Zebra Technologies XiII-Series User Manual

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Zebra XiII-Series

User's Guide

Customer order # 48460L Manufacturer part # 48460LB Rev. 2

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Proprietary Statement

This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the informa tion and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Corporation.

Product Improvements

Continuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and signs are subject to change without notice.

FCC Compliance Statement

NOTE: This equipment has been tested and found to comply with the limits for a Class A digital Device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

In order to insure compliance, this printer must be used with a Shielded Power Cord and Shielded Communication Cables. "The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies Corporation

could void the user's authority to operate the equipment."

Canadian DOC Compliance Statement

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in the radio interference regulations of the Canadian Department of Communications.

CE Compliance

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

Liability Disclaimer

Zebra Technologies Corporation takes steps to assure that its published Engineering Specifications and Manualsare correct; however, errors do occur. Zebra Technologies Corpora tion reserves the right to correct any such errors and dis- claims liability resulting therefrom.

No Liability for Consequential Damage

In no event shall Zebra Technologies corporation or anyone else involved in the creation, production, or delivery of the accompanying product (including hardware and software) be liable for any damages whatsoever (including,without limitation, damages for loss of business profits, business interruption, loss of business information, or other pecuniary loss) arising out of the use of or the results of use of or inability to use such product, even if Zebra Technologies Corpo ration has been advised of the possibility of such damages. Because some states do not allow the exclusion or limitation of liability for consequential or incidental damages, the above limitation may not apply to you.

Copyrights

This copyrighted manual and the label printer described herein are owned by Zebra Technologies Corporation. 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.

All trademarks are the property of their respective owners. Centronics is a registered trademark of Genicom Corporation. Compugraphic is a registered trademark and CG Triumvirate, CG Triumvirate Condensed, CG Palacio, and CG Times are all Trademarks of AGFA Corporation. Futura is a trademark of Fundicion Tipografica Neufville, S.A. TrueType is a registered trademark of Apple Computer, Inc. Univers is a registered trademark of Linotype AG and/or its subsidiaries. IBM is a registered trademark and Windows is a trademark of IBM Corporation. BAR-ONE, SCAN-ONE, Stripe, TRACK-ONE, WEDGE-ONE, Zebra, ZPL, and ZPL II are registered trademarks and TotalCare is a trademark of Zebra Technologies Corporation.

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Warranty Information

1. Printer Warranty

ZEBRA printers, excluding thermal printheads which are warranted separately below, are warranted against defects in material or workmanship for six (6) months from the date of original shipment by ZEBRA Technologies Corporation. This warranty does not cover normal wear and tear and shall be null and void if the equipment is modified, improperly installed or used, damaged by accident or neglect, or in the event any parts are improperly installed or replaced by the user.

Since printhead wear is part of normal operations, the original printhead and replacement printheads are covered by a limited warranty of six (6) months from the date of original shipment by ZEBRA Technologies. To qualify for this warranty, the printer must be returned to the factory or other authorized service center. Although the user is not required to purchase ZEBRA brand supplies (media and/or ribbons), to the extent it is determined that the use of other supplies (media and/or ribbons) shall have caused any defect in the thermal printhead for which a warranty claim is made, the user shall be responsible for ZEBRA Technologies customary charges for labor and materials to repair such defect. To the extent that it is determined that failure to follow the preventive maintenance schedule and procedures listed in the Users Guide shall have caused any defect in the thermal printhead for which a warranty claim is made, this limited warranty shall be void.

ZEBRA TECHNOLOGIES SOLE OBLIGATION UNDER THIS WARRANTY SHALL BE TO FURNISH PARTS AND LABOR FOR THE REPAIR OR REPLACEMENT OF PRODUCTS FOUND TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP DURING THE WARRANTY PERIOD.

As a condition of this warranty, the user must: (a) obtain a ZEBRA Return Authorization for the printer, or subassem- bly(s); (b) ship the printer or subassembly(s), transportation prepaid to the authorized service location; and (c) include with the Product or subassembly(s) a written description of the claimed defect. Unless ZEBRA Technologies authorizes return of the entire Product, the user shall return only the subassembly(s). Products returned shall be packaged in the original packing and shipping container or comparable container. In the event equipment is not so packaged or if ship- ping damage is evident, it will not be accepted for service under warranty. Surface transportation charges for the return of the printer to the customer shall be paid by ZEBRA Technologies within the 48 contiguous states and the District of Columbia. Customer shall pay shipping costs, customs clearance, and other related charges outside the designated area. If ZEBRA Technologies determines that the Product returned to it for warranty service or replacement is not defective as herein defined, BUYER shall pay all costs of handling and transportation.

2. Supplies Warranty

ZEBRA supplies are warranted to be free from defects in materials or workmanship for a period of either the stated ma terial shelf life or 6 months from date of shipment, whichever occurs first, provided that the BUYER has complied with ZEBRA Technologies guidelines on storage, handling, and usage of the labeling supplies in ZEBRA printers. ZEBRA Technologies does not warrant the performance of ZEBRA labeling supplies on non-ZEBRA printers.

Any supplies product shown to the satisfaction of ZEBRA Technologies, within the time provided, to be so defective shall be replaced without charge, or ZEBRA Technologies may issue a credit in such an amount as it deems reasonable.

3. Warranty Exclusions and Conditions

The above warranties are in lieu of all other warranties, expressed or implied, oral or written, statutory or otherwise, in cluding any implied warranty of merchant-ability or fitness for a particular purpose.

ZEBRA Technologies shall not be responsible for the specific application to which any Products are applied, including but not limited to compatibility with other equipment.

All statements, technical information and recommendations relating to ZEBRA Products are based upon tests believed to be reliable but do not constitute a guarantee or warranty.

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ZEBRA TECHNOLOGIES SHALL NOT, UNDER ANY CIRCUMSTANCES WHATSOEVER, BE LIABLE TO BUYER OR ANY OTHER PARTY FOR LOST PROFITS, DIMINUTION OF GOOD WILL OR ANY OTHER SPECIAL OR CONSEQUENTIAL DAMAGES WHATSOEVER WITH RESPECT TO ANY CLAIM HEREUNDER. IN ADDITION, ZEBRA TECHNOLOGIES LIABILITY FOR WARRANTY CLAIMS SHALL NOT, IN ANY EVENT, EXCEED THE INVOICE PRICE OF THE PRODUCT CLAIMED DEFECTIVE, NOR SHALL ZEBRA TECHNOLOGIES BE LIABLE FOR DELAYS IN REPLACEMENT OR REPAIR OF PRODUCTS.

No salesperson, representative or agent of ZEBRA Technologies is authorized to make any guarantee, warranty, or rep resentation in addition to the foregoing warranty.

NO WAIVER, ALTERATION, ADDITION, OR MODIFICATION OF THE FOREGOING WARRANTIES SHALL BE VALID UNLESS MADE IN WRITING AND SIGNED BY AN EXECUTIVE OFFICER OF ZEBRA TECHNOLOGIES.

Zebra Software License Agreement

The enclosed software and documentation are protected by the United States copyright law and international treaty, and therefore you must treat them like a book, with the exception that you may make copies to protect yourself against loss of the original.

Your right to use the enclosed software and documentation as described below is non-exclusive and non-transferable. Zebra retains ownership in the software and documentation and all other right, title and interest. The enclosed software and documentation may be used by any number of people and may be freely moved from one computer to another as long as there is no possibility of their being used by more than one person on more than one computer at the same time.

Machine readable files representing graphics or fonts which you have created independently may be converted to ZPL format files using the enclosed software and such files may be used, copied onto diskettes or font cards, given away, or sold without paying license fees to Zebra.

Pictorial or graphic images and machine readable files representing them may be protected by United States copyright law and international treaty provisions which prohibits you from transcribing or scanning such images or using copying, or converting such files without permission of the copyright owner. You may not use this software in violation of U.S. copyright law or international treaty. By using this software, you agree to be bound by these terms.

Zebra Technologies Corporation (Zebra) warrants the enclosed diskette to be free of defects in material and workmanship for a period of 60 days from the date of purchase. In the event of notification within the warranty period of defects in material and workmanship, Zebra will replace the defective diskette or documentation. Zebra specifically disclaims all other warranties, expressed or implied, including but not limited to implied warranties of merchantability and fitness for a particular purpose.

IN NO EVENT WILL ZEBRA TECHNOLOGIES BE LIABLE FOR LOST PROFITS, LOST DATA, OR ANY OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES CAUSED BY ABUSE OR MISAPPLICATION OF THE SOFTWARE OR BY ITS USE IN VIOLATION OF THE U.S. COPYRIGHT LAW OR INTERNATIONAL TREATY.

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Warranty Information . . . . . . . . . . . . . . . iii

Printer Warranty . . . . . . . . . . . . . . . . iii

Supplies Warranty . . . . . . . . . . . . . . . iii

Warranty Exclusions and Conditions. . . . . . iii

Zebra Software License Agreement . . . . . . . . iv

List of Figures . . . . . . . . . . . . . . . . . . . xi

List of Tables . . . . . . . . . . . . . . . . . . . xii

Getting Started 1

Contents

Introduction. . . . . . . . . . . . . . . . . . . . . 1

Print Mechanism Capabilities . . . . . . . . . . 1

Media Transport Mechanism Capabilities . . . 2

Front Panel Display . . . . . . . . . . . . . . . 2

System Requirements. . . . . . . . . . . . . . . . 2

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

Unpacking . . . . . . . . . . . . . . . . . . . . . 3

Reporting Damage. . . . . . . . . . . . . . . . 4

Storage and Reshipping . . . . . . . . . . . . . 4

Site Requirements . . . . . . . . . . . . . . . . . 5

Printer Power-Up . . . . . . . . . . . . . . . . 5

Communications . . . . . . . . . . . . . . . . . . 6

Loading Media . . . . . . . . . . . . . . . . . . . 6

Introduction to Media Loading . . . . . . . . . 6

Tear-Off Mode Media Loading . . . . . . . . . 8

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Cutter Mode Media Loading . . . . . . . . . . 11

Rewind Mode Media Loading . . . . . . . . . 11

Peel-Off Mode Media Loading . . . . . . . . 14

Removing the Label Backing Material . . . . . . 15

Transmissive Media Sensor

Position Adjustment. . . . . . . . . . . . . . . . 15

Adjusting the Upper Media Sensor Position . . 16

Lower Media Sensor Adjustment . . . . . . . 17

Ribbon Loading . . . . . . . . . . . . . . . . . . 18

Ribbon Removal . . . ..............20

Operation 21

Operating Your Zebra XiII-Series Printer . . . . . 21

Printer Operating Modes . . . . . . . . . . . . . 21

Tear-Off Mode . . . ..............21

Peel-Off Mode . . . ..............22

Rewind Mode . . . ..............22

Cutter Mode . . . . . . . . . . . . . . . . . . 22

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

Power Switch. . . . . . . . . . . . . . . . . . 23

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

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

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

Printer Status Sensors . . . . . . . . . . . . . 27

Initial Printer Power-Up. . . . . . . . . . . . . . 28

Configuration and Calibration . . . . . . . . . . 29

Entering the Program Mode . . . . . . . . . . 29

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Changing Password-Protected Parameters 30

Leaving the Program Mode . . . . . . . . . . 31

Configuration and Calibration Sequence . . . 32

Sample ZPL II Label Formats . . . . . . . . . . 46

Format 1: Simple Text and a Barcode . . . . . 48

Format 2: Saving a Label Format

As a Graphic Image . . . . . . . . . . . . . . 48

Format 3: Using a Serialized Data Field . . . . 49

Routine Care and Adjustment 51

Cleaning . . . . . .................51

Cleaning the Exterior . . . . . . . . . . . . . 52

Cleaning the Interior . . . . . . . . . . . . . . 52

Cleaning the Printhead and Platen Roller . . . 52

Cleaning the Sensors . . . . . . . . . . . . . . 53

Cleaning the Cutter Module . . . . . . . . . . 54

Lubrication . . . . . . . . . . . . . . . . . . . . 54

Fuse Replacement . . . . . . . . . . . . . . . . . 54

Adjustments . . . . . . . . . . . . . . . . . . . . 56

Toggle Positioning . . . . . . . . . . . . . . . 56

Printhead Pressure Adjustment . . . . . . . . 57

Media Sensor Position Adjustment . . . . . . 57

Troubleshooting and Diagnostics 59

Printer Diagnostics . . . . . . . . . . . . . . . . 65

Power-On Self Test . . . . . . . . . . . . . . 65

Additional Printer Self Tests . . . . . . . . . . 65

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Options 71

Rewind Option . . . . . . . . . . . . . . . . . . 71

Cutter . ......................71

Internal Fanfold Media Supply Bin . . . . . . . . 72

MemorySIMMs..................72

Zebra On-Line Verifier . . . . . . . . . . . . . . 72

Applicator Interface . . . . . . . . . . . . . . . . 73

Media Supply Spindle. . . . . . . . . . . . . . . 73

Optional Media Supply Fins . . . . . . . . . . . 73

Fonts........................73

PCMCIA Type I Memory Cards . . . . . . . . . 74

KMT Printhead . . . . . . . . . . . . . . . . . . 74

Communication Interfaces . . . . . . . . . . . . 74

IBM

Twinax Interface . . . . . . . . . . . . 74

Coax Interface. . . . . . . . . . . . . . 74

ZebraNet™ (Ethernet) Interface . . . . . . . . 74

RS-485 Interface . . . . . . . . . . . . . . . . 75

Specifications 77

Media Handling . . . . . . . . . . . . . . . . . . 77

Options ......................77

Zebra Programming language (ZPL II

Bar Codes .....................78

General Specifications . . . . . . . . . . . . . . 79

Printing Specifications . . . . . . . . . . . . . . 79

).....78

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Ribbon Specification . . . . . . . . . . . . . . . 80

