead per the recommended Preventive Maintenance procedures.

8. Reload media and ribbon, close and latch the printhead.

9. Print labels and inspect for improved print quality. If quality has not improved, contact our Technical Support staff.

*Only one pass is required to remove contamination buildup. *Each strip of film can be used up to 10 times. *Discard the strip when residue buildup or other contamination is apparent.

NOTE: In the case that a replacement printhead is needed, product from

the Original Equipment Manufacturer (OEM) is strongly recommended to ensure that your printer and pa rt warranties remain intact, and that the product performs optimally.

How to Order Save-a-Printhead Cleaning Film Kits

There are five kits to accommodate the different width printers. Each kit contains three 10" long strips of film. Reference the following table to order the kit fo r your printer:

Order kit number:

46902 3.0"-4.0" 44902 4.0"-5.0" 48902 5.0"-6.0" 38902 6.0"-7.0" 22902 8.0"-9.0"

68 Zebra XiIII-Serie s User’s Guide

For Printers with Print Widths:

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The media, ribbon, and label available sensors should be cleaned on a regular basis to ensure proper operatio n of the printer. To locate these sensors, refer to Figure 27 on page 65, Figure 6 on page 11, and Figure 7 on page 12. Brush/vacuum any accumulated paper lint and dust off of these sensors.

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Clean the snap plat e to remove l abel adhe sive or a l abel that has adher ed to the underside of the snap plate.

Refer to Figu re 28.

1. Insert a small- blade sc rewdriver or similar tool in to the loop on t he left side of the snap plate. Lift the snap plate.

CAUTION: Take care not to 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.

Refer to Figu re 29.

5. T o reinstal l the snap plate , insert th e two tabs on the botto m of the snap plate into the two slots of the media pathway.

6. Slide the snap plate toward you.

7. Press down on the loops to lock the snap plate into place.

Zebra XiIII-Series User’s Guide 69

Figure 28

Figure 29

70 Zebra XiIII-Serie s User’s Guide

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(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 removes 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.

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CAUTION! No lubricating agents of any kind should be used on

this printer! Some commercially available lubric ant s will damage the finish and the mechanical parts if used.

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The printer uses a metric-style fuse (5 x 20 mm IEC) rated at F5A, 250V. The end caps of the fuse must bear the certification mark of a known international safety organization (see Figure 38 on page 92). The printer comes with two approved fuses: one in the circuit and one in the “spare fuse” holder.

1. Turn of f the prin ter power and unplug the p ower cord from the ba ck of the printer. See Figure 30.

2. Using a small-blade screwdriver or similar tool, remove the fuse holder from the printer.

3. Remove the faulty fus e and install a new fuse of the correct type. Refer to Figure 31. The fu se that goes into the printer first is the one that is “in-circuit.” If you use the spare fuse, be sure to order a replacement fuse (fuses can be ordered from your Zebra distributor).

Zebra XiIII-Series User’s Guide 71

4. Snap the fuse holder back into position.

5. Reconnect the power cord. NOTE: If the new fuse fails right a way, the printer has an internal

component failure and must be repaired.

Figure 30

Figure 31

72 Zebra XiIII-Serie s User’s Guide

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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 narr ow to accommod ate both tog gles, posit ion one toggle over the center of the media and decrease the pressure on the unused toggle. If you are using a 90 or 96XiIII printer, position the single toggle over the center of the media.

NOTE: Make sure that the toggle pressur e is even acr oss the width of the

media. Otherwise, the media and/or ribbon may “drift.”

Figure 32

Zebra XiIII-Series User’s Guide 73

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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 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. Loosen the knurled (upper) locking nuts at the top of the toggle assembly/assemblies.

5. Increase or decrease spring pressure using the knurled (lower) adjusting nuts on the shafts of the toggle until the left and right edges of printed area are equally dark.

NOTE: Printhead life can be maxi mized by usi ng the lo west pres sure that

produces the desired print quality.

6. Increase darkness to the optimum level for the media being used.

7. Retighten locking nuts.

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See “Positioning the Media Sensors” on page 10.

74 Zebra XiIII-Serie s User’s Guide

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Problem Solution

In thermal transfer mode, the ribbon is not loaded or loaded incorrectly.

In thermal transfer mode, the ribbon sensor is not sensing correctly loaded ribbon.

