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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