Media Specifications . . . . . . . . . . . . . . . 81

Power Line Cord Specifications . . . . . . . . . 82

Printer Fonts. . . . . . . . . . . . . . . . . . . . 83

Standard Printer Fonts . . . . . . . . . . . . . 83

Standard Printer Font Examples . . . . . . . . 84

Optional Printer Fonts . . . . . . . . . . . . . 85

Optional Printer Font Examples.. . . . . . . . 86

Appendix 87

Printer Interface Technical Information. . . . . . 87

System Considerations . . . . . . . . . . . . . 87

RS-232/RS-422/RS-485 Serial Data Port . . . 88

Parallel Data Port . . . . . . . . . . . . . . . 92

Cabling Requirements . . . . . . . . . . . . . 93

ASCII Code Chart. . . . . . . . . . . . . . . . . 94

Adjusting Darkness for “In-Spec” Bar Codes. . . 95

Too Dark . . . . . . . . . . . . . . . . . . . . 96

Slightly Dark . . . . . . . . . . . . . . . . . . 96

Slightly Light. . . . . . . . . . . . . . . . . . 96

Too Light. . . . . . . . . . . . . . . . . . . . 96

“In-Spec”. . . . . . . . . . . . . . . . . . . . 96

Glossary 99

Index 103

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List of Figures

1. Media Loading 8

2. Roll Media Loading 9

3. Fanfold Media Loading 10

4. Upper Media Sensor Adjustment 16

5. Lower Media Sensor Adjustment 17

6. Ribbon Loading Diagram for the 90XiII and 140XiII Printers 19

7. Ribbon Loading Diagram for the 170XiII and 220XiII Printers 19

8. Removing Used Ribbon 20

9. Front Panel 24

10. Media and Ribbon Sensor Profile Sample Printout 46

11. Cleaning Diagram 53

12. Fuse Replacement Step 1 55

13. Fuse Replacement Step 2 55

14. Toggle Adjustment 56

15. Cancel Key Self Test Sample Printout 66

16. Pause Key Self Test Sample Printout 67

17. Feed Key Test Sample Printout 69

18. Communications Diagnostics Test Sample Printout 69

19. Power Line Cord 82

20. International Safety Organizations 82

21. Standard Printer Font Examples 84

22. Select Examples of Optional Fonts 86

23. Bitmap Smooth Fonts: Point Size Examples 86

24. RS-232 Connections 89

25. 9 Pin to 25 Pin Interconnecting Cable 90

26. 25 Pin to 25 Pin Interconnecting Cable 90

27. RS-422/RS-485 Interconnecting Cable 91

28. RS-422/RS-485 Connections 91

29. Bar Code Examples 97

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List of Tables

1. Front Panel Keys 25

2. Front Panel Lights 26

3. Printer Status Sensors 27

4. Power-On Self Test Sequence 28

5. Cleaning Schedule 51

6. Troubleshooting 59

7. Eight Dots/mm Printhead 83

8. Twelve Dots/mm Printhead 84

9. Optional Printer Fonts Currently Available 85

10. RS-232/RS-422/RS-485 Pinouts 88

11. Parallel Connector Pinouts 92

12. ASCII Code Chart 94

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Getting Started

Congratulations! You have just purchased a high-quality thermal demand printer manufactured by the industry leader in quality, service, and value— Zebra Technologies Corporation. For over 25 years, Zebra has provided customers with the highest caliber of products and support.

This manual provides all of the information you will need to operate your printer on a daily basis. To create label formats, refer to the ZPL II Pro gramming Guide (part # 46469L). This guide is available by contacting your distributor or Zebra Technologies Corporation.

There is also a maintenance manual for this printer: The maintenance manual (part # 48452L) contains the information you may need in order to maintain your printer.

Introduction

The XiII printer, when connected to a host computer, functions as a complete system for printing labels, tickets, and tags. The printer receives instructions from the host computer. Microprocessors continuously monitor these signals along with the inputs received from the control panel and various sensors. The microprocessors interpret this information and control the XiII printer’s mechanics, printhead, communications, command inter pretation, label formatting, media control, and mechanical drive.

Print Mechanism Capabilities

The XiII print mechanism has been designed to print information on labels, tickets, and tags. It uses a square or rectangular dot thermal printhead that heats a ribbon as it passes beneath the print elements, melting its ink onto the media (direct thermal print mode involves using heat-sensitive media instead of an inked ribbon). Print speeds are selected via software control.

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Media Transport Mechanism Capabilities

The media transport mechanism of the XiII printer has been designed to accommodate various types of media including die-cut labels, ticket and tag stock, continuous roll media, fanfold media, and black-mark media.

Media may be rewound internally onto standard three-inch cores if the Rewind Option is installed. The Rewind Option also allows backing material to be rewound internally, so that the printer can operate in Peel-Off mode.

Front Panel Display

The XiII printer features a two-line by 16-character-per-line liquid crystal display screen. Operational status, programming modes and parameters, and other messages are displayed here. This display features adjustable backlighting for added visibility.

System Requirements

In addition to the XiII printer, you will need the following items to form a complete label preparation system:

Label-, ticket-, or tag-stock.

A device, such as a computer, for data entry and output of label formats.

A data communication cable to connect the controlling device to the XiII printer. (Remote installations may require additional cables and communication devices such as modems and/or protocol converters.)

Thermal transfer ribbon (if printing in Thermal Transfer mode).

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Media and Ribbon Requirements

Print quality not only depends on the XiII-Series printer but also on the media and ribbon used. Factors such as reflectivity and contrast are impor tant for bar code scanning applications. Factors such as paper abrasion and temperature requirements are important to maintaining printhead life.

We STRONGLY RECOMMEND the use of Zebra Technologies Corporation-brand supplies for continuous high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the printing capabilities of the Zebra XiII-Series printer and to ensure against premature printhead wear.

Continuous roll media, fanfold media, or cardstock with optional perfora tions and registration holes may be used. Printhead life may be reduced by the abrasion of exposed paper fibers when using perforated media.

Ribbons used in the Zebra XiII printer MUST be as wide as or wider than the media used. Zebra-brand ribbons provide an extremely smooth backing surface which protects the printhead from abrasion by the media. If the ribbon is narrower than the media, areas of the printhead will be unprotected and will be subject to premature wear.

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. This is especially true if you’re operating in Peel-Off mode, where these variables combine with label size, backing content, die-cut depth, and even humidity to affect printer operation.

Unpacking

Save the carton and all packing materials in case shipping is ever required. Inspect the printer for possible damage incurred during shipment.

Check all exterior surfaces.

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Reporting Damage

If you discover shipping damage upon inspection:

Immediately notify the shipping company of the damage.

Retain all packaging material for shipping company inspection.

File a damage report with the shipping company and notify your local distributor and Zebra Technologies Corporation of the damage.

Zebra Technologies Corporation is not responsible for any damage incurred during shipment of the equipment and will not repair this damage under warranty. Immediate notification of damage to the shipping company or its insuring agency will generally result in ensuring any damage claim validity and ultimate monetary compensation.

Storage and Reshipping

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

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

Relative humidity: 5 to 85% non-condensing

To ship the Zebra XiII-Series printer, first remove all media and ribbon from the supply and take-up/rewind spindles to prevent damage to the printer. Then carefully pack the printer in a suitable container to avoid dam age during transit. Whenever possible, use the original shipping container. If the original shipping container is lost or destroyed, one can be purchased from Zebra Technologies Corporation . If a different container is used, package the printer carefully to avoid damage. Zebra will not be responsible for shipping damage incurred due to improper packaging!

CAUTION: When packaging the printer in a rigid container, use

shock mounts or shock-absorbing packing material. A rigid container will allow shock on the outside to be transmitted undamped to the printer which may cause damage.

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Site Requirements

CAUTION: To insure that the printer has proper ventilation and

cooling, do not place any padding or cushioning mate rial under the unit because this restricts air flow.

The Zebra XiII-Series printer may be installed on any solid, level surface of sufficient size and strength to accommodate the physical dimensions and weight of the unit. The area enclosure in which the printer will operate must meet the environmental conditions specified. Electrical power must be available and in close proximity to the printer.

Since the Zebra XiII-Series printer was designed and is fabricated as an industrial-type unit, it will function satisfactorily in areas such as ware houses, factory floors, and office environments that conform to specified environmental and electrical conditions.

Printer Power-Up

Follow the instructions in this section to connect this printer to a source of electrical power and a data source.

Voltage Selection

The XiII printer auto-adjusts for 90-264 VAC electrical power. No further adjustment is required.

Power Cord

WARNING! For personnel and equipment safety, always

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.

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 82.

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

use a three-prong plug with a ground (earth) connection.

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Communications

The XiII printer has been designed with flexible communication capabilities that allow the printer to be interfaced to a variety of controlling devices. A single DB25 connector includes all signals necessary for interfacing the printer to RS-232, RS-422, or RS-485 serial data communication devices at data rates from 110 to 57,600 baud. Baud rate, parity, data length, number of stop bits, and handshaking protocol are programmable via the front panel display and keypad.

A parallel data communication port is also provided. This port allows data to be sent to the printer at a higher speed than serial communications and still permits printer status information to be sent back to the host via the RS-232 serial port.

CAUTION: Zebra printers comply with international regulations

governing radiated emissions when using fully shielded data cables. Data cables must be fully shielded and fitted with metal or metalized connector shells. Shielded data cables and connectors are required to prevent radiation and reception of electrical noise. Use of unshielded data cables may increase radiated emissions above the regulated limits.

Loading Media

Introduction to Media Loading

NOTE: A Calibration must be performed when media and ribbon (if used)

are first installed in the printer and when a different type of media or ribbon is installed. See “Media and Ribbon Sensor Calibration” on page 36.

NOTE: Media widths and thicknesses vary between applications. To

maintain print quality from one application to another, refer to “Adjustments” on page 56.

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Non-Continuous Media

This type of media has some type of physical characteristic (gap, notch, per foration, etc.) which indicates the start/end of each label. The Media Sensor must be properly positioned to sense these indicators. See “Transmissive Media Sensor Position Adjustment” on page 15.

Continuous Media

Since continuous media does not contain label start/end indicators, you must tell the printer via software how long each label is. If you are using ZPL or ZPL II, include a Label Length (^LL) instruction in each label for

mat you send to the printer (refer to your ZPL II Programming Guide). If you are using other software to communicate with your printer, refer to the instructions provided with that software.

Black-Mark Media

This type of media has black marks printed on the back that indicate the start/end of each label. The Reflective Media Sensor detects these marks, which allows the printer to differentiate between labels. It is generally used with a cutter to separate the labels because there is no gap between the labels to allow them to be peeled off.

To load media, refer to Figures 1 through 3 and follow the loading procedure for your application. This section details the media loading instructions for the printer. For descriptions of the operating modes, refer to the Opera tion section.

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TEAR OFF/

PEEL OFF

BAR

CLOSED

PLATEN ROLLER

SPINDLE

OPEN

LOWER

ROLLER

HOOK

MEDIA GUIDE

MEDIA

DANCER

ROLLER

ASSEMBLY

REWIND

SPINDLE

(OPTION)

ONLY ON SELECT MODELS

SUPPLY

GUIDE

MEDIA

SUPPLY

MEDIA

SUPPLY

HANGER

Figure 1. Media Loading

Tear-Off Mode Media Loading

Figure 1 illustrates the method of loading media. First, move the Printhead Open Lever counterclockwise to the open position and raise the printhead. Second, slide the Media Guide and the Media Supply Guide as far out from the printer frame as possible and flip down the Media Supply Guide.

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TEAR-OFF

CUTTER

CUTTER REWIND

Figure 2. Roll Media Loading

REWINDPEEL-OFF

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Roll Media Loading

Place the media roll on the Media Supply Hanger and thread the media through the printhead assembly as shown in the “Tear-Off” loading part of Figure 2. Flip up the Media Supply Guide and adjust the Media Supply Guide and the Media Guide against the outer edge of the media. These guides must not cause pressure or excessive drag on the media. Close the Printhead Open Lever and see “Transmissive Media Sensor Position Adjustment” on page 15.