In direct thermal mode, when ribbon is not used:

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Problem Solution

The media is not loaded or loaded incorrectly. Reload the media. Refer to “Roll Media Loading” on

The media sensor is not adjusted properly. Check the position of the upper and lower media sensors.

The printer is set for non-continuous media, but continuous media is loaded.

The incorrect media sensor is being used.

The maximum label length is set shorter than the label length being used.

Load the ribbon correctly. See “Ribbon Loading” on page 38.

Perform the media and ribbon sensor calibration (see page 17).

Put the printer in direct thermal mode via the front panel and remove ribbon (if loaded).

Ensure that the printer driver or software settings are correctly set (if applicable).

page 27.

Refer to “Positioning the Media Sensors” on page 10. Either load the correct media or set the printer for the

correct media type via the front panel. Ensure that the printer driver or software settings are

correctly set (if applicable). Calibrate the printer (see page 17). Via the front panel, check the sensor type to ensure that the

correct one is used for the media loaded. See page 16. Calibrate the printer (see page 17).

Via the front panel, set the label length to a value that is slightly longer than the length of the label being used.

Zebra XiIII-Series User’s Guide 75

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Problem Solution

The printhead is not fully closed. Close the printhead.

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Problem Solution

One or more of the printhead elements has failed the printhead element test.

If the failed elements impact your printing application, replace the printhead. To override this error , disable the head test count feature on the front panel by defaulting the value to “0000.” See page 57.

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Problem Solution

Remove the ribbon and set the printer to direct thermal mode.

The ribbon is loaded.

Ensure that the printer driver and/or software settings are correctly set (if applicable).

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Problem Solution

Allow the printer to cool. Printing automatically resumes

The printhead is over temperature.

when the printhead elements cool to an acceptable operating temperature.

76 Zebra XiIII-Serie s User’s Guide

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Problem Solution

The printhead is under temperature.

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.

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Problem Solution

Cutter blade is in the media path. 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 71.

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Problem Solution

Insufficient memory for the label length, downloaded fonts/

*There is not enough memory to perform the function shown on the second line of the error message.

graphics, and images. Ensure that the device, such as FLASH memory or

PCMCIA card, is installed and not write protected or full. Ensure that the data is not directed to a device that is not

installed or available.

Zebra XiIII-Series User’s Guide 77

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Problem Solution

You are using an incorrect media and ribbon combination for your application.

The printer is set at the incorrect print speed. For optimal print quality, set the print speed to the lowest

The printer is set at the incorrect darkness level.

The printhead is dirty. Clean the printhead according to the instructions on

There is light printing (or no printing) on the left or right side of the label or the printed image is not sharp.

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Problem Solution

The printhead is dirty. Clean the printhead according to the instructions on

/LJKWFRQVLVWHQWYHUWLFDOOLQHVUXQQLQJWKURXJKDOORIWKHODEHOV

Consult your authorized Zebra reseller/distributor for information and advice.

possible setting via ZPL II, the driver, or the software. For optimal print quality, set the darkness to the lowest

possible setting via the front panel, the driver, or the software.

page 64. The toggle pressure needs to be adjusted. Follow the

printhead pressure adjustment instructions on page 74.

page 64.

Problem Solution

The printhead or platen roller is dirty. Clean the printhead, platen roller, or both according to the

instructions on page 64.

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Problem Solution

There is too much toggle pressure on the printhead.

78 Zebra XiIII-Serie s User’s Guide

Reduce the toggle pressure. See “Printhead Pressure Adjustment” on page 74.

Zebra XiIII-Series User’s Guide 79

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Problem Solution

The host is set to EPP parallel communications.

The serial communication settings are incorrect.

Change the settings on the computer host to standard parallel communications.

Ensure that the flow control settings match. Check the communication cable length. See page 22 for

requirements. Check the printer driver or software communications

settings (if applicable).

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Problem Solution

The prefix and delimiter characters set in the printer do not match the ones in the label format.

Incorrect data is being sent to the printer.

Verify the prefix and delimiter characters. See page 54.

Ensure that ZPL is being used. Check the communication settings on the computer.

Ensure that they match the printer settings.

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Problem Solution

The printer was not calibrated for the label being used.

The printer is configured for continuous media.

The driver or software configuration is not set correctly.

Perform the calibration procedure on page 17.

Set the media type to non-continuous media.