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TEAR-OFF

UTTER

BOTTOM SUPPLY REAR SUPPLY

Figure 3. Fanfold Media Loading

Fanfold Media Loading

Fanfold media, from outside the printer, feeds through either the bottom or rear access slot. You may also use the Fanfold Supply Bin to hold media inside the printer housing.

To load fanfold media, thread the media through the Printhead Assembly as shown in Figure 3. Adjust the Media Guide against the outer edge of the media. This guide must not cause pressure or excessive drag on the media. Close the Printhead Open Lever, and turn to “Transmissive Media Sensor Position Adjustment” on page 15.

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Continuous Media Loading

Continuous media mounts inside the printer in the same manner as roll me dia. For proper printer operation, a label length instruction must be included in the label format sent to the printer.

Cutter Mode Media Loading

(Cutter Option Required)

To ensure proper media loading, follow the directions for the Tear-Off Mode with the exception that the media must also be routed through the Cutter Module as shown in Figures 2 and 3.

Close the Printhead Open Lever. The printer will automatically feed out and cut one label when the printer is powered on. Turn to “Transmissive Media Sensor Position Adjustment” on page 15.

Rewind Mode Media Loading

(Rewind Option Required)

NOTE: For best results, install the printer on a level surface. This is

especially helpful with wider printers using wide media. If the surface is not level, the media may “telescope” off of the Rewind Spindle, causing unsatisfactory results.

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Rewind Mode for Printers Without the Cutter Option

1. Remove the Media Rewind Plate from its storage location in front of

the print mechanism inside the media compartment.

2. Invert the Rewind Plate so that the lip on the attached Hook Plate points

down.

3. Insert the Hook Plate lip a short distance (½") into the lower opening in

the Side Plate.

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4. Align the upper end of the Rewind Plate with the corresponding open

ing in the Side Plate and slide the Rewind Plate in so that it stops against the printer’s main frame.

5. Load the media as described in the instructions for Roll Media Loading on page 9. When loading the media, allow about one yard of media to extend past the Tear-Off bar. If using label stock remove all labels from this portion of the media to create a leader.

6. Remove the Spindle Hook from the Rewind Spindle. If you are using a core, remove all tape from the core and slide it onto the Rewind Spindle until it is flush against the guide plate.

7. Route the media as shown in Figures 1 and 2 and wind it once or twice around either (1) the Rewind Spindle and reinstall the Hook, or (2) a 3" core. (With some media, especially tag stock, you may need to tape the end of the media to the core if it will not otherwise tighten onto the core. DO NOT tape the label stock unless absolutely necessary.)

NOTE: Before closing the Printhead Open Lever, make sure that the

following guidelines are met:

the media is positioned against the inside guides, and the outer guide and Media Supply Guide barely touch the media

the media is taut

the media is parallel with itself and with the pathway when wound on the Rewind Spindle/core

8. Media loading is now complete. See “Transmissive Media Sensor Position Adjustment” on page 15.

Rewind Mode for Printers With the Cutter Option

1. Remove the Media Rewind Plate from its storage location in front of the print mechanism inside the media compartment.

2. Invert the Rewind Plate so that the lip on the attached Hook Plate points down.

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3. Insert the Hook Plate lip a short distance (½") into the lower opening in the Side Plate and slide the Rewind Plate in 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.)

6. Remove the Hook from the Rewind Spindle. If you are using a core, re move all tape from the core and slide it onto the Rewind Spindle until it is flush against the guide plate.

NOTE: Before closing the Printhead Open Lever, make sure that the

following guidelines are met:

the media is positioned against the inside guides, and the outer guide and Media Supply Guide barely touch the media

the media is taut

the media is parallel with itself and with the pathway when wound on the Rewind Spindle/core

8. Media loading is now complete. See “Transmissive Media Sensor Position Adjustment” on page 15.

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Peel-Off Mode Media Loading

(Rewind Option Required)

NOTE: For best results, install the printer on a level surface. This is

especially helpful with wider printers using wide media. If the surface is not level, the media may “telescope” off of the Rewind Spindle, causing unsatisfactory results.

1. Remove the Rewind Plate if one is present on the front of the printer and store it on the two mounting screws on the inside of the front panel. Align the notch in the bracket so the Label Available Sensor (shown in Figure 14 on page 56) can detect a peeled label.

2. Load the media as described in the instructions for Roll Media Loading on page 9. When loading the media, allow about one yard of media to extend past the Tear-Off bar. Remove all labels from this portion of the media to create a leader.

3. Remove the Hook from the Rewind Spindle. If you are using a core, remove all tape from the core and slide it onto the Rewind Spindle until it is flush against the guide plate.

4. Wind the backing around either (1) the Rewind Spindle and reinstall the hook or (2) a 3” core. Make sure that the media backing is against the Backing Guide Plate.

NOTE: Before closing the Printhead Open Lever, make sure that the

following guidelines are met:

the media is positioned against the inside guides, and the outer guide and Media Supply Guide barely touch the media

the media is taut

the media is parallel with itself and with the pathway when wound on the Rewind Spindle/core

5. See “Transmissive Media Sensor Position Adjustment” on page 15.

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Removing the Label Backing Material

(Rewind Option Required)

Since the Backing Rewind Spindle holds the backing from a standard-size media roll, we recommend that you perform this procedure whenever you change the media.

To remove the backing material from the Backing Rewind Spindle, follow these steps (you don’t need to turn the printer power off for this procedure).

1. Unwind about one yard (one meter) of backing from the Backing Rewind Spindle and cut it off at the spindle.

2. Pull out the Spindle Hook and slide the backing material off of the spindle and discard.

3. Wind the media around the Rewind Spindle once or twice and reinstall the Spindle Hook. Continue winding to remove any slack in the media.

Transmissive Media Sensor Position Adjustment

When the XiII printer is powered on, it performs a self test and configures its operating characteristics. Some of these characteristics are determined by the position of the Transmissive Media Sensor. The factory-set position is sufficient for most types of media. However, if media sensor position adjustments are needed, follow the procedures below.

NOTE: The Reflective (Black-Mark) Media Sensor position is not

adjustable; it is positioned to accommodate all black-mark media that meets the specifications listed in “Media Specifications” on page 81.

NOTE: If you are using continuous media (no gap, notch, or hole between

labels) or black-mark media, position the transmissive sensor over the media so that the printer can detect an out-of-paper condition. The factory-set position should be sufficient for this purpose.

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The Transmissive Media Sensor consists of two sections. The media passes between a light source (Lower Media Sensor) and a light sensor (Upper Media Sensor).

This adjustment aligns the position of the Upper and Lower Media Sensors with the notch or edge of the label.

UPPER

MEDIA SENSOR

ADJUSTMENT

Figure 4. Upper Media Sensor Adjustment

Adjusting the Upper Media Sensor Position

NOTE: If you own a 140XiII or 170XiII printer and need to move the

sensor to the outside half of the maximum media width, or from the outside half to the inside half, contact a service technician to perform this procedure because it will require additional steps which are beyong the scope of this user’s guide.

To adjust the upper media sensor, follow these steps.

1. Remove ribbon if it is installed.

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2. Locate the Upper Media Sensor. Refer to Figure 4. The Upper Media Sensor is directly below the adjustment screw head.

3. Loosen the Upper Media Sensor Adjustment screw (Phillips head).

4. Slide the upper sensor along the slot to the desired position. When using label stock that has a gap between labels (die-cut label stock), position the media sensor anywhere along the gap EXCEPT where the rounded corners of the label are detected. When using tagstock, position the up

per sensor directly over the hole or notch.

5. Tighten the screw.

Lower Media Sensor Adjustment

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LOWER

MEDIA SENSOR

Figure 5. Lower Media Sensor Adjustment

Refer to Figure 5 throughout this procedure.

1. Locate the Lower Media Sensor assembly (a spring clip holding a circuit board) near the bottom rear of the printhead assembly.

2. Position the sensor by sliding it in its slot so that the two brass-colored infrared emitters are centered under the upper sensor.

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3. If you are moving the sensor away from the printer’s main frame: Gently pull wires out of the printer frame as required. (Wires should have a little slack.) Call a service technician if there is not enough slack in the wires to adjust the sensor to the desired position. If you are mov ing the sensor toward the printer’s main frame and a large loop of wire develops, call a service technician to properly adjust the wires.

Ribbon Loading

To load ribbon, refer to Figures 6 and 7 and follow the procedure below.

NOTE: Use ribbon that is at least as wide as the media. The smooth

backing of the ribbon protects the printhead from wear and premature failure due to excessive abrasion. (For Direct Thermal

Print Mode, ribbon is not used and should not be loaded in the printer.)

1. Align the segments of the Ribbon Supply Spindle.

2. Place the ribbon roll on the Ribbon Supply Spindle.

NOTE: Make sure that the core is pushed up against the stop on the ribbon

supply spindle and that the ribbon is aligned squarely with its core. If this is not done, the ribbon may not cover the printhead entirely on the inside, thereby exposing print elements to potentially damaging contact with the media.

3. Open the Printhead by moving the Printhead Open Lever counterclock wise to the “open” position.

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

RIBBON

LABEL

STRIP OF MEDIA

6-12 INCHES LONG

ribbon roll if it doesn’t already have one.

Tear off a strip of media (labels and backing) about 6 to 12 inches long from the roll. Peel off a label from this strip. Apply half of this label to the end of the strip and the other half to the end of the ribbon. This acts as a ribbon leader.

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

6. Before wrapping the ribbon around the Take-Up Spindle, ensure that the arrow on the knob aligns with the indented notch (see Figure 8 inset).

RIBBON TAKE-UP SPINDLE

HEAD OPEN

CLOSED

PLATEN ROLLER

UPPER ROLLER

RIBBON SUPPLY

SPINDLE

Figure 6. Ribbon Loading Diagram for the 90XiII and 140XiII Printers

RIBBON TAKE-UP SPINDLE

HEAD OPEN

CLOSED

RIBBON SUPPLY

SPINDLE

Figure 7. Ribbon Loading Diagram for the 170XiII and 220XiII Printers

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PLATEN ROLLER

RIBBON

DOUBLE ROLLER

ASSEMBLY

UPPER ROLLER

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7. Place the ribbon (with leader, if used) around the Ribbon Take-Up

8. Close the Printhead by moving the lever clockwise to the “closed” position.

Spindle and wind counterclockwise for several turns.

Figure 8. Removing Used Ribbon

Ribbon Removal

1. Break the ribbon as close to the Ribbon Take-Up Spindle as possible.

2. Refer to Figure 8. While holding the Ribbon Take-Up Spindle, turn the knob (1) clockwise until it stops. This will cause the Ribbon Release Bars to pivot down (2), easing the spindle’s “grip” on the wound rib bon.

3. Slide the ribbon off of the Ribbon Take-Up Spindle. Once the used rib bon has been removed, ensure that the arrow on the knob aligns with the indented notch in the Ribbon Take-Up Spindle (see inset).

4. Remove the empty core from the Ribbon Supply Spindle.

5. Follow the Ribbon Loading procedure on page 18 to load the new ribbon.

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Operating Your Zebra XiII-Series Printer

Operation

Now that your printer is ready for operation, how does it work? The Zebra XiII-Series printer is designed to receive instructions from a host computer, such as an IBM-compatible PC. To create a label, you will either need to write a format in ZPL II , which is a programming language for creating la bel formats, or you will need to use a software program designed to format labels for the Zebra XiII-Series printer. If you are using label design soft ware, refer to the instructions provided with your software package to deter mine how to do this.

If you are using, or plan to use, ZPL II programming language to format your labels, make sure you have a copy of the ZPL II Programming Guide. Refer to the mail/fax-in card at the front of this book to obtain a copy. For some sample ZPL II label formats, refer to page 46.

Printer Operating Modes

Tear-Off Mode

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The XiII printer can be configured for one of several different operating modes by sending the proper commands from the host computer or by con figuring the printer for a certain mode using the front panel display.

When the media is in the rest (idle) position, the gap between labels is over the Tear-Off/Peel-Off Plate. The operator then tears off the label, and a new label may be printed.

This mode of operation may also be used to print a large quantity of labels. To do this, send a format for printing a batch of labels to the printer. The printing will continue until all labels have been printed.

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Peel-Off Mode

(Peel-Off Option Required)

In this mode, once the label is printed the media passes over the TearOff/Peel-Off Plate at a sharp angle. The backing material is peeled away from the label and winds around the Backing Rewind Spindle. The media feeds forward until most of the label hangs loose from the backing. The Label Available Sensor detects this label and pauses printing until the operator removes the label, at which time the next label prints.

The Backing Rewind Spindle will hold the backing from a standard-size media roll. To remove the backing from the Rewind Spindle, refer to page 15.

Rewind Mode

(Rewind Option Required)

In this mode, the media and backing are rewound onto a core as the labels are printed.

When the media is in the rest (idle) position, the start of the next label is directly under the printhead. After the label is printed, the media feeds forward until the start of the next label is under the printhead. The media never backfeeds in this mode. The completed labels are rewound onto a core for later use. When the printer completes a batch of labels, printing will stop.

Cutter Mode

(Cutter Option Required)

In this mode, the printer prints the entire label and automatically cuts the label after it is printed. The Cutter Catch Tray “catches” the completed labels.

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Operator Controls

Power Switch

This section discusses the functions of the various controls and indicators on the XiII printer. The operator should become familiar with each of these functions.

This switch is located on the back of the printer above the Power Cord and Fuse. The Power Switch should be turned off before connecting or discon necting any cables.

Turning the switch on activates the printer and causes it to perform a Power-On Self Test as it begins operation. Turning the printer power on while holding down certain front panel keys will launch additional Printer Self Tests following the Power-On Self Test.

External influences such as lightning storms or unwanted noise on the power or data 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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Front Panel Display

The Front Panel Display communicates operational status and programming modes and parameters.

Figure 9. Front Panel

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Front Panel Keys

Key Function

NOTE:

The keys below are used only when configuring the printer. Specific uses of

these keys are explained in the Configuration and Calibration topic, starting on page 29.

Table 1. Front Panel Keys

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 feeds immediately  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 will cancel 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 will turn off.

When in Pause mode, this key will calibrate the printer for:  Media length  Media type (continuous or non-continuous)  Print mode (direct thermal or thermal transfer)

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Scrolls back to the previous parameter.

Scrolls forward to the next parameter. Saves any changes youve made in the Configuration and Calibration sequence.

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: increase/decrease a value, answer yes or no, indicate on or off, scroll through several choices, input the password.

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Front Panel Lights

NOTE: If two operating conditions occur simultaneously, one which

Light Status Indication

Power Off Printer is off or power is not applied.

Take Label Off Normal operation.

Error

Check

Ribbon

Paper Out

causes a light to be on constantly and one which causes the same light to flash, the light will flash.

Table 2. Front Panel Lights

On Printer is on.

Flashing

Off Normal operationno printer errors.

Flashing

Off Normal operationribbon (if used) is properly loaded.

Off Normal operationmedia is properly loaded.

(Peel-Off Mode Only) Label is available. Printing is paused until the label is removed.

Printer error exists. Check the display screen for more information.

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.

No media is under the media sensor. Printing is paused, the display shows an error message, and the Pause light is on.

Pause

Off Normal operation.

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.

Data

Data processing or printing is taking place. No data is being received.

Printer is receiving data from the host computer. Flashing slows

Flashing

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

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Printer Status Sensors

Sensor What It Monitors How It Works

Printhead Position Sensor

Printhead Temperature Sensor

Transmissive Media Sensor

Reflective Media Sensor

Ribbon Sensor

Label Available Sensor

Zebra XiII-Series printer contains several status sensors. These sensors alert the operator to various conditions by either stopping the printing or turning on a light. Sensors are described in Table 3.

Table 3. Printer Status Sensors

Checks the open/closed status of the printhead lever.

Checks the temperature of the printhead.

Checks for proper media loading.

If non-continuous media is used, this sensor detects the label length for individual labels.

Detects the presence of black marks on the back of black-mark media.

Monitors the presence of ribbon.

In Peel-Off Mode, it checks to see if a label is available.

If the printhead is open, the Error light flashes.

If the printhead is too cold, the front panel display indicates this condition and printing continues while the printhead warms up. If the printhead is too hot, printing stops while the printhead cools to standard operating temperature.

The Paper Out light will turn on if you run out of media. This condition will also occur if you are using non-continuous media and the media does not move because it is jammed.

If it detects a black mark, the printer knows that it is at the beginning of a label.

If you run out of ribbon, the Check Ribbon light turns on.

Once a label prints, it will pass between the two parts of this sensor and cause the printer to pause. The Take Label light turns on. When the label is removed, printing resumes and the light turns off.

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Initial Printer Power-Up

Each time you turn the printer on, it automatically performs a self-test called the Power-On Self Test (POST).

Turn the printer on now by pressing the Power Switch at the rear of the printer. The Front Panel Power-On indicator will light up. The other front panel indicator lights and the Liquid Crystal Display (LCD) monitor the progress of the Power-On Self Test (POST). The self test sequence is shown in Table 4.

The POST prompts are in English unless an error occurs, in which case the display cycles through all available languages repeatedly. However, you may change the display language for all other prompts. Refer to “Selecting the Display Language” on page 45.

NOTE: If the printer fails any of these tests, the word “FAILED” will be

added to the display. If this occurs, refer to the Troubleshooting and Diagnostics section (starting on page 59).

If loading the printer with media and ribbon for the first time, or changing the type of media, perform the Calibration procedure on page 36.

Table 4. Power-On Self Test Sequence

This sequence occurs each time the printer is powered up.

Front Panel Display Description

3 SRAM TEST SRAM functionality test performed.

4 OPTION ROM TEST

5 PRINTHEAD TEST Printhead is checked for proper operation. 6 PROCESSOR TEST Processor functionality test performed. 7 E-CUBED TEST E-Cubed functionality test performed.

All indicator lights turn on simultaneously. Then, through the following steps, they turn off in sequence starting at the bottom.

Three different sets of characters will be displayed to verify that the display screen is working properly.

Optional ROM functionality test performed. (The words NOT INSTALLED will be added to display if no optional ROM is used.)

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Front Panel Display Description

8 EEPROM TEST EEPROM functionality test performed.

MEMORY CARD

TEST

11 PRINTER READY Printer is ready for operation.

Configuration and Calibration

Table 4. Power-On Self Test Sequence (Continued)

Memory Card functionality test performed. (NOT INSTALLED will be added to the display if no card is present.)

Depending on how the label format was set up, the printer will feed to the first web or label length, calibrate ribbon and media sensors, set label length and feed one or more labels, or no media may be fed. The ZPL II command that controls this is ^MF.

After you have installed the media and ribbon and the POST (Power-On Self Test) is complete, the front panel display will show “PRINTER READY.” You may now set printer parameters for your application using the front panel display and the five keys directly below it.

If it becomes necessary to restore the initial printer defaults, see “Feed Key and Pause Key Self Test” on page 68.

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

are displayed, starting with “DARKNESS”.

Entering the Program Mode

To enter the programming mode, press the Setup/Exit key. Press either the Next/Save key or Previous key to scroll to the parameter you wish to set. 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 go back to the previous parameter in the cycle.

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

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Changing Password-Protected Parameters

Certain parameters are password-protected by factory default.

CAUTION: Do not change password-protected parameters unless

you’re sure you know what you’re doing! If they are set incorrectly, these parameters could cause the printer to function in an unpredictable way.

The first attempt to change one of these parameters (pressing one of the black oval keys) will require you to enter a four-digit password. This is done via the “ENTER PASSWORD” display. 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 are trying to change will be 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.

NOTE: Once the password has been entered correctly, it will not have to

be entered again unless you leave and re-enter the programming mode using the Setup/Exit key.

NOTE: 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, 1-4 digits in length, except Ø.

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Leaving the Program Mode

You can leave the Program Mode at any time by pressing the Setup/Exit key. The SAVE CHANGES display will appear. There are five choices, described below. Pressing the left or right black oval key displays other choices and pressing the Next/Save key selects the displayed choice.

PERMANENT - permanently saves the changes. Values are stored in the printer even when power is turned off.

TEMPORARY - saves the changes until changed again or until power is turned off.

CANCEL - cancels all changes since pressing the Setup/Exit key except the Darkness and Tear-Off settings (if they were changed).

LOAD DEFAULTS - loads factory defaults. The factory defaults are shown on the following pages.

NOTE: Loading factory defaults will require ptinter calibration and

resetting the Head Resistor value.

LOAD LAST SAVE - loads values from the last Permanent Save.

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Configuration and Calibration Sequence

Press Display Shows Action/Explanation

---- PRINTER READY Normal printer operation.

Setting Print Parameters

Adjusting Print Darkness

darkness. Press the left oval key to decrease darkness.

DARKNESS

TEAR OFF

PRINT MODE

Default:

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 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 68 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:

provides good print quality. Darkness set too high may cause ink smearing and/or it may burn through the ribbon.

Adjusting the Tear-Off Position

increase the value, press the left oval key to decrease the value. Each depression of the key adjusts the Tear-Off position by four dot rows.

Default:

This parameter establishes the position of the media over the tear bar after printing. The label and backing can be torn off or cut between labels.

Selecting Print Mode

display other choices.

Default:

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.

+10

Tear-Off

Press the right oval key to increase

Range:

0to+30

Set the Darkness to the lowest setting that

Press the right oval key to

Range:

-64 to +64

Press the right or left oval key to

Selections:

Tear-Off, Peel-Off, Cutter, Rewind, Applicator

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Press Display Shows Action/Explanation

MEDIA TYPE

SENSOR TYPE

PRINT METHOD

Setting Media Type

Press the right or left oval key to display

other choices.

Default:

Continuous

Selections:

Continuous,

Non-continuous

This parameter tells the printer the type of media you are using. Selecting continuous media requires that you include a label length instruction in your label format (^LLxxxx if you are using ZPL or ZPL II).

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

Setting the Sensor Type

Press the right or left oval key to

display other choices.

Default:

Web

Selections:

Web, Mark

This parameter tells the printer 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 on the back, leave your printer at the default (Web).

Selecting Print Method

Press the right oval key for the next

value; press the left 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 will continue.

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Press Display Shows Action/Explanation

PRINT WIDTH

MAXIMUM LENGTH

Listing Printer Information

LIST FONTS

LIST BAR CODES

Setting Print Width

Press the right oval key to increase the value, press the left oval key to decrease the value. To change the unit of measurement, press the left oval key until the unit of measurement is active, then press the right oval key to toggle to a different unit of measure (inches, mm, or dots).

Default:, Range:

The default and range of acceptable values varies depending on what printer you have. Refer to Printing Specifications on page 79 for further information about the ranges available for your model.

Select a print width that is closest to your media, but AT LEAST as wide. Print width tells the printer the width of the media you are using. Setting width too narrow may result in unprinted portions of your label format. Setting width too wide wastes formatting memory and may cause printing off the right side of the label.

Setting Maximum Length

Press the left oval key to decrease

the value, press the right oval key to increase the value.

Default:, Range:

The default and range of acceptable values varries depending on your printers configuration. Values are adjustable in 1.0 inch (25.4 mm) increments.

Maximum Length is used in conjunction with the Calibration procedure. The value of this setting determines the maximum label length that will be 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 closest to, but not lower than, the length of the label you are using. For example, if the length of the label is 14.5 inches, set the parameter for

15.0 inches (381 mm).

List Fonts

Press the right oval key to print a label listing all of

the available fonts. This selection is used to print a label that lists all of the fonts

currently available in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM, in Font EPROMs, or on Font Cards.

List Bar Codes

Press the right 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.

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Press Display Shows Action/Explanation

LIST IMAGES

LIST FORMATS

LIST SETUP

INITIALIZE CARD

List Images

Press the right 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, optional EPROM, or on an optional memory card.

List Formats

Press the right oval key to print a label listing all

available formats. This selection is used to print a label that lists all of the

formats currently stored in the printers RAM, optional EPROM, or on an optional memory card.

List Setup

Press the right 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 Cancel Key Self Test.)

Initialize Memory Card CAUTION:

Initializing will erase all previously stored

information from the memory card. Press the right oval key to select yes and proceed to the

verification menu. If your printer is set to require a password, you will now be prompted to enter the password.

This selection initializes the memory card.

ARE YOU SURE?

Press the right oval key to initialize the card. Press the left oval key to cancel the request and return to INITIALIZE CARD.

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Media and Ribbon Sensor Calibration NOTE:

Before you begin this procedure, make sure that the Maximum Length is set to a value equal to or greater than the length of the labels you are using. If the Maximum Length is set to a lower value, the calibration process will assume that continuous media is in the printer. See page 34 for more information.

There are two different types of calibration that can be performed by the printer:

1) Standard Calibration.

printer to feed media and ribbon and set the values it detects for media, media backing material (the spaces between labels), media out, and ribbon or no ribbon (which determines the print modeThermal Transfer or Thermal Direct). This type of calibration also occurs as part of the Sensor Profile and Media and Ribbon Calibrate procedures specified below.

2) Media and Ribbon Sensor Sensitivity Calibration.

Calibrate procedure below 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 described above. 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

MEDIA AND RIBBON CALIBRATE

Pressing the Calibrate key on the printers front panel causes the

Performing the Media and Ribbon

Sensor Profile

Press Next/Save to skip this standard calibration procedure and continue with Media and Ribbon Calibrate parameter which follows.

Press the right oval key to initiate this standard calibration procedure and print a Media Sensor Profile.

See Figure 10, Media and Ribbon Sensor Profile Sample Printout, on page 46.

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 below.

Media and Ribbon Sensor Sensitivity

Press Next/Save to skip the calibration procedure shown on the next page and continue with Setting Host Port parameter which follows.