As driver or software settings produce ZPL commands that can overwrite the printer configuration, check the driver or software media-related setting.

80 Zebra XiIII-Serie s User’s Guide

3ULQWHU'LDJQRVWLFV

3RZHU2Q6HOI7HVW

A limited Power-On Self Test (POST) is performed automatically each time the printer is turned on (additional self tests can be performed by pressing the CANCEL and CALIBRATE keys when you turn the printer on). During either test sequence, the front panel lights and liquid crystal display (LCD) monitor t he progres s of the POST. If the printer fails a ny of these tests, the word “FAILED” is added to the display. If this occurs , notify an authorized Zebra reseller.

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These self tests p rodu ce sampl e pri ntout s and pr ovide speci fic i nformat ion that help de termine the operating con ditions for the printer.

Each self test is enabled by pressing a specific front panel key or combination of keys while turning the POWER switch on. Keep the key(s) depressed until the DATA light turns off. When the power-on self test is complete, the selected self test starts automatically.

NOTE: When performing self tests, avoid sending a label format to the

printer. In the case of a remote hos t, disconnect all data inter fa ce cables from the printer.

When canceling a self test prior to its act ual completion, always turn the printer power off and then back on to reset the printer.

When performing these self test s whil e in the peel - off mode, you must remove the labels as they become available.

If your media is not wide enough or long enough, unexpected and/or undesired results may occur. Make sure that your print width is set correctly for the media you are using before you run any self tests, oth erwise the t est may print out on the pla ten roller.

Zebra XiIII-Series User’s Guide 81

CANCEL Key Self Test

This self te st prints a listing of the configuration parameters currently stored in th e 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). Saving new parameters occurs whenever a calibration procedure is performed. Refer to page 15 for further information about the configuration procedure. Additional Power- Up Self Tests are also performed during the POST for t his tes t.

Figure 33

82 Zebra XiIII-Serie s User’s Guide

PAUSE Key Self Test

This self test can be used to provide the test labels required when making adjustments to the prin ter’s mechanica l assemblies. See the sample printout in Figure 34.

1. Turn of f the printer.

2. Press and hold the PAUSE key while turning on the power.

• The initial self test prints 15 labels at 2.4"/61 mm per second (1"/25.4 mm per second for the 96XiIII), then automatically pauses the printer. When the PAUSE key is pressed, an additional 15 labels print.

• While the printer is paused, pressing the CANCEL key alters the self test. When the PAUSE key is pressed, the printer prin ts 15 labels at 6"/152 mm per second (4"/102 mm per second for the 96XiIII).

• While the printer is pause d, pr ess ing the CANCEL key agai n al ter s the self test again. When the PAUSE key is pressed, the printer prints 50 labels at 2.4"/61 mm per second (1"/25.4 mm per second for the 96XiIII).

• While the printer is pause d, pr ess ing the CANCEL key agai n al ter s the self test a third time. When the PAUSE key is pressed, the printer prints 50 labels at 6"/152 mm per second (4"/102 mm per second for the 96XiIII).

• While the printer is pause d, pr ess ing the CANCEL key agai n al ter s the self test a fourth time. When the PAUSE key is pressed, the printer prints 15 labels at the printer’s maximum speed.

• To exit this self test at any time, press and hold the CANCEL key.

Figure 34

Zebra XiIII-Series User’s Guide 83

FEED Key Self Test

See Figure 35.

1. Turn of f the printer.

2. Press and hold the FEED key while turning on the power.

The FEED key self test pri nt s ou t a t 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 44 for more information.

Figure 35

The value printed on that label is added to (plus) or subtracted from (minus) the darkness value specified on the configuration label. The resulting nume ric val ue (0 to 30) is the b est dark ness v alue for that s pecif ic media/ribbon combination.

84 Zebra XiIII-Serie s User’s Guide

FEED Key and PAUSE Key Self Test

1. Turn of f the printer.

2. Press and hold the FEED and PAUSE keys while turning on the power. Performing this self test temporarily r esets the printer configura tion to the

factory default values. These values are active only until power is turned off unless you save them permanently in memory.

Communications Diagnostics Test

This test is controlled from the fron t panel display. Refer to “COMMUNICATIONS” on page 53. A typical printout from this test is shown in Figure 36. Turn off the pow er to exit this self test.

NOTE: This label is inverted when printed.

Figure 36

Additional Printer Diagnostics

Additional diagnostic tests are available for this printer, however, they are beyond the scope of this user’s guide. Refer to the maintenance manual for information about these additional tests.

Zebra XiIII-Series User’s Guide 85

86 Zebra XiIII-Serie s User’s Guide

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NOTE: Printer specifications are subject to change without notice.

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• Tear-off mode: Labels are produced in strips.

• Peel-off mode: Labels are dispensed and peeled from the liner as

needed.

• Cutter mode: Labels are printed and individually cut.

• Rewind mode: Labels are rewound internally.

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• Cutter • IBM twinax interface

• Rewind • IBM coax interface

• Cutter-rewind • RS-485 interface

• Cutter tray • Font cards

• Media supply spindle (1.6”/40 mm core) • DRAM memory expandable to 12 MB

• Media supply spindle (3”/76 mm core) • Memory cards

• Applicator interface • Printer drivers for Windows™ operating systems

• Real time clock • Double-hinged media door with clear panel

• Bar-One

• Advanced counter

on-screen label design and print application software

Windows™-based WYSIWYG

• ZebraNet® PrintServer II, including Ethernet interface (10Base-T), ZebraLink™ WebView graphical setup and printer control, and ZebraLink™ Alert unsolicited error notification

Zebra XiIII-Series User’s Guide 87

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• 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 • Communicates in printable ASCII characters

• Adjustable print cache • Error-checking protocol

• Data compression • Status message to host upon request

• Automatic virtual input buffer management • Serialized fields

• Format inversion • In-spec OCR-A and OCR-B

• Mirror image printing • UPC/EAN

• Four-position field rotation (0°, 90°, 180°, 270°) • User-programmable password

• Slew command

• Controlled via mainframe, mini-computer, PC, portable data terminal

• Programmable quantity with print, pause, and cut control

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• Bar code ratios - 2:1, 7:3, 5:2, 3:1 • ISBT-128

• Codabar (supports ratios of 2:1 up to 3:1) • LOGMARS

• CODABLOCK • MaxiCode

• Code 11 • Micro PDF

• Code 39 (supports ratios of 2:1 up to 3:1) • M SI

• Code 49 (2-dimensional bar code) • PDF-417 (2-dimensional bar code)

• Code 93 • Plessey

• Check digit calculation where applicable • POSTNET

• Data Matrix • QR-Code

• EAN-8, EAN-13, EAN extensions • Standard 2 of 5

• Industrial 2 of 5 • UPC-A, UPC-E, UPC extensions

• Interleaved 2 of 5 (supports ratios of 2:1, up to 3:1, Modulus 10 Check Digit)

• Code 128 (with subsets A, B, and C and UCC case C codes)

88 Zebra XiIII-Serie s User’s Guide

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General Specifications 90/96XiIII 140XiIII 170XiIII 220XiIII

Height 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 55 lb 25 kg 67 lb 30.5 kg 72 lb 32.7 kg

General (auto adjusting) 90-26 4 V AC;

Printing

Electrical

Temperature

Relative Humidity Operating Environment 20% to 85% non-condensing

Power Consumption

Compliance Complies with FCC class “B” and Canadian D oc. class “A” rules.

Operating environment

Storage –40° to

Storage 5% to 85% non-condensing

PAUSE test label at slowest speed

Printer idle 20 W 19 W 19 W 20 W

Thermal transfer

Direct thermal

48-62 Hz

121 W 180 W 220 W 269 W

41° to

104° F

32° to

104° F

140°F

5° to

40° C

0° to

40° C

–40° to

60° C

90-264 VAC;

48-62 Hz

Carries the CE mark of compliance.