Press the right 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 on the next page. All steps must be performed even if only one of the sensors requires adjustment.

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Press Display Shows Action/Explanation

LOAD BACKING

REMOVE RIBBON

CALIBRATING PLEASE WAIT

---- RELOAD ALL

MEDIA AND RIBBON CALIBRATE

Media and Ribbon Calibration Procedure

Press the left oval key to cancel the operation, or do the following:

Open the Printhead. Remove as many labels as needed to load a section of blank backing material under the media sensor (just behind the printhead). See Figure 4, Upper Media Sensor Adjustment, on page 16 to locate the sensor.

Press the left oval key to cancel the operation or do the following:

1) Remove the ribbon (sliding it as far to the right as possible will have the same effect as removing it.)

2) Close the Printhead. The printer automatically adjusts the scale (gain) of the signals

it receives from the media and ribbon sensors based on the specific media and ribbon combination you are using. On the sensor profile, this essentially corresponds to moving 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) Move the ribbon back to its proper position.

3) Close the Printhead. Now that the scale has changed, the printer performs a

calibration equivalent to pressing the Calibrate key. During this process, the printer checks the readings for the media and ribbon based on the new scale youve established, determines the label length, and determines whether you are in thermal direct or thermal transfer print mode. The process is now complete! To see the new readings on the new scale, print a Sensor Profile (see previous page).

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Setting Communication Parameters

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

Press Display Shows Action/Explanation

HOST PORT

BAUD

SET DATA BITS

PARITY

STOP BITS

Setting Host Port

Press the right or left oval key to display

other choices.

Default:

Main RS232.

Selections:

Main RS232, RS422/485,

RS485Multidrop, Parallel Select the communications port that matches the one being

used by the host computer.

Setting Baud

Press the right or left oval key to display

other choices.

Default:

9600

Selections:

110, 300, 600, 1200, 2400, 4800,

9600, 19200, 28800, 57600 The baud setting of the printer must match the baud setting of

the host for accurate communications to take place. Select the value that matches the one being used by the host.

Setting Data Bits

Press the right or left 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 for accurate communications to take place. Set the Data Bits to match the setting being used by the host.

NOTE:

Must be set to 8 data bits to use Code Page 850 or the Twinax or Coax interface options.

Setting Parity

Press the right or left oval key to display

other choices.

Default:

Even

Selections:

Even, Odd, None

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

Setting Stop Bits

Press the right or left 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 for accurate communications to take place. Select the stop bits that match the ones being used by the host.

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Press Display Shows Action/Explanation

HOST HANDSHAKE

PROTOCOL

NETWORK ID

Setting Host Handshake

Press the right or left 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 for communications to take place. Select the handshake protocol that matches the one being used by the host.

Setting Protocol

Press the right or left 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 signifying that data has been received. Select the Protocol that is requested by the host. Further details on Protocol can be found in the ZPL II Programming Guide, available from Zebra Technologies Corporation.

NOTE:

Zebra is the same as ACK/NACK except that with

Zebra the response messages are sequenced.

NOTE:

If Zebra is selected, printer must use DTR/DSR host

handshake protocol.

Setting Network ID

Press the left oval key to move to the next digit position, press the right oval key to increase the value of the digit.

Default:

000

Range:

000 - 999

Network ID is used to assign a unique number to a printer used in a network. This gives the host the means to address a specific printer. If the printer is used in a network, you must select a Network ID number.

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Press Display Shows Action/Explanation

COMMUNI- CATIONS

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:

To change the values, refer to the ASCII code chart on page 94 for character choices. DO NOT use the same hex value for the Control, Format, and Delimiter character. The printer needs to see different characters to function properly.

CONTROL PREFIX

FORMAT PREFIX

Setting Communications Mode

Press the right or left 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. When Diagnostics is selected, all data sent from the host to the printer will be printed as straight ASCII hex characters. The printer prints all characters received including control codes, like CR (Carriage Return). A sample printout is shown in Figure 18 on page 69.

NOTES

on diagnostic printouts:  An FE indicates a framing error.  An OE indicates an overrun error.  An PE indicates a parity error.  An 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 34 for more information.

Control Prefix Character

Press the left oval key to move to the next digit position, press the right oval key to increase the value of the digit.

Default:

7E (tilde - displayed as a black square)

Range:

00-FF

(Exclude the values indicated on the ASCII code chart on page

94.) 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 oval key to move to the next digit position, press the right oval key to increase the value of the digit.

Default:

5E (caret)

Range:

00 - FF (Exclude the values

indicated on the ASCII Code Chart in the Appendix.) The printer looks for this 2-digit hex character to indicate the

start of a ZPL/ZPL II format instruction.

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Press Display Shows Action/Explanation

DELIMITER CHAR

Selecting ZPL Mode

ZPL MODE

Power-Up and Head Close Parameters

MEDIA POWER UP

HEAD CLOSE

Delimiter Character

Press the left oval key to move to the next digit position, press the right 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 the ZPL II Programming Guide for more information.

Selecting ZPL Mode

Press the right or left oval key to

display other choices.

Default:

ZPL II

Selections:

ZPL II, ZPL

The printer will remain in the selected mode until it is changed by this front panel instruction or by using a ZPL/ZPL II command. The printer accepts label formats written in either ZPL or ZPL II . This eliminates the need to rewrite any ZPL formats you already have. 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 oval key to display

other choices.

Default:

Feed

Selections:

Feed, Calibration, Length, and No

Motion This parameter establishes the action of the media when the

printer is turned on.  Calibrationrecalibrates the media and ribbon sensors  Feedfeeds the label to the first web  Lengthdetermines the length of the label  No Motionmedia does not move

Head Close

Press the right or left oval key to display other

choices.

Default:

Feed

Selections:

Feed, Calibration, Length, No

Motion Determines the action of the media after the printhead has

been opened and then closed.  Calibrationrecalibrates the media and ribbon sensors  Feedfeeds the label to the first web  Lengthdetermines the length of the label  No Motionmedia does not move

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Label Positioning Parameters

Press Display Shows Action/Explanation

BACKFEED

LABEL TOP

LEFT POSITION

Backfeed Sequence

Press the right or left oval key to

display other choices.

Default: Selections:

Default (Default is defined as 90%)

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

60%, 70%, 80% 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% 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 will take place before the next label is printed.

Adjusting Label Top Position

Press the right oval key to increase the value, press the left oval key to decrease the value. The displayed value represents dots.

Default:

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 Position

Press the left oval key to move to the next position, press the right oval key to change between + and - and to increase the value of the digit. The displayed value represents dots.

Default: NOTE:

0000

Range:

-9999 to +9999

For a negative value, enter the value before changing

to the minus sign. This parameter establishes how far from the left edge of a

label the format will begin 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.

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Press Display Shows Action/Explanation

HEAD TEST COUNT

HEAD RESISTOR

VERIFIER PORT

Setting the Head Test Count

Press the left oval key to move to the next digit position, press the right oval key to change the value of the digit.

Default:

0000 (Disables the test)

Range:

0000 to 9999

The printer periodically performs a test of the printhead functionality, called a Printhead Test or Head Test. This parameter establishes how many labels are printed between these internal tests.

Setting the Head Resistor Value

Press the left oval key to move to the next digit position, press the right oval key to increase the value of the digit.

CAUTION:

This parameter should only be changed by

qualified personnel!

Initial Value:

Factory-set to match the printhead shipped with

your printer (varries).

Default Value:

0500

Range:

0500 - 1175

This value has been pre-set at the factory to match the resistance value of the printhead. It will not need to be changed unless...

1) The printhead is replaced.

2) The printer is set to the factory defaults. (The factory default value is usually lower than the actual resistance value.)

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 bottom of the

printhead element for the label that shows the resistance value (ohm value).

Setting the Verifier Port

Press the right or left 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 will react to the Zebra On-Line Verifier. There are currently three operating conditions for this port.

 OffThe Verifier Port is off.  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 will be 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 1 to 3 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.

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Press Display Shows Action/Explanation

APPLICATOR PORT

WEB S.

Setting the Applicator Port

Press the right or left oval key

to display other choices.

Default:

Off

Selections:

Off, Mode 1, Mode 2, Mode 3, Mode 4 Determines the action of the verifier port.  OffThe applicator port is off.  Mode 1Asserts the ~END_PRINT signal low while the

printer is moving the label forward.  Mode 2Asserts the ~END_PRINT signal high while the

printer is moving the label forward.  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.

MEDIA S.

RIBBON S.

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.

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LCD Display Adjustment

Press the left oval key to

decrease the value (reduce brightness), press the right oval

LCD ADJUST

key to increase the value (increase brightness).

Range:

00 to 19

This parameter allows you to adjust the brightness of your display if your display is difficult to read.

Selecting the Display Language

Press the right or left oval

key to display other choices.

LANGUAGE

Default:

English

Choices:

English, Spanish, French,

German, Italian This parameter allows you to change the language used on

the front panel display.

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

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

DARKNESS

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 oval key to display other

choices.

Default:

Permanent

Choices:

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.

SAVE SETTINGS

 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 will require Calibration and resetting the Head Resistor value.

 Load Last Save: Loads the values from the last permanent save.

Press the Next/Save key to activate the displayed choice.

PRINTER READY

You have exited the Configuration and Calibration Sequence and you are now ready for normal printer operation

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Figure 10. Media and Ribbon Sensor Profile Sample Printout

Sample ZPL II Label Formats

ZPL II®is Zebra Technologies Corporation’s Zebra Programming Language II label design language. ZPL II lets you create a wide variety of labels from the simple to the very complex, including text, bar codes, and graphics.

This section contains three sample label formats for you to begin experi menting with. It is not intended as an introduction to ZPL II . To learn about ZPL II , send in the request card at the beginning of this book for a free copy of the ZPL II Programming Guide.

For each format, do the following:

1. Set up the printer and turn the power on.

2. Use a text editing program (ex: Windows™ Write or DOS Editor) and type in the label format exactly as shown in the sample label format below.

3. Save the file in a directory for future use. Use the extension “ . zpl”.

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4. Copy the file to the Zebra XiII printer.

NOTE: Typically, computers running DOS use the “COPY” command to

send a file to the Zebra printer. For example, if your file name is “format1.zpl” then type, “COPY FORMAT 1.ZPL XXXX”, where “XXXX” is the port to which your Zebra printer is connected, for example, “COM1" or ”LPT1".

5. Compare your results with those shown. If your printout does not look like the one shown, confirm that the file you created is identical to the format shown, then repeat the printing procedure. If nothing prints, refer to the “Getting Started” section to make sure your system is set up correctly, otherwise refer to the “Troubleshooting and Diagnostics” section.

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Format 1: Simple Text and a Barcode

Line # Type this label format Youll get this printout

1. ^XA

2. ^LH30,30

3. ^FO20,10^AD^FDZEBRA^FS

4. ^FO20,60^B3N,Y,20,N^FDAAA001^FS

5. ^XZ

Line #1: Indicates start of label format. Line #2: Sets label home position (in dots) from the upper left-hand corner of the label. Line #3: Sets field origin, selects font D, defines field data as ZEBRA. Line #4: Sets field origin, selects bar code Code 39, sets barcode height at 20 dot rows,

defines field data for bar code as AAA001".

Line #5: End of label format

Format 2: Saving a Label Format As a Graphic Image

Line # Type this label format Youll get this printout

1. ^XA

2. ^LH30,30

3. ^FO20,10^AD^FDZEBRA^FS

Same as Format 1, but this format was also saved in the printers memory as a graphic image named FORMAT2".

4. ^FO20,60^B3N,Y,20,N^FDAAA001^FS

5. ^ISFORMAT2,N

6. ^XZ

7. ^XA

8. ^ILFORMAT2

9. ^XZ

defines field data for bar code as AAA001".

Line #5: Saves the format in the printers memory as a graphic image named FORMAT2:,

the N" indicates do not print after saving. Line #6-7: (See Format 1) Line #8: Load and print the graphic image saved as FORMAT2". Line #9: (See Format 1)

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Format 3: Using a Serialized Data Field

Line # Type this label format

Youll get this

printout

1. ^XA

2. ^LH30,30

3. ^FO20,10^AD^FDZEBRA^FS Ten labels should

4. ^FO20,60^B3,,40,^FDAAA001^FS

print. The first and last are shown here.

^FO20,180^AF^SNSERIAL NUMBER

00000000111,1,Y^FS

6. ^PQ10

7. ^XZ

Line #1-3: See Format 1) Line #4: Defines field data for bar code as AAA001". Line #5: Defines serialized field, starting value of 111, increment by 1, insert leading zeros. Line #6: Sets print quantity to 10 Line #7: (See Format 1)

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Routine Care and Adjustment

Cleaning

Table 5 provides a brief cleaning schedule. Specific cleaning procedures are provided on the following pages. A Preventive Maintenance Kit (part # 01429) is available from Zebra. Kit items are also sold separately by the part numbers shown.