41° to

104° F

32° to

104° F –40° to

140°F

5° to

40° C

0° to

40° C

–40° to

60° C

90-264 V AC ; 48-

62 Hz

41° to

104° F

32° to

104° F –40° to

140°F

5° to

40° C

0° to

40° C

–40° to

60° C

90-264 VAC;

48-62 Hz

41° to

104° F

32° to

104° F

–40° to

140°F

5° to

40° C

0° to

40° C

–40° to

60° C

Zebra XiIII-Series User’s Guide 89

3ULQWLQJ6SHFLILFDWLRQV

Printing Specifications 90XiIII 96XiIII 140XiIII 170XiIII 220XiIII

Resolution 300 dots/inch

Dot size (width x length)

First dot location measured from inside media edge

Maximum print width 3.4" (86 mm) 3.2" (81 mm) 5.04" (128 mm) 6.6" (168 mm) 8.5" (216 mm)

Noncontinuous printing

Print length (maximum)

Continuous printing

Bar code modulus (“X”) dimension

Thin film printhead with Element Energy Equalizer (E3)

Ladder (rotated) orientation 3.9 mil to 39 mil 1.6 mil to 16 mil 4.9 mil to 49 mil 3.9 mil to 39 mil 4.9 mil to 49 mil Picket fence (non-rotated)

orientation

With standard memory

With 12 MB memory

With standard memory

With 12 MB memory

(12 dots/mm)

0.0033" x

0.0039"

(0.84 mm x

0.100 mm)

0.12" ± 0.035" (3 mm ±

0.89 mm)

39" (991 mm) 20" (508 mm) 39" (991 mm) 39" (991 mm) 39" (991 mm)

39" (991 mm) 39" (991 mm) 39" (991 mm) 39" (991 mm) 39" (991 mm)

80" (2032 mm) 20" (508 mm) 121" (3073 mm) 41" (1041 mm) 71" (1803 mm)

100" (2540 mm) 52" (1321 mm) 150" (3810 mm) 100" (2540 mm) 150" (3810 mm)

3.33 mil to 33 mil 1 .6 mil to 16 mil 4.9 mil to 49 mil 3.33 mil to 33 mil 4.9 mil to 49 mil

Yes Yes Yes Yes Yes

600 dots/inch

(23.5 dots/mm)

0.0016" x

0.0016"

(0.042 mm x

0.042 mm)

0.12" ± 0.035" (3 mm ±

0.89 mm)

2 0 3 d o t s/ i nc h

(8 dots/mm)

0.0049" x

0.0049"

(0.125 mm x

0.125 mm)

0. 1 0 " ± 0 . 0 3 5 " (2.5 mm ±

0.89 mm)

30 0 d o t s/ in c h (12 dots/mm)

0.0033" x

0.0039"

(0.84 mm x

0.100 mm)

0.10" ± 0.035" (2.5 mm ±

0.89 mm)

20 3 d ot s/ in ch

(8 dots/mm)

0.0049" x

0.0049"

(0.125 mm x

0.125 mm)

0.10" ± 0.035" (2.5 mm ±

0.89 mm)

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Ribbon Specifications 90/96XiIII 140XiIII 170XiIII 220XiIII

Ribbon must be wound with the coated side out. Ribbon width (Zebra recommends using ribbon at least

as wide as the media to protect the printhead from wear.)

Standard lengths

Ribbon core inside diameter 1.0" (25.4 mm) 1.0" (25.4 mm) 1.0" (25.4 mm) 1.0" (25.4 mm) Maximum ribbon roll outside diameter 3.2" (81.3 mm) 3.2" (81.3 mm) 3.2" (81.3 mm) 3.2 (81.3 mm)

2:1 media to ribbon roll ratio 984 ft. (300 m) 984 ft. (300 m) 984 ft. (300 m) 984 ft. (300 m) 3:1 media to ribbon roll ratio 1476 ft.

Minimum 0.79" (20 mm) 1.57" (40 mm) 2.0" 51 mm) 4.25" (108 mm) Maximum 3.40" (87 mm) 5.10" (130 mm) 6.7" 170 mm) 8.60" (220 mm)

(450 m)

1476 ft. (450 m)

90 Zebra XiIII-Serie s User’s Guide

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Media Specifications 90/96XiIII 140XiIII 170XiIII 220XiIII

Tear-off 0.7" (18 mm) 0.7" (18 mm) 0.7" (18 mm) 0.7" (18 mm)

Minimum label length*

Total media width (label + liner, if any)

Total thickness (includes liner, if any)

Cutter maximum full-width media thickness 0.014" (0.35 mm) 0.009" (0.23 mm) 0.007" (0.18 mm) 0.005" (0.14 mm) Roll media core inside diameter 3" (76 mm) 3" (76 mm) 3" (76 mm) 3" (76 mm) Maximum roll diameter 8.0" (203 mm) 8.0" (203 mm) 8.0" (203 mm) 8.0" (203 mm)

Inter-label gap

Maximum internal fanfold media pack size (label + liner) L x W x H

Ticket/tag sensing notch L x W 0.12" x 0.25"

Ticket/tag sensing hole diameter 0.125" (3 mm) 0.125" (3 mm) 0.125" (3 mm) 0.125" (3 mm)

Effective leading edge registration accuracy*

Mark length (measuring parallel to label/tag edge)

Mark width (measuring to

Additional specifications for black mark sensing

perpendicular label/ tag edge)

Mark location Marks must be located within 0.040" (1 mm) of the inside media edge. Mark density >1.0 Optical

Maximum density of the back of the media on which the black mark is printed

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) Minimum 0.79" (20 mm) 1.57" (40 mm) 2.00" (51 mm) 4.25" (108 mm) Maximum 3.54 mm

Minimum 0.003"

Maximum 0.012"

Minimum 0.079" (2 mm) 0.079" (2 mm) 0.079" (2 mm) 0.079" (2 mm) Preferred 0.118" (3 mm) 0.118" (3 mm) 0.118" (3 mm) 0.118" (3 mm) Maximum Maximum i n ter-label g a p =

Vertical ± 0.060"

Horizontal ± 0.060"

Minimum 0.12" (3 mm) 0.12" (3 mm) 0.12" (3 mm) 0.12" (3 mm) Maximum 0.43" (11 mm) 0.43" (11 mm) 0.43" (11 mm) 0.43" (11 mm)

Minimum 0.43" (11 mm) 0.43" (11 mm) 0.43" (11 mm) 0.43" (11 mm) Maximum Full media width Full media width Full media width Full media width

(90 mm)

(0.076 mm)

(0.305 mm)

2 x (label length for which you have calibrated the printer) + 1"

8.0" x 4.5 " x 4.5" (203 mm x

114 mm x

114 mm)

(3 mm) x (6 mm)

(±1.5 mm)

Density Unit

(ODU)

0.5 ODU 0.5 ODU 0.5 ODU 0.5 ODU

5.51 mm (140 mm)

0.003"

(0.076 mm)

0.012"

(0.305 mm)

8.0"x 5.5" x 4.5" (203 mm x 140 mm x

114 mm)

0. 12" x 0 .2 5 "

(3 mm) x (6 mm)

± 0.070"

(±1.8 mm)

± 0.070"

(±1.8 mm)

>1.0 Optical Density Unit

(ODU)

7.1 mm

(180 mm)

0.003"

(0.076 mm)

0.012"

(0.305 mm)

8.0" x 7.1" x 4.5" (203 mm x

180 mm x

114 mm)

0. 1 2" x 0 . 25 "

(3 mm) x (6 mm)

± 0.060"

(±1.5 mm)

± 0.060"

(±1.5 mm)

>1.0 Optical Density Unit

(ODU)

8.80 mm

(224 mm)

0.003"

(0.076 mm)

0.012"

(0.305 mm)

8.0" x 8.8" x 4.5 " (203 mm x

224 mm x

114 mm)

0. 1 2" x 0. 25 "

(3 mm) x 6 mm)

± 0.050”"

(±1.3 mm)

± 0.060"

(±1.5 mm)

>1.0 Optical Density Unit

(ODU)

* Media registration and minimum label length are affected by media type and width, ribbon type, print speed, and printer mode of operation.

Performance improves as these factors are optimized. Zebra recommends always qualifying any application with thorough testing.

Zebra XiIII-Series User’s Guide 91

3RZHU/LQH&RUG6SHFLILFDWLRQV

• The overall length must be less than 9.8 feet (3.0 meters).

• It must be rated for at least 5 A, 250 V.

• The chassis ground (earth) MUST be connected to ensure safety and reduce electromagnet ic interference. The gro und c onnection is handled by the third wire (earth) in the power line cord. See Figure 37.

• 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.

Figure 37

Figure 38

92 Zebra XiIII-Serie s User’s Guide

Zebra Technologies XiIII-Series User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General Specifications 90/96XiIII 140XiIII 170XiIII 220XiIII

Printing Specifications 90XiIII 96XiIII 140XiIII 170XiIII 220XiIII

Ribbon Specifications 90/96XiIII 140XiIII 170XiIII 220XiIII

Media Specifications 90/96XiIII 140XiIII 170XiIII 220XiIII