Preventive Maintenance Kit

Solvent (Alcohol), 4 oz. bottle (part # 01426)

Applicators, bag of 100 (part # 01427)

Table 5. Cleaning Schedule

Area Method Interval

Printhead Solvent* Platen Roller Solvent* Transmissive Media Sensor Air blow Reflective (Black-Mark)

Media Sensor Media Path Solvent* Ribbon Sensor Air blow Peel/Tear Bar Solvent* As needed. Label Available Sensor Air blow Monthly. Cutter Module Solvent* As needed. * Zebra recommends using solvent containing 70% alcohol.

Solvent*

Direct Thermal Print Mode: After every roll of media (or 500 ft. of fanfold media)

Thermal Transfer Print Mode: After every roll of ribbon.

CAUTION: Use only the cleaning agents indicated. Zebra

Technologies Corporation will not be responsible for any other fluids being used on this printer.

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Cleaning the Exterior

The exterior surfaces of the Zebra XiII-Series printer may be cleaned with a lint-free cloth. Do not use harsh or abrasive cleaning agents or solvents. If necessary, a mild detergent solution or desktop cleaner may be used sparingly.

Cleaning the Interior

Remove any accumulated dirt and lint from the interior of the printer using a soft bristle brush and/or vacuum cleaner. Inspect this area after every four rolls of media.

Cleaning the Printhead and Platen Roller

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 the printer off before cleaning the

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

To clean the printhead, refer to Figure 11 and follow these steps:

1. Open the Media Compartment Door.

2. Open the Printhead by moving the Printhead Open Lever to the open position (as shown in Figure 11).

3. Remove the media and ribbon (if present).

4. Moisten an applicator tip with Zebra Technologies Corporationrecommended solvent and wipe along the print elements from end to end. (The print elements are the brown strip just behind the chrome strip on the printhead.) Allow a few seconds for the solvent to evapo rate.

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BLACK

MARK

SENSOR

5. Rotate the platen roller and clean thoroughly with solvent and an applicator.

6. Brush/vacuum any accumulated paper lint and dust away from the rollers.

7. Reload ribbon and/or media, close and latch the printhead, close the Front Panel and the Media Compartment Door, and continue printing.

PRINTHEAD

RIBBON

SENSOR

LABEL

AVAILABLE

SENSORS

PLATEN ROLLER

PEEL/TEAR

BAR

Figure 11. Cleaning Diagram

Cleaning the Sensors

The Media, Ribbon, and Label Available Sensors should be cleaned on a regular basis to ensure proper operation of the printer. To locate the position of these sensors, refer to Figure 11 above, Figure 4 on page 16, and Figure 5 on page 17. Brush/vacuum any accumulated paper lint and dust off of these sensors.

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Cleaning the Cutter Module

(For printers equipped with the optional cutter.)

The Cutter Module requires periodic cleaning to remove paper dust and gummed label residue. The procedure should be performed by the operator as needed to ensure proper cutter action. If labels are not being cut properly, or if the cutter jams with labels, this is an indication that the cutter probably needs cleaning. The cleaning frequency depends on your application and media type.

Clean the stationary cutter blade with cleaning solvent when it becomes gummed up with label adhesive and/or paper debris. If further cutter clean ing is necessary, or if the cutter performs unsatisfactorily, contact a service technician.

Lubrication

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

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

Fuse Replacement

The Zebra XiII 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 20, “International Safety Organizations,” on page 82). The printer comes with two approved fuses: one in the circuit and one in the “spare fuse” holder.

1. Turn the printer power off and unplug the power cord from the back of the printer. See Figure 12.

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

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3. Remove the faulty fuse and install a new fuse of the correct type. Refer to Figure 13. The fuse 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).

4. Snap the Fuse Holder back into position.

5. Reconnect the power cord.

If the new fuse fails right away, the printer has an internal component failure and must be repaired.

FUSE

HOLDER

AC POWER

ENTRY

MODULE

SMALL BLADE

SCREWDRIVER

Figure 12. Fuse Replacement—Step 1

SPARE

FUSE

HOLDER

IN-CIRCUIT

FUSE

Figure 13. Fuse Replacement—Step 2

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Adjustments

Toggle Positioning

Both toggles should be positioned so that they provide even pressure on the media. The toggles are positioned by sliding them to the desired location. On media too narrow to accommodate both toggles, position one toggle over the center of the media and decrease the pressure on the unused toggle.

NOTE: Make sure that the toggle pressure is even across the width of the

media, otherwise the media and/or ribbon may drift.

LABEL

AVAILABLE

SENSORS

ADJUSTING

NUTS

Figure 14. Toggle Adjustment

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Printhead Pressure Adjustment

This adjustment may be necessary if printing is too light on one side or if thick media is used. Refer to Figure 14.

1. Perform the Toggle Positioning procedure above. If the problem is solved, you may stop here; otherwise, continue with the rest of this procedure.

2. Print some labels at Speed A, such as by running the Pause Key Self

Test (see page 67).

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 adjustment nuts on the shafts of the toggles) until the left and right edges of printed area are equally dark.

NOTE: Printhead life can be maximized by using the lowest pressure

that produces the desired print quality.

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

7. Retighten locking nuts.

Media Sensor Position Adjustment

See “Transmissive Media Sensor Position Adjustment” on page 15.

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Troubleshooting and Diagnostics

Symptom Diagnosis Action

All lights light, but nothing appears on the front panel display.

All lights are on but the display screen is not.

Printer locks up when running the Power-On Self Test.

ERROR CONDITION RIBBON OUT Printer stops and Error light

flashes.

WARNING RIBBON IN Error light flashes.

This section contains troubleshooting charts used to localize and repair the printer when faults occur. The procedures called out in the “Action” column may be performed by the operator or by a service technician as indicated.

Table 6. Troubleshooting

Internal electronic failure. Call a service technician.

Possibility of bad EPROMs (firmware) installed in printer.

Normally caused by some hardware failure. Display screen will describe the cause.

For thermal transfer mode: Ribbon not loaded or incorrectly loaded.

Ribbon Sensor not sensing ribbon that is loaded correctly.

For direct thermal mode: Ribbon is loaded.

For thermal transfer mode:

Restart printer. If symptom persists call a service technician.

Load ribbon correctly. See Ribbon Loading on page 18.

Perform the Media and Ribbon Sensor Calibration on page 36.

Remove ribbon.

Load ribbon and recalibrate printer.

Make sure that the snap plate is in place and clean.

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Symptom Diagnosis Action

ERROR CONDITION PAPER OUT Printer stops and Error light

flashes.

ERROR CONDITION HEAD OPEN Printer stops and Error light

flashes.

WARNING HEAD TOO HOT Printer stops and Error light

flashes.

WARNING HEAD COLD Error light flashes.

No media loaded or incorrectly loaded.

Misadjusted media sensor.

Reload media. Rewind Mode Media Loading on page 11.

Check position and sensitivity of media sensors.

Printer set for non-continuous media but continuous media was

Load proper media or reset printer for current media type.

loaded. Printhead is not fully

closed.

Close printhead completely.

Set the head resistor value to Printhead Resistor value not set correctly.

match the head resistance

value printed on the printhead.

See page 43. Printhead Open sensor not

working.

Call a service technician.

Allow printer to cool. Printing Printhead is overheated.

resumes automatically when

the printhead element cools to

operating temperature. Printhead is dirty. Clean printhead. See page 52.

Set the head resistor value to Printhead Resistor value not set correctly.

match the head resistance

value printed on the printhead.

See page 43.

Printing continues while print- Printhead is not hot

enough.

head heats up. If error remains,

environment may be too cold

for proper printing. Relocate

printer to warmer area.

Set the head resistor value to Printhead Resistor value not set correctly.

match the head resistance

value printed on the printhead.

See page 43.

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Symptom Diagnosis Action

ERROR CONDITION HEAD ELEMENT BAD Experiencing print quality

problems.

WARNING CUTTER JAMMED

OUT OF MEMORY XXXXXXXXXXXXXX

Printer stops and PAUSE light is on.

XXXXXXXXXXXXXX can be any of the following messages:

 Creating bitmap  Storing bitmap  Building format  Storing format  Storing graphic  Storing font

Printhead element is bad or going bad.

Printhead Resistor value not set correctly.

Cutter blade in media path.

Not enough memory to perform the function shown on the second line of the error message (XXXXXXXXXXXXXX).

correct

the situation, call a service technician to replace the printhead.

override

this error message, place ^JT0 and ~JO in your ZPL II format.

Set the head resistor value to match the head resistance value printed on the printhead. See page 43.

Turn the power off. Remove the media, reload the media, and turn the power on. If the error condition still exists, call a service technician.

You may do any of the following (A, B, or C):

A. (For errors related to storing things)

With PAUSE on, use the ~HM ZPL II command to display the amount of free memory. Then...

Redesign graphic/format to fit available memory or remove items from memory to create more space.

OR Press the Pause key to skip the

step in the process and continue on to the next step.

B. In Pause Mode, press Cancel. The printer skips the current label formatting process and goes on to the next label.

C. Turn the printer power off to clear printer memory and start over.

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Symptom Diagnosis Action

Long tracks of missing print on several labels.

Fine gray lines on blank labels at angles.

Wrinkled ribbon.

Printhead is dirty.

See Wrinkled Ribbon in this table.

Clean the printhead. See page

52.

Print element is damaged. Call a service technician.

Wrinkled ribbon.

Ribbon fed through machine incorrectly.

See Wrinkled Ribbon in this table.

See Ribbon Loading on page 18.

Set darkness to the lowest

Incorrect darkness setting.

setting possible for good print quality. See Setting the Darkness on page 32.

Incorrect printhead pressure or balance.

Media not feeding properly; it is walking from side to side.

Set the pressure to the minimum needed. See Adjustments on page 56.

Make sure that the media is snug by adjusting the Media

Guides. Strip Plate needs adjusting. Roller under Printhead

needs realigning. Ribbon Supply tension

needs adjusting. Printhead Shaft needs

adjusting using the Wear Plate.

Printhead needs realigning with Platen Roller.

Call a service technician. Ribbon Take-Up tension needs adjusting to the minimum value.

Three-point mount for Ribbon Supply Spindle needs adjusting. (Not applicable to the 220XiII printer.)

Ribbon supply core slipping; spindle blades need adjusting.

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Symptom Diagnosis Action

Light vertical lines approximately 0.005" wide running through all labels.

Light printing or no printing on the left or right side of the label.

Short printed lines at 45° to label edge on left or right side of label.

Misregistration and misprint of 1 to 3 labels.

Truncated printing, no printing, or Feed key operates incorrectly while using non-continuous media.

Label jam in rear area of printhead.

Missing characters or parts of characters on the front panel display screen.

Printed label feeds out and then backfeeds immediately to rest under the printhead.

Changes in configuration parameter settings did not take affect.

Dirty printhead or ribbon rollers.

Toggle pressure needs adjustment.

Clean the printhead and/or ribbon rollers. See page 52.

See Adjustments on page

56.

Printhead angle needs adjusting using the Wear Plate adjustment

Call a service technician.

procedure.

Too much toggle pressure.

Media was pulled when motor was not moving.

In Rewind or Peel-Off mode: printer was calibrated without media properly installed.

Reduce toggle pressure. See Adjustments on page 56.

Recalibrate the printer.

Load media correctly for rewind or peel-off modes. See Rewind Mode Media Loading on page 11.

Reduce the size of the format Label format is larger than available memory.

or contact your sales

representative for information

on memory upgrades.

Snap Plate needs cleaning. Call a service technician.

Display screen may be bad.

Printer set for Cutter mode with no Cutter installed.

Run the Power-On Self Test. If

problem persists, call a service

technician.

Set correct print mode. See

Selecting Print Mode on

page 32.

Enter the Configuration mode. Parameters are set

incorrectly.

Set parameters correctly and

save permanently. Refer to

Configuration and

Calibration. If problem continues, there

may be a problem with the

Call a service technician. Main Logic Board.

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Symptom Diagnosis Action

A label format was sent to the printer but not recognized.

A label format was sent to the printer but not recognized. Data light flashes but no printing occurs.

A batch of labels was sent. Several labels print then printer skips, misplaces, misses, or distorts the printing on the labels.

Communications parameters are incorrect.

Prefix and delimiter characters set in printer do not match the ones used in the label format.

Communications parameters are incorrect.

Prefix and delimiter characters set in printer do not match the ones used in the label format.

Buffer is overfilling.

Print a Communications Diagnostic label. Check for Format or Overrun Errors. See "Setting Communication Parameters" on page 38.

Set the characters in the printer to match the label format. See Selecting Prefix and Delimiter Characters on page 40.

If the problem continues, check the ZPL II format for changed ^CC, ^CT, and ^CD commands.

Print a Communications Diagnostic label. Check for Format or Overrun Errors. See "Setting Communication Parameters" on page 38.

Set the characters in the printer to match the label format. See Selecting Prefix and Delimiter Characters on page 40.

If the problem continues, check the ZPL II format for changed ^CC, ^CT, and ^CD commands.

Check for proper flow control setting. Refer to Configuration and Calibration.

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Printer Diagnostics

Power-On Self Test

Additional Printer Self Tests

A Power-On Self Test (POST) is performed automatically each time the printer is turned on. This test checks for proper initialization of various elec tronic circuits and establishes starting parameters as those stored in the printer’s memory. During this test sequence, the front panel lights turn on and off to ensure proper operation. See “Power-On Self Test Sequence” on page 28.

These self tests produce sample printouts and provide specific information which helps determine the operating conditions 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 depressed until the Data light turns off. When the Power-On Self Test is complete, the selected self test starts automatically.

NOTES: When performing self tests, disconnect all data interface cables

from the printer.

When canceling a self test prior to its actual completion, always

turn the printer power off and then back on to reset the printer.

When performing these self tests while 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, otherwise the test may print out on the platen. See page 34 for information on setting the print width.

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Cancel Key Self Test

Turn the printer off. Press the Cancel Key and hold while turning the power on. This self test prints a listing of the configuration parameters currently stored in the printer’s memory. See Figure 15.

The configuration may be changed either temporarily (for specific label for mats or ribbon and label stock), or permanently (by saving the new parame ters in memory.) Saving new parameters occurs whenever a Calibration procedure is performed. Refer to page 29 for further information about the Configuration procedure.

Figure 15. Cancel Key Self Test Sample Printout

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Figure 16. Pause Key Self Test Sample Printout

Pause Key Self Test

This self test can be used to provide the test labels required when making adjustments to the printer’s mechanical assemblies. See the sample printout in Figure 16.

Turn the printer off. Press the Pause key and hold while turning the power on.

1. The initial self test prints 15 labels at speed “A” (2.4" per second) then automatically pauses the printer. Each time the Pause key is pressed, an additional 15 labels print.

2. While the printer is paused, pressing the Cancel key alters the self test. Now each time the Pause key is pressed the printer prints 15 labels at speed “D” (6" per second).

3. While the printer is paused, pressing the Cancel key again alters the self test again. Now each time the Pause key is pressed the printer prints 50 labels at speed “A”.

4. While the printer is paused, pressing the Cancel key again alters the self test a third time. Now each time the Pause key is pressed the printer prints 50 labels at speed “D”.

5. While the printer is paused, pressing the Cancel key again alters the self test a fourth time. Now each time the Pause key is pressed the printer prints 15 labels at 12" per second.

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Feed Key Self Test

The Cancel Key Self Test should be performed prior to this self test. Infor

mation on the “Configuration” printout (Cancel Key Self Test) can be used with the results of this self test to determine the best Darkness setting for a specific media/ribbon combination.

The Feed Key Self Test will print out at various Darkness settings above and below that of the Darkness value shown on the Configuration Label. See Figure 17. Inspect these labels and determine which one has the best darkness setting for the application. This value can be entered into the printer by setting the Darkness during the configuration procedure. Refer to page 32 for more information.

The value printed on that label is added to (plus) or subtracted from (minus) the “Darkness” value specified on the Configuration Label. The resulting numeric value (0 to 30) is the best darkness value for that specific media/ribbon combination.

Feed Key and Pause Key Self Test

Pressing these two keys at the same time, while turning the Power on, temporarily resets the Printer Configuration to the factory default values. These values will be active only until power is turned off unless you save them permanently in memory.

Communications Diagnostics Test

This test is controlled from the front panel display. Refer to page 40. A typi cal printout from this test is shown in Figure 18. Turn the power off to exit this self test.

NOTE: This label will be inverted when printed.

Additional Printer Diagnostics

Additional diagnostic tests are available for the Zebra XiII printer, however they are beyond the scope of this user’s guide. Refer to the maintenance manual (part # 48452L) for information about these additional tests.

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Figure 17. Feed Key Test Sample Printout

Figure 18. Communications Diagnostics Test Sample Printout

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Rewind Option

Options

NOTE: Your printer may not have all of the options described in this

chapter. Call your sales representative for more information about these options.

Your Zebra XiII-Series printer may be equipped with the optional Media Rewind capability required for Rewind and Peel-Off modes of operation.

In Rewind Mode, both labels and backing material rewind internally onto a 3-inch core. A Rewind Bracket guides the media back to the Rewind Spindle after printing.

In Peel-off Mode, only the backing rewinds onto the Rewind Spindle. The Peel/Tear Bar separates the label from the backing and the Label Available Sensor activates to allow the operator to remove a printed label before subsequent labels print. Select either the Rewind or Peel-off Print Mode from the front panel display.

Cutter

Your Zebra XiII printer may be equipped with a cutter used to cut the labels after they are printed. The Cutter Option may be installed concurrently with other options including the Rewind Option. The Cutter Option may be factory-installed or it may be installed in the field by a qualified service technician.

The Cutter Option must be enabled by entering the Programming Mode and using the front panel display to select the Cutter Print Mode. Refer to the “Operation” section for additional information. The Cutter Catch Tray may be installed to collect labels, tickets, or tags after being cut.

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Internal Fanfold Media Supply Bin

Your Zebra XiII-Series printer may be equipped with an optional internal Fanfold Media Supply Bin. It is used to load fanfold media within the XiII printer’s media compartment, and protects the media from environmental contaminants such as dust and dirt. The Fanfold Media Supply Bin may be installed in the field by the operator.

NOTE: The Fanfold Media Supply Bin may not be installed in XiII

printers with the Rewind Option. Fanfold media may be used on printers with the Rewind Option installed by using one of the external fanfold supply access slots at the bottom and rear of the printer.

Memory SIMMs

Memory SIMMs increase the graphics storage capacity of the printer, increase the maximum print length, and/or increase through-put by increasing format-while-print abilities. Contact your sales representative to purchase compatible SIMMs in 1, 2, 4, and 8 MB sizes.

On-Line Verifier

The On-Line Verifier is an external device that provides the means to auto matically scan and analyze certain bar code symbols as they are printed. If the verifier detects a problem with the bar code, it will automatically pause the printer. The operator must then correct the problem and take the printer out of pause mode before printing will resume.

Several operational modes are available, ranging from simple freescan to one where specific symbology and data is required.

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Applicator Interface

Media Supply Spindle

The Applicator Interface is an ideal method of integrating XiII printers into custom applications. This interface allows printer control from a personal computer or Programmable Logic Controller (PLC) via one cable attached to a connector located at the rear of the printer. This provides the capability of placing the XiII printers on a production line in a loose loop, print and apply configuration, or other applications where the printer must be con trolled by a machine.

The optional Media Supply Spindle replaces the standard hanger. This is useful for applications that require the printer to be mounted in a nonhorizontal position where the standard media hanger prohibits consistent media flow.

Optional Media Supply Fins

Optional Media Supply Fins are available to convert the standard 3-inch (76 mm) core diameter to a 1.77 inch (45 mm) core for smaller core media rolls. Simply remove the current fins and install the reduced-diameter fins.

Fonts

There is a wide range of optional character fonts that can be purchased for your XiII printer in addition to those fonts which are standard in the unit. Fonts may be purchased on EPROMs or on PCMCIA cards, depending on your needs.

Refer to “Optional Printer Fonts” on page 85 for information about optional fonts. From time to time, additions may be made to the list of available fonts. Contact your sales representative for further information.

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PCMCIA Type I Memory Cards

These memory cards work with the XiII printer’s standard memory card interface. With these cards, users can store complete label formats, images/ graphics, and fonts for easy transfer to the printer’s memory. Storing data on PCMCIA cards minimizes download time and maximizes throughput. Contact your sales representative to purchase compatible cards.

KMT Printhead

The KMT printhead, used on all older printers, is available for use with the XiII printers for customers who want to maintain full compatibility with their existing printers.

Communication Interfaces

IBM® Twinax Interface

This interface emulates IBM® System 3/X and AS/400 (5224, 5225, 5256, and 4214) printers. This option comes with an auto-terminating 1 ft. Y-connector cable.

IBM® Coax Interface

This interface emulates an IBM® System 3287 printer used in the IBM 3270 environment. This option comes with a BNC connector to interface to your host mainframe’s controller.

ZebraNet™ (Ethernet) Interface

The ZebraNet™ Micro Print Server (MPS) provides ethernet connectivity for your Zebra printer. The ZebraNet MPS is a multiprotocol print server. It provides shared network access to a Zebra printer for a variety of network protocols and operating systems. The MPS1-T provides a twisted pair (10Base-T) connector for network connections and a parallel Centronics®

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RS-485 Interface

port to which network nodes can spool print jobs. The MPS1-2 provides a thinwire (10Base-2) connector and a parallel port for the same purposes. Both servers can queue multiple pending jobs and service those jobs in the order in which they are received from the hosts.

The RS-485 interface provides a simple and cost-effective way to connect a PC and multiple printers together to create an instant network. This simple cabling system connects directly to a personal computer’s serial port and al lows multiple hook-ups—perfect for anyone who wants to connect several printers to a single host.

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Media Handling

Specifications

NOTE: Your printer may not have all of the options described in this

chapter.

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

Applicator mode: labels are peeled from the liner and presented for use by an external applicator device

Options

IBM Twinax Interface

IBM Coax Interface

ZebraNet™—Ethernet Interface: 10Base-T and 10Base-2

RS-485 Interface

Font Cards

Font EPROMs

Memory Expandable to 2, 3, 5, or 9 MB

Memory Cards

KMT Printhead (not applicable to the 220XiII printer)

Programmable Print Speeds from 2.4" (61 mm) to 8" (203 mm) per second

Printer Drivers for Windows™ 3.X and Windows 95 Operating Systems

Cutter

Rewind

Cutter-Rewind

Cutter Tray

Media Supply Spindle

Clear Media Supply Door

Applicator Interface

On-Line Bar Code Verifier

Internal Fanfold Media Supply Bin

PC-470 Print Controller with Keyboard and Display for Stand-Alone Applications

Bar-One®Windows™-Based WYSIWYG On-Screen Label Design and Print Application Software

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Zebra Programming language (ZPL II®)

Downloadable graphics, scalable and bitmap fonts, and label formats

Object copying between memory areas (RAM and memory card)

Code Page 850 character set

Adjustable print cache

Data compression

Automatic virtual input buffer management

Automatic memory allocation

Format inversion

Mirror image printing

Four-position field rotation (0º, 90º, 180º, and 270º)

Bar Codes

Bar code ratios - 2:1, 7:3, 5:2, & 3:1

Code 11

Code 39 (Supports ratios of 2:1 up to 3:1)

Code 49 (2-dimensional bar code)

Code 93

Code 128 (With subsets A, B, and C and UCC Case C Codes)

Codabar (Supports ratios of 2:1 up to 3:1)

CODABLOCK

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

Slew command

Programmable quantity with print, pause, and cut control

Communicates in printable ASCII characters

Error-checking protocol

Controlled via mainframe, minicomputer, PC, portable data terminal

Serialized fields

In-spec OCR-A and OCR-B

UPC/EAN

User-programmable password

Status message to host upon request

Industrial 2 of 5

Standard 2 of 5

ISBT-128

LOGMARS

Plessey

EAN-8, EAN-13, EAN EXTENSIONS

UPC-A, UPC-E, UPC EXTENSIONS

MSI

PDF-417 (2-dimensional bar code)

POSTNET

MaxiCode

Data Matrix

Check digit calculation where applicable

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General Specifications

General Specifications 90XiII 140XiII 170XiII 220XiII

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 11.2" 285.7 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 23 kg 55 lb 25 kg 67 lb 30.5 kg 72 lb 32.7 kg

General

Electrical

Temperature

Relative Humidity

Power Consumption

Compliance

Operating Environment

Storage

Operating Environment

Storage

90-264 VAC;

48-62 Hz

Printing Pause Test label at speed "A"

Printer idle 20 W 19 W 19 W 20 W

Thermal Transfer

Direct Thermal

121 W 180 W 220 W 269 W

Complies with FCC class A and Canadian Doc. class A rules.

41º to

104º F

32º to

104º F

140º F

5º to

40º C

0º to

40º C

-40º

-40º to

60º C

20 to 85%

non-condensing

5 to 85%

non-condensing

90-264 VAC;

48-62 Hz

Carries the CE mark of compliance. 41º to

104º F 32º to

104º F

140º F

5º to 40º C

0º to 40º C

-40º

-40º to

60º C

20 to 85%

non-condensing

5 to 85%

non-condensing

90-264 VAC;

48-62 Hz

41º to

104º F

32º to

104º F

140º F

non-condensing

-40º to

20 to 85%

5 to 85%

5º to

40º C

0º to

40º C

-40º to 60º C

90-264 VAC;

48-62 Hz

41º to 104º F

32º to 104º F

-40º

-40º to

140º F

20 to 85%

non-condensing

5 to 85%

non-condensing

5º to

40º C

0º to

40º C

60º C

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Printing Specifications

Printing Specifications 90XiII 140XiII 170XiII 220XiII

Resolution

Dot size (Width x Length)

First dot location from inside media edge

Maximum print width 3.4 (86 mm) 5.04 (128 mm) 6.6 (168 mm) 8.5 (216 mm)

With

Non-continuous 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 4.9 mil to 49 mil 3.9 mil to 39 mil 4.9 mil to 49 mil

Picket Fence (Non-rotated) 3.33 mil to 33 mil 4.9 mil to 49 mil 3.33 mil to 33 mil 4.9 mil to 49 mil

standard memory

With 9 MB memory

With standard memory

With 9 MB memory

300 dots/inch (12 dots/mm)

0.0033 x 0.0039 (.084 x .100 mm)

0.12" ± .035"

(3 mm ±.89 mm)

20 (508 mm) 30 (762 mm) 10 (254 mm) 16 (406 mm)

39 (991 mm) 39 (991 mm) 39 (991 mm) 39 (991 mm)

20 (508 mm) 30 (762 mm) 10 (254 mm) 18 (457 mm)

100 (2540 mm) 150 (3810 mm) 100 (2540 mm) 150 (3810 mm)

Yes Yes Yes Yes

203 dots/inch

(8 dots/mm)

0.0049 x0.0049 (.125 x .125 mm)

0.10" ± .035"

(2.5 mm ±.89 mm)

300 dots/inch (12 dots/mm)

0.0033 x 0.0039 (.085 x .100 mm)

0.10" ± .035"

(2.5 mm ±.89 mm)

203 dots/inch

(8 dots/mm)

0.0049 x 0.0049 (.125 x .125 mm)

0.10" ± .035"

(2.5 mm ±.89 mm)

Ribbon Specification

Ribbon Specifications 90XiII 140XiII 170XiII 220XiII

Ribbon must be wound with the coated side out.

Ribbon Width (Zebra recom- mends 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. (450 m) 1476 ft. (450 m) 1476 ft. (450 m) 1476 ft. (450 m)

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)

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Media Specifications

Media Specifications 90XiII 140XiII 170XiII 220XiII

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

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

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

Additional specs. for black mark sensing

perpendicular to label/tag edge

Mark location Marks must be located within .040" (1 mm) of the inside media edge.

Mark density

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 (50.8 mm) 4.25 (108 mm) Maximum 3.54" (90 mm) 5.51 (140 mm) 7.17 (182 mm) 8.80 (224 mm) Minimum 0.003 (0.076 mm) 0.003 (0.076 mm) 0.003 (0.076 mm) 0.003 (0.076 mm) Maximum 0.012 (0.305 mm) 0.012 (0.305 mm) 0.012 (0.305 mm) 0.012 (0.305 mm)

.014" (.35 mm) .009" (.23 mm) .007" (.18 mm) .005" (.14 mm)

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

Vertical ±0.060 (±1.5 mm) ±0.070 (±1.8 mm) ±0.060 (±1.5 mm) ±0.050 (±1.3 mm)

Horizontal ±0.060 (±1.5 mm) ±0.070 (±1.8 mm) ±0.060 (±1.5 mm) ±0.060 (±1.5 mm) 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

Maximum Inter-label gap = 2 x (label length for which you

8.0 x 3.54 x 4.5 (203x90x114 mm)

0.12" x .25"

(3 mm) x (6 mm)

> 1.0 ODU

(Optical DensityUnit)

0.5 ODU 0.5 ODU 0.5 ODU 0.5 ODU

8.0 x 5.51 x 4.5 (203x140x114 mm)

(Optical DensityUnit)

have calibrated the printer) + 1

8.0 x 7.1 x 4.5 (203x180x114 mm)

0.12" x .25"

(3 mm) x (6 mm)

> 1.0 ODU

(3 mm) x (6 mm)

(Optical DensityUnit)

0.12" x .25"

> 1.0 ODU

8.0 x 8.8 x 4.5 (203x224x114 mm)

(Optical DensityUnit)

(3 mm) x (6 mm)

0.12" x .25"

> 1.0 ODU

print speed, and printer mode of operation. Performance improves as these factors are optimized. Zebra recommends always qualifying any application with thorough testing.

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Power Line Cord Specifications

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

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

The chassis ground (earth) MUST be connected to assure safety and reduce electromagnetic interference. The ground connection is handled by the third wire (earth) in the power line cord. See Figure 19.

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 20.

AC POWER

PLUG FOR

YOUR COUNTRY

Figure 20. International Safety Organizations

IEC 320

3 CONDUCTOR

<HAR> CABLE

CONNECTOR

Figure 19. Power Line Cord

CONTACT

VIEW

NEUTRAL

EARTH

LIVE

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Printer Fonts

Standard Printer Fonts

For more information on fonts, refer to the ZPL II Programming Guide.

Bit-mapped fonts A, B, C, D, E, F, G, H, and GS are expandable up to 10 times, height- and width-independent. However, fonts E and H (OCR-B and OCR-A) are not considered in-spec when expanded.

The scalable (smooth) font (CG Triumvirate™ Bold Condensed) is expandable on a dot-by-dot basis, height- and width-independent, while maintaining smooth edges, to a maximum of 1500 x 1500 dots.

IBM Code Page 850 international characters are available in fonts A, B, C, D, E, F, G, and Ø through software control.

Table 7. Eight Dots/mm Printhead

Dot Matrix Type Minimum Character Size

Standard

Fonts

C, D 18 x 10 2 U-L-D

GS 24 x 24 0 SYMBOL

Height x Width

(in dots)

A 9 x 5 1 U-L-D

B11x7 2 U

E 28 x 15 5 OCR-B

F 26 x 13 3 U-L-D

G 60 x 40 8 U-L-D

H 21 x 13 6 OCR-A

Ø Default: 15 x 12 U-L-D Scalable (smooth) font

Inter-character Gap

U = Uppercase L = Lowercase D = Descenders

Height x Width Character Density

0.044" x 0.029"

1.13 mm x 0.75 mm

0.054" x 0.044"

1.38 mm x 1.13 mm

0.088" x 0.059"

2.25 mm x 1.50 mm

0.138" x 0.098"

3.50 mm x 2.50 mm

0.128" x 0.079"

3.25 mm x 2.00 mm

0.295" x 0.236"

7.50 mm x 6.00 mm

0.103" x 0.093"

2.63 mm x 2.38 mm

0.118" x 0.118"

3.00 mm x 3.00 mm

33.90 Char/inch

1.33 Char/mm

22.60 Char/inch

0.89 Char/mm

16.95 Char/inch

0.67 Char/mm

10.17 Char/inch

0.40 Char/mm

12.71 Char/inch

0.50 Char/mm

4.24 Char/inch

0.17 Char/mm

10.71 Char/inch

0.42Char/mm

8.48 Char/inch

0.33 Char/mm

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Standard

Fonts

C, D 18 x 10 2 U-L-D

GS 24 x 24 0 SYMBOL

Height x Width

A 9 x 5 1 U-L-D

B11x7 2 U

E 41 x 20 6 OCR-B

F 26 x 13 3 U-L-D

G 60 x 40 8 U-L-D

H 30 x 19 9 OCR-A

Ø Default: 15 x 12 U-L-D Scalable (smooth) font

Table 8. Twelve Dots/mm Printhead

Dot Matrix Type Minimum Character Size

U = Uppercase L = Lowercase D = Descenders

Height x Width Character Density

0.030" x 0.020"

0.76 mm x 0.51 mm

0.037" x 0.030"

0.93 mm x 0.76 mm

0.060" x 0.040"

1.53 mm x 1.02 mm

0.137" x 0.087"

3.47 mm x 2.20 mm

0.087" x 0.053"

2.20 mm x 1.36 mm

0.200" x 0.160"

5.08 mm x 4.07 mm

0.100" x 0.093"

2.54 mm x 2.37 mm

0.080" x 0.080"

2.03 mm x 2.03 mm

(in dots)

Inter-character Gap

50.00 Char/inch

1.97 Char/mm

33.33 Char/inch

1.31 Char/mm

25.00 Char/inch

0.98 Char/mm

11.54 Char/inch

0.45 Char/mm

18.75 Char/inch

0.74 Char/mm

6.25 Char/inch

0.25 Char/mm

10.71 Char/inch

0.42Char/mm

12.50 Char/inch

0.49 Char/mm

Standard Printer Font Examples

Figure 21. Standard Printer Font Examples

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Optional Printer Fonts

There are many optional character fonts that can be purchased for your XiII printer in addition to those which are standard in the unit. From time to time, additions may be made to the list of available fonts. Contact your sales representative for further information.

Only one additional font EPROM can be installed in the printer at a time. This installation should be performed by a service technician. Once in

stalled, this font can be used in addition to the standard fonts available in the printer. Refer to your ZPL II Programming Guide or, if using another software package to drive your printer, to the instructions accompanying that package.

Optional fonts may also be stored on PCMCIA font cards.

Once an optional font is installed in the printer, the Configuration Printout produced during the Cancel Key Self Test will indicate the font type as the “Socket 1 ID”.

Figure 22 illustrates the optional fonts and Figure 23 shows sample point sizes for the bitmap smooth fonts.

Scalable (smooth) Fonts (each is supplied as a complete set of Normal, Bold, Italic, and Bold Italic styles)

Arabic -- Century Schoolbook -- CG Palacio CG Palacio CG Times CG Times CG Triumvirate CG Triumvirate

Cyrillic East European Futura Futura Greek Icelandic Kanji, Gothic Kanji, Mincho Kanji, Mincho and Gothic Turkish

Universe

Table 9. Optional Printer Fonts Currently Available

Bitmap Fonts (supplied only in Bold). Type sizes: 6, 8, 10, 12, 14, 18, and 24 point.

CG Triumvirate Condensed

Universe

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Optional Printer Font Examples.

CG Palacio™ - Standard 0123, Bold 0123, Italic 0123, Bold Italic 0123

CG Times™ - Standard 0123, Bold 0123, Italic 0123, Bold Italic 0123

CG Triumvirate™ - Standard 0123, Bold 0123, Italic 0123, Bold Italic 0123

CG Triumvirate Condensed™ - Bold 0123

CG Futura™ - Standard 0123, Bold 0123, Italic 0123, Bold Italic 0123

Greek - Standard 0123, Bold 0123, Italic 0123, Bold Italic 0123

Univers

- Standard 0123, Bold 0123, Italic 0123, Bold Italic 0123

Figure 22. Select Examples of Optional Fonts

@ABCDEFGHIJKLMNO

8pt

10 pt

12 pt

14 pt

18 pt

24 pt

30 pt

Figure 23. Bitmap Smooth Fonts: Point Size Examples

@ABCDEFGHIJKLMNO

@ABCDEFGHIJKLM

@ABCDEFGHIJ

@ABCDEFG

@ABCDEF

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Printer Interface Technical Information

System Considerations

Appendix

Communications Code

The XiII printer sends and receives American Standard Code for Informa tion Interchange (ASCII). This code consists of 128 characters (256 for Code Page 850) including uppercase and lowercase letters, characters, punctuation marks, and various control codes.

Interfaces

The method of interfacing the Zebra XiII-Series printer to a data source depends on the communication options installed in the printer. The standard interfaces are an RS-232/RS-422/RS-485 serial data port and a bi-directional parallel port. The IBM® Twinax or IBM Coax option is available for those applications which require them.

Data Specifications

When communicating via an asynchronous serial data port (RS-232/ RS-422/RS-485), the baud rate, number of data and stop bits, parity, and handshaking are user-selectable. Parity only applies to data transmitted by the XiII printer since the parity of received data is ignored.

When communicating via the parallel port, the previously mentioned parameters are not considered. Refer to “Configuration and Calibration” on page 29 to configure the communication parameters for the XiII printer. The values selected must be the same as those used by the host equipment connected to the XiII printer.

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

The connections for these standard interfaces are made through the DB25S connector on the rear panel. For all RS-232 input and output signals, the XiII printer follows both the Electronics Industries Association’s (EIA) RS-232 specifications and the Consultative Committee for International Telegraph and Telephone (CCITT) V.24 standard signal level specifica tions.

Table 10 shows the pin configuration and function of rear panel serial data connector on the XiII-Series printers.

Table 10. RS-232/RS-422/RS-485 Pinouts

Pin No. Description

1 Frame ground for cable shield 2 TXD (RS-232 transmit data) output from printer 3 RXD (RS-232 receive data) input to printer 4 RTS (RS-232 request to send) output from printer 6 DSR (data set ready)input to printer 7 Signal ground for RS-232

9 +5 VDC source output (1 Amp maximum) 11 Signal ground reference for RS-422/RS-485 13 RS-422/RS-485 data input A (-) 14 RS-422/RS-485 data output A (-) 16 RS-422/RS-485 data input B (+) 19 RS-422/RS-485 data output B (+) 20 DTR (RS-232 data terminal ready) output from printer

NOTE:

Pins 5, 8, 10, 12, 15, 17-18, 21-25 are not used and are unterminated.

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Zebra Technologies XiII-Series User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual