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Zebra XiII™-Series Maintenance Manual

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1. 45189 5 T DIMENSIONS FROM o MAIN FRAME TO INSIDE LOCATION PULLEY GUIDING EDGE OF PULLEY J7 01117 1 TAKEUP 30336 1 FIXED SUB ASSY 2 MAINPLATEN 40355M 11MM 433 IN 01130 3 STEPPER 40357M 10MM 40 IN 49700M o 76 J9 d 2 MEDIA TAKEUP 30336 2M FIXED IN SUB ASSY no C o Q 5 PEELOFF 30914M 8MM 28 IN 01117 2 01117 2 O J11 8226M J12 30392 004 2 E Ji 06222 01117 p o TYPICAL 916 CABLE CLAMP J17 o INSTALLATION 18 E J19 O J20 3 45189 2 S qms 46392 006 4 5 111 41 49604 010 J10 J9 O 49780M 49600 010 J8 J7 40185 N N J6 H J5 40484 04393 J4 i wy 40815 40357M J1 O E _ 46677 O TWISTED 49790M 45189 J3 J2 45189 2 40357 3 WO REWIND 3 WITH REWIND MAIN FRAME SECTION A A 220Xill FINAL ASSEMBLY ELECTRICAL PG 2 OF 2 48452L Rev 2 Xill Series Maintenance Manual 8 11 Drawings and Parts Lists PRINTER MODEL 90Xill 140Xill 170 Print Mechanism Assembly Page 1 of 3 PRINTER MODEL 90Xill 140Xill 170 Xill Print Mechanism Assembly Page 1 of 3 PART NUMBER DESCRIPTION QUANTITY 01130 Nut 6 32 Hex Washer Head PART NUMBER DESCRIPTION QUANTITY 01159 Washer Lock 6 40031 C
2. Darkness Properly Set Printhead Positioned Correctly Toggles Balanced Equal Pressure on Left and Right Sides 183456789012345578901234567830123456 8901234567890123456 890123456 Darkness Set Too High Printhead Positioned Correctly Toggles Balanced Equal Pressure on Left and Right Sides Page 6 8 Xill Series Maintenance Manual 48452L Rev 2 Troubleshooting Unacceptable Label Darkness Set Low Printhead Positioned Correctly Toggles Balanced Equal Pressure on Left and Right Sides Unacceptable Label Darkness Set Very Low Printhead Positioned Correctly Toggles Balanced Equal Pressure on Left and Right Sides 48452L Rev 2 Xill Series Maintenance Manual Page 6 9 Troubleshooting Unacceptable Label Darkness Properly Set Printhead Too Far Forward Scratch Flowers on Black Area Foggy Appearance Printhead Needs to be Moved Rearward Walk Out Wrinkle with Feed Button and Readjust Toggles Balanced Equal Pressure On Left and Right Sides Unacceptable Label Darkness Properly Set Printhead Way Too Far Forward Scratch Flowers on Black Area Washed Out Appearance db Hoc Printhead Needs to be Moved Rearward Walk Out Wrinkle with Feed Button and Readjust Toggles Balanced Equal Pressure On Left and Right Sides Page 6 10 Xill Series Main
3. Figure 5 22 90 140 170 220 Rewind Drive Belt Page 5 38 Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance AC Power Fuse Replacement The Xill Series printer uses metric style fuse 5 x 20 mm rated at 5 250V The AC Power Entry Module comes with two approved fuses in the Fuse Holder one is In Circuit and the second is provided as a spare refer to Figure 5 23 below The end caps of the fuse must bear the certification mark of a known international safety organization refer to Figure 5 24 To replace a faulty fuse use the following procedure WARNING Turn the printer s AC Power Switch OFF and disconnect the printer s AC Power Cable before replacing any Fuses 1 Refer to Figure 5 23 Using a small blade screwdriver or similar tool remove the Fuse Holder which is part of the AC Power Entry Module at the rear of the printer 2 Remove the faulty fuse and install a new fuse in the In Circuit position If you use the Spare Fuse be sure to order a new replacement fuse Fuses can be ordered from your Zebra distributor 3 Snap the Fuse Holder back into the AC Power Entry Module 4 the Power Cable and turn printer ON NOTE If AC power is not restored an internal component failure may have occurred The printer will require servicing POLDER AC POWER ENTRY MODULE SMALL BLADE SCREWDRIVER SPARE gt 4 FUSE x 2
4. 5 33 Main Drive Belt Removal Replacement amp Adjustment 5 36 Rewind Drive Belt Removal Replacement amp Adjustment 5 38 AC Power Fuse Replacement 5 39 Basic Troubleshooting 6 1 Tr ublesh tI e Charts s o e e ES 6 1 sample Lab ls s s ste w qua ee 6 7 Factory Assistance 6 14 Returning Equipment 6 14 Printer IBSEOVETVIBW oos coa ox w hob no x e x os 7 2 Power ON Sell Tests 1 2 4 23 ew ew wae 7 2 Power Up Media 7 5 Self Test Labels BE RS KO Ee ee 7 5 Automatically Executed Format 7 7 Operator Interfaces 522552555 S e ddd S x GS EE Sus 7 7 Communications 7 9 Ee rc FC 7 12 Memory Manager 25 v s sa v k G s 7 14 Print sue 039 309 9 3 oS us s 7 15 Print MOdES 425 4230 a S 7 18 ZPL Commands Supported 7 20 Power Up Diagnostics 7 20 Mechanical Parts and Assemblies 8 1 90 140 170 Final Assembly Page 1 of 2 Parts 115 8 4 90 140 170Xill Final Assembly Page 1 of 2 Drawing 8 5 90 140 170XilI Final Assembly Page 2 of 2 Parts List 8 5 90 140 170Xill Final Assembly Page 2
5. POSITION RIBBON SENSOR 46665 TAB NOT TO BE FLUSH WITH TOP EDGE OF PIVOT BAR 48162 GAP 010 MIN 030 MAX REMOVE TAB AS SHOWN FROM PRINTHEAD DATA CONNECTOR REMAINING PRINTHEAD DATA CONNECTOR TAB MUST SNAP OVER CONNECTOR SCREW TIGHTENING TORQUES UNLESS OTHERWISE SPECIFIED TO BE 10 12 IN LBS OTHER VALUES APPEAR IN BOXES IN IN LBS X Y N e gt 484521 Rev 2 48289 30392 004 2 ADHESIVE THIS SIDE ONLY 1 2 3 4 Drawings and Parts Lists 30392 004 2 4 01159 2 2 45481142 40194 2 40193 2 47162 47014 30392 004 2 Xill Series Maintenance Manual DETAIL SCALE 2 1 06268 4 30392 004 4 30013 FRONT SURFACE OF PRESSURE PLATE 47212 SHOULD BE FLUSH TO BELOW ENDS OF MTG BRKT 47103 WRAP GROUND STRAP 7 AS SHOWN 90X7ll PRINTHEAD SUPPORT ASSEMBLY 8 25 Drawings and Parts Lists PRINTER MODEL 140XIl Printhead Support Assembly QUANTITY PART NUMBER DESCRIPTION 01153 Washer Flat 250 x 125 x 028 01159 Washer 6 Lock 06268 Washer 6 Split Lock 22015 Spring Printhead Mounting 22016 Screw Printhead Mounting 30007 4 Shaft Roller 30314R Adhesive 30391 003 Screw 4 40 19 30392 004 Screw 6 32 25 e 3
6. 8 44 Media Rewind Option Assembly Drawing 8 45 Cutter Option Assembly Parts iuo eee ett tete tad 8 46 Cutter Option Assembly Drawing else ax ect eant 8 47 Page 8 2 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists 220X717 L Zebra 170 will LU Wi ws t ves etre im LL Y wi 1 gt a niiin 28 WENO we 59 484521 Rev 2 Xill Series Maintenance Manual 8 3 PRINTER MODEL 90Xill 140 Xill 170 Xill Final Assembly page 1 of 2 PART NUMBER DESCRIPTION QUANTITY 01130 Nut 6 32 Hex Washer Head 01861 Label Supplies w Logo 07257 Washer Flat 438 x 188 x 065 22246 Support Cover 22492M Switch Membrane 30256 Nut Thumb 6 32 50 30269 Pad PVG 30363 Panel Door with Window 30392 003 Screw 6 32 19 NIN mH A GQ 30392 004 Screw 6 32 25 30407 008 Screw 6 32 Socket head Flat A Drawings and Parts Lists PRINTER MODEL 90 140Xill 170 Xill Final Assembly page 1 of 2 PART NUMBER DESCRIPTION QUANTITY 44114 Screw Hi Lo Hex M4 2 8 12 44356 Washer 198 75 085 Co 46037 1 Cover Front 170X11 46038 1
7. a N fs fa eS 8 12 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists 30305RM 90 40305RM 140 46305M 170 30353 30392 004 30307 01130 pov Q10057 Y is gt 30033 47302 4 90 30392 004 01159 48302 4M 140X ill ET 46302 4 170 e 47444 90Xill 1 9 I 5 30392 004 48444 140xill lt 46444 170Xill I UPPER MEDIA SENSOR SUB ASSEMBLY Pd 48411 2 _ 38099 1 2 hee 30266 EL MON Gc 26 7 9 06268 E 30392 006 T Se _ lt j 2910019 E gt I I kas I I 29023 2 44001 2 la 47009 1 90X ll 50296 47009 3 140 30825 90Xill La 47009 8 170Xill 38825 2 140Xill l 38825 1 170Xill Y mE 46691 1M 90Xill 30007 1 90Xill 46691 2 140X ll 30007 3 140 i 46691 3M 170Xill 30007 6 170Xill D 1 1 2 7 eo LU p _ Dg 30827 gt NN 30423 003 pA c U Bl um Ns ie ue 30392 001 s MES F 30956 06268 _ lt
8. 30392 004 2 o 01159 2 49640 021 30392 004 2 Xill Series Maintenance Manual 46481 1 2 40194 2 40193 2 V DETAIL SCALE 2 1 06268 4 30392 004 4 40013 FRONT SURFACE OF PRESSURE PLATE 48212 SHOULD BE FLUSH TO BELOW ENDS OF MTG BRKT 48003 WRAP GROUND STRAP N AS SHOWN 140Xill PRINTHEAD SUPPORT ASSEMBLY 8 27 Drawings and Parts Lists PRINTER MODEL 170Xil Printhead Support Assembly QUANTITY PART NUMBER DESCRIPTION 01153 Washer Flat 250 x 125 x 028 01159 Washer 6 Lock 06268 Washer 6 Split Lock 22015 Spring Printhead Mounting 22016 Screw Printhead Mounting 30007 7 Shaft Roller 30314R Adhesive 30391 003 Screw 4 40 19 30392 004 Screw 6 32 25 e 30402 006 Screw 6 32 37 30494 Washer 320 x 119 x 062 30781 Cable Printhead Ground 40193 Washer Flat 406 x 172 x 048 40194 Washer Curved 312 x 144 x 016 46002 1 Bar Head Pivot 46013 Plate Washer 46017 Plate Ribbon Strip 46169 Bracket Head Mounting 46170 Plate Pressure 46171 Pad Pressure 46173 Brush Static 46174 Plate Guard 46481 1 Screw Adjustment 6 32 46500M Printhead 1 70 Xill
9. 5 25 Installing the Main Logic 5 25 Removing the DC Power Supply Assembly 5 29 Installing the DC Power Supply Assembly 5 29 Removing the AC Power Supply Assembly 5 30 Installing the AC Power Supply Assembly 5 30 Program ROM Installation cedo a d ierat 5 32 Option 5 33 Memory Card and Font Card Installation 5 34 Installg80 0 L aus t ond aiat Depp dti saeua 5 35 Main Drive Belt Removal Replacement amp Adjustment 5 36 Rewind Drive Belt Removal Replacement amp Adjustment 5 38 Power Fuse Replace nei 5 39 Corrective Maintenance Functions When a problem is encountered with the Zebra Xill Printer the Service Technician should first insure the unit is being used properly then exercise it to localize the fault Once localized refer to the appropriate replacement or adjustment procedure to correct the fault 48452L Rev 2 Xill Series Maintenance Manual Page 5 1 Corrective Maintenance Tools Required Screwdriver Regular 1 4 flat blade Extended Reach 10 shaft Magnetic Screwdriver Regular 1 4 flat blade Screwdriver Phillips No 1 Screwdriver Phillips No 1 Extended Reach 10 shaft Magnetic Screwdriver P
10. 8 40 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists Complete Spindle Assemblies 90Xi II 47150M 140Xi II 48150M 170Xi Il 46150M 220Xi Il 22150M ap 47158 RIBBON TAKE UP SPINDLE ASSEMBLY 48452L Rev 2 Xill Series Maintenance Manual 8 41 Drawings and Parts Lists PRINTER MODEL Xill Series Printers PART NUMBER DESCRIPTION QUANTITY 22253M Assembly Spindle Replacement 220 ill 22282 Blade 3 Core Media Supply 220 30140 Screw 6 32 125 46068 Spring Compression 46253M Assembly Spindle Replacement 170 11 46282 Blade 3 Core Media Supply 170Xill 47253M Assembly Spindle Replacement 90 Xill 47282 Blade 3 Core Media Supply 90 48253M Assembly Spindle Replacement 140 11 48282 Blade 3 Core Media Supply 140Xill GO GO 00 O CO 46397 625 Nut Locking 5 8 18 8 42 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists Complete Spindle Assemblies 90Xi ll 47253M 140Xi ll 48253M 47282 1 170Xi II 46253M 48282 3 140 Xill 30140 6 46282 3 170 Xill 220Xi II 22253M 22282 3 220Xill 46068 46397 625 N O p RV m OPTIONAL MEDIA SUPPLY SPINDLE ASSEMBLY 48452L Rev 2 Xill Series Maintenance Manual 8 43 Drawings and Parts Lists PRINTER MODEL AII Xill Series Print
11. N 1 1 BO T s 1 1 Related Manuals 1 2 Description Scope 48452L Rev 2 The Zebra XiII Series Thermal Transfer Demand Printers are versatile label and ticket printers designed to print high quality bar codes various sizes and styles of alphanumeric characters and graphics in either the thermal transfer or direct thermal mode The XilI Series printers have the flexibility to meet a wide variety of applications The Zebra Programming Language ZPL II allows the programmer to format the printed material ZPL II is transparent to protocol converters and allows the XilI Series printers to be easily integrated with most systems and host mainframes This manual contains the information necessary for the proper maintenance of the Zebra 90XiII M the Zebra 140XiII the Zebra 170XiIITM and the Zebra 220XiII printers Information presented applies to all XilI Series models unless otherwise indicated Section 1 Introduction provides an overview of the contents of this Maintenance Manual Section 2 The Zebra XilI Series System details the printer specifications communication specifications and a brief description of the front panel controls and indicators Section 3 Printer Diagnostics presents the diagnostic tests which are built into the XilI Series printers Examples of the labels which print for most of these diagn
12. user is cautioned that any changes or modifications not expressly approved by Zebra Technologies Corpora tion 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 Liability Disclaimer Zebra Technologies Corporation takes steps to assure that its published Engineering specifications and manuals are correct however errors do occur Zebra Technologies Corporation reserves the right to correct any such errors and disclaims 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 with out limitation 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 Corpora tion has been advised of the possibility of such damages Because some states do not allow the exclusion or limita tion of liability for consequential or incidental damages the above limitation may not apply to you Copyrights The copyrights in
13. 46249M 220Xill 22155M 45090 1 3 90Xi II 45090 2 3 140Xi II 46090 3 170Xill 22090 3 220Xill I e 38210 UA 9 30062 90Xill 40062 140Xill 46062 170Xill 22062 220Xill 46397 500 MEDIA REWIND SPINDLE ASSEMBLY Xill Series Maintenance Manual 8 35 Drawings and Parts Lists PRINTER MODEL 170Xill and 220 Xill Printers Compliance Arm Assembly PART NUMBER DESCRIPTION QUANTITY 01130 Nut 6 32 Hex Washer Head 170Xill 3 22212M Roller Assembly 220 ill 22213M Assembly Compliance Arm 220 11 30392 004 Screw 6 32 25 30392 014 Screw 6 32 87 220Xill 46127 Washer 312 153 030 46812M Roller Assembly 170 46813M Assembly Compliance Arm 170Xill 8 36 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists 2 1 46127 2 M 170Xill T 22212 220 Complete Assemblies 170Xi II 46813M 220Xi Il 22213M 01130 COMPLIANCE ROLLER ASSEMBLY 48452L Rev 2 Xill Series Maintenance Manual 8 37 Drawings and Parts Lists PRINTER MODEL All Xill Series Printers Ribbon Supply Spindle Assembly QUANTITY PART NUMBER DESCRIPTION 22151M Assembly Spindle Replacement 220Xill 30070 1 Blade Ribbon Supply Outer 30070 2 Blade Ribbon Supply Inner 30401 002 Screw 4 40 12 38042 Spring Torsion 739 x 805 4007
14. 46691 2M Assembly Dancer Arm w Springs 140 Xill 30392 006 Screw 6 32 37 46691 3M Assembly Dancer Arm w Springs 170 Xill 30392 008 Screw 6 32 50 46808 Bar Peel Tear off 170 11 30393 006 Screw 8 32 37 47009 1 Roller 37 312 90Xill 30423 003 Screw Set 8 32 187 47009 3 Roller 37 312 140Xill 30494 Washer 32 119 062 47009 8 Roller 37 312 170Xill 30825 Plate Upper Media Guide 90 11 47101 Roller Main Platen 90 Xill 30826 Plug Hole 47302 4 Assembly Bracket Media Sensor 90 30827 Holder media Sensor PCB 47444 Bar Toggle 90 Xill 30909 Handle Head 47808 Bar Peel Tear off 90 Xill 30956 Washer Flat 207 x 146 x 030 48001 Roller Main Platen 140 11 38099M Assembly Toggle 90 Xill N 48007 Side Plate 38825 1 Plate Upper Media Guide 170Xill 48023 Bearing Rulon 313 x 190 x 375 38825 2 Plate Upper Media Guide 140Xill O 48302 4M Assembly Bracket Media Sensor 140 11 48404 Spring Torsion Inboard 48405 Spring Torsion Outboard 48411 Screw Thumb 48444 Bar Toggle 140 11 48808 Bar Peel Tear off 140 XIII Q10019 Ring E Ext 250 Q10057 Washer 372 x 158 x 032 lt
15. 3 8 Extended Print r DIS60ostiesu uoi tectis tona tn ie nau 3 9 PAUSE key Loopback tit tirs i us 3 9 PEED key Loopback Test onn o poo ei ro Po eid 3 10 Test routines are built into the Zebra Xill Series Printers to aid the technician in diagnosing faults Some of these tests are enabled by pressing a front panel key while turning the Printer Power Switch ON Power On Self Test A Power ON Self Test POST is performed each time the Printer is turned ON This test checks for proper initialization of various electronic circuits and establishes starting parameters as those stored in the printer s memory During this test sequence the front panel LEDs will turn ON and OFF to insure proper operation At the end of this Self Test only the POWER LED will remain lit If other LEDs are also lit refer to Section 6 Troubleshooting in this manual If the printer is set up for non continuous media one or more labels will feed out up to a maximum length of one label plus three additional inches of media To initiate the Power On Self Test POST turn the Printer ON using the Power Switch in the rear The front panel Power On indicator will light The other front panel LEDs and the Liquid Crystal Display LCD monitor the progress and indicate the results of the Self Test The normal Self Test sequence is shown on the following page 48452L Rev 2 Xill Series Maintenance Manual Page 3 1 Pri
16. I I 01130 2 l e 1 49790M 22035 07435 4 220Xill PRINT MECHANISM ASSEMBLY PG 3 OF 3 8 23 Drawings and Parts Lists PRINTER MODEL 90Xill Printhead Support Assembly QUANTITY PART NUMBER DESCRIPTION 01153 Washer Flat 250 x 125 x 028 01159 Washer 6 Lock 06268 Washer 6 Split Lock 22015 Spring Printhead Mounting 22016 Screw Printhead Mounting 30007 5 Shaft Roller 30013 Plate Washer 30314R Adhesive 30391 003 Screw 4 40 19 30392 004 Screw 6 32 25 e 30402 006 Screw 6 32 37 30494 Washer 320 x 119 x 062 30781 Cable Printhead Ground 40193 Washer Flat 406 x 172 x 048 40194 Washer Curved 312 x 144 x 016 46481 1 Screw Adjustment 6 32 46665 Assembly Ribbon Sensor 46882 003 Screw 4 40 19 47000M Printhead 90 ill 47009 Brush Static 47014 Plate Guard 47017 Plate Ribbon Strip 47103 Bracket Head Mounting 47162 Bar Head Pivot 47181 Pad Pressure 47212 Plate Pressure 47640 Cable Assy Printhead Power 47641 Cable Assy Printhead Data 48099 2 Roller 48182 Rivet Plastic 48289 Label Q06020 Tiewrap 8 24 Xill Series Maintenance Manual 48452L Rev 2 47181
17. 8 25 140XilI Printhead Support Assembly Parts List 8 26 140XiII Printhead Support Assembly Drawing 8 27 170XilI Printhead Support Assembly Parts List 8 28 170XilI Printhead Support Assembly Drawing 8 29 484521 Rev 2 Xill Series Maintenance Manual Page 8 1 Drawings and Parts Lists Drawing Page 220Xill Printhead Support Assembly Parts List 8 30 220Xill Printhead Support Assembly Drawing 8 31 Media Supply Hanger Assembly Parts List 8 32 Media Supply Hanger Assembly Drawing 8 33 Media Rewind Spindle Assembly Parts List 8 34 Media Rewind Spindle Assembly Drawing 8 35 Compliance Roller Assembly Parts List erre 8 36 Compliance Roller Assembly Drawing 8 37 Ribbon Supply Spindle Assembly Parts List 8 38 Ribbon Supply Spindle Assembly Drawing 8 39 Ribbon Take Up Spindle Assembly Parts List 8 40 Ribbon Take Up Spindle Assembly Drawing 8 41 Optional Media Supply Spindle Assembly Parts List 8 42 Optional Media Supply Spindle Assembly Drawing 8 43 Media Rewind Option Assembly Parts List
18. 46665 Assembly Ribbon Sensor 46682 Cable Assy Printhead Data 46882 003 Screw 4 40 3 16 48099 8 Roller 48182 Rivet Plastic 48289 Label 49640 023 Cable Assy Printhead Power Q06020 Tiewrap 8 28 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists 30392 004 2 Y 01159 2 30392 004 48289 2 46171 DETAIL SCALE 2 1 FRONT SURFACE OF PRESSURE PLATE 46212 SHOULD BE FLUSH TO BELOW ENDS OF MTG BRKT 46169 WRAP GROUND STRAP N AS SHOWN 30314R ADHESIVE THIS SIDE ONLY 06268 4 O 30392 004 4 N o _ 46013 30402 006 2 46660 46682 6 8 E p 49640 023 AND 30781 CABLES NOTE POSITION RIBBON SENSOR 46665 TAB NOT TO BE FLUSH WITH TOP EDGE OF PIVOT BAR 48162 GAP 010 MIN 030 MAX PRINTHEAD DATA CONNECTOR TABS MUST SNAP OVER CONNECTOR SCREW TIGHTENING TORQUES UNLESS OTHERWISE SPECIFIED TO BE 10 12 IN LBS aS 46481 1 12 40194 2 N w OTHER VALUES APPEAR IN BOXES IN 40193 2 IN LBS 46002 1 49640 023 30392 004 2 170Xill PRINTHEAD SUPPORT ASSEMBLY 48452L Rev 2 Xill Series Maintenance Manual 8 29 Drawings and Parts Lists PRINTER MODEL 220XilI Printhead Support Assembly PART NUMBER DESCRIPTI
19. 30214 Link Main 30215 Link Slotted 30216 Post Pivot 30217 1 Link Pin 30219 Flag Sensor 30236 Screw 4 40 30313 Clamp Wire Cutter 30320 Brush Anti Static 90 Xill 30374M Assembly Cutter Motor 30380M Assy Drive Arm 30382RM Plate Cutter Rewind 90 Xill 30391 003 Screw 4 40 19 30392 004 Screw 6 32 25 30394 005 Screw 10 32 312 30405 006 Screw 1 4 20 38 140 170X 30405 008 Screw 1 4 20 50 220Xill 30816 Bracket Lower Cutter 30819 Bracket Cutter Support 90 Xill Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists SET SCREWS TO ENGAGE FLATS UPPER CUTTER BRACKET ROTARY CUTTER BLADE ON MOTOR SHAFT WHEN LOWER MOUNTING SCREW m SQ ARM IS IN VERTICAL POSITION 100 MEDIA GUIDE 2 MOTOR ROTATION MOTOR INSURE THE TOP OF THE TEAR DIRECTION SHAFT OFF BAR IS POSITIONED ABOVE WEAR OFS SEE OR LEVEL WITH THE TOP OF BAR ZA THE REAR CUTTER BLADE CLEARANCE OF 030 REAR CUTTER 14 BLACK FLAG TO BE MINIMUM BETWEEN BLADE 01660 CABLE HOLDER CENTERED IN OPTICAL REAR CUTTER BLADE GREASE 30313 TO BE ASSY AND TEAR OFF BAR ALL AROUND SECURELY RELATIVE POSITION OF THE ROTARY CUTTER 10421 SCREWS 4 CONTROL OVER CABLES BLADE WHEN THE DRIVE LINK ASSEMBLY IS POSITION OF CUTTER MODULE FRONT
20. The Configuration may be changed either temporarily for specific label formats or ribbon and label stock or permanently by saving the new parameters in EEPROM Memory Saving new parameters occurs whenever a Printer Configuration procedure is performed Refer to the User s Guide for further details on the Printer Configuration procedure PRINTER CONFIGURATION DARKNESS TERR OFF CUTTER PRINT MODE NON CONTINUOUS 128 0 8 MM 1237 1111 MAXIMUM LENGTH HOST PORT BRUD BITS PARITY STOP BITS HOST HANDSHAKE PROTOCOL NETWORK ID COMMUNICATIONS CONTROL PREFIX FORMAT PREFIX DELIMITER CHAR ZPL MODE MEDIA POWER UP HERD CLOSE BACKFEED LABEL TOP LEFT POSITION HERD TEST COUNT HERD RESISTOR VERIFIER PORT TEL ICA TUR PORT MEDIA S RIBBON 5 MARK S MARK MED S MEDIA LED RIBBON LED MODES ENABLE rese D MODES DISABLED RESOLUTION SOCKET 1 ID FIRMWARE CONFIGURATION MEMORY B MEMORY 904 J12 INTERFACE 904 J11 INTERFACE 319 INTERFACE XXX FIRMWARE IN THIS PRINTER IS COPYRIGHTED Figure 3 1 Cancel Key Test Sample Label 48452L Rev 2 Xill Series Maintenance Manual Page 3 3 Printer Diagnostics PAUSE Key Self Test This Self Test is actually comprised of four individual test features 1 initial Self Test prints 15 lab
21. 8 Step Motor Test The LCD displays Motor Test The step motor is driven forward a short distance three to four inches then reversed for an equal distance before locking into position for the next test cycle The second processor s tests are now complete and the main processor resumes control of the SRAM The second processor is placed in the reset state and waits for the test to be repeated before running again Serial Port Test The LCD displays Serial Port Test The loopback of pin 2 with pin 3 pin 6 with pin 20 pin 13 with pin 14 and pin 16 with pin 19 is tested If the test fails the LCD displays FAILED and all testing stops Parallel Port Test The LCD displays Parallel Test The Zebra parallel port loopback connector is tested The loopback connector involves a small circuit board and is manufactured by Zebra If the test fails the LCD displays FAILED and all testing stops Xill Series Maintenance Manual 48452L Rev 2 8 Drawings and Parts Lists In this section Page Mechanical Parts and Assemblies 8 1 Parts Lists and DESWEPIES dire votadas atrae Qusaqa qaya 8 4 Mechanical Parts and Assemblies Use the following Mechanical Assembly Drawings when troubleshooting or replacing components and use the Associated Parts Lists when ordering replacement patts Drawing Page 90 140 170Xill Final Assembly Page 1 of 2 Parts List 8 4 90 140 170
22. Guide Upper Cutter 140 XIII 01822 Nut 4 40 40193 Washer Felt 406 x 172 x 048 02133 E Ring 188 Black 40320 Brush Anti Static 140 08449 Tiewrap 40382RM Plate Cutter Rewind 140 10421 Screw MA x 7 x 5 40819 Bracket Cutter Support 140 Xill 22193 Guide Upper Cutter 220 Xill 44632 Ferrite Ring 1 1 x 75 22320 Brush Anti Static 220 11 46181 Guide Upper Cutter 170Xill 22382 Plate Cutter Rewind 220 Xill 46224 Grommet Rubber 22819 Bracket Cutter Support 220 46280M Arm Upper Drive 30133 Bearing Ball 375 x 187 x 125 46320 Brush Anti Static 170 Xill 30181 Guide Upper Cutter 90 46382M Plate Cutter Rewind 170Xill 30196 100 Module Cutter 90 XIII 46618 Assembly Cutter Sensor 30196 150 Module Cutter 140 Xil 46807 Bracket Upper Cutter 30196 200 46819 Bracket Cutter Support 170 Xill 30196 251 Module Cutter 170 ill Module Cutter 220 Xill 49600 012 Assy Cable 30198 Bearing 49604 010 Assy Power Cable 30199 Bearing 49730M Assy Cutter Printed Circuit Board 30208 Washer Felt 500 x 191 x 030 Q10011 Screw M4 7 30210 Washer Felt 564 x 384 x 060 Q10019 E Ring 250 Black
23. PAUSE LED lights LCD displays OUT OF MEMORY CREATING BITMAP OUT OF MEMORY STORING BITMAP OUT OF MEMORY BUILDING FORMAT OUT OF MEMORY STORING FORMAT OUT OF MEMORY STORING GRAPHIC OUT OF MEMORY STORING FONT 48452L Rev 2 Not enough memory to perform the function indicated in the second line of the display It is possible that the printer is configured for Continuous Label Stock with the Maximum Label Length set too long Functions 1 Creating a Bitmap Bitmap size is larger than the label length width specified Storing a Bitmap Not enough memory available to store the Bitmap created Building a Format Label is too complex Storing a Format Format size is too large to fit in available memory Storing a Graphic Graphic image is too large to fit in the available memory Storing a Font not enough memory to store the font Xill Series Maintenance Manual You may do any of the following A STORING ERRORS With PAUSE ON use the HM ZPL II Command to display the amount of memory available Then redesign the graphic format to fit in the available memory or remove items from mem ory to create more space or Press PAUSE to skip that step in the process and continue to he next step With PAUSE press CANCEL and the printer skips that label formatting process and con
24. e If the Printhead is too hot or too cold PAUSE flashes and the LCD displays TEMP OUT RANGE Printing will resume automatically when the printhead reaches operating temperature 48452L Rev 2 Xill Series Maintenance Manual Page 2 11 The XilIl Series System DATA Status Indicator ON indicates that Data Processing or Printing is taking place but no data is being received OFF indicates that no data is being received or processed FLASHING indicates that Data is being received Flashing slows down when the printer is unable to accept any more data due to the Data Input Buffer being full Flashing returns to normal rate when the Data Input Buffer is no longer full and data is once again being received Front Panel Keys The Front Panel Keys shown in Figure 2 3 control the various printer operations PREVIOUS NEXT SAVE and SETUP EXIT Keys See the description under Liquid Crystal Display LCD on page 2 13 PAUSE Key Allows the operator to interrupt the lt p printing of a batch of labels and then complete the batch by pressing the key a second time 4 gt gt gt When this key is pressed printing will stop after the PREVIOUS NEXVUSAVE SETUP EXIT label being printed is completed The PAUSE Indicator will light Label counter stops but maintains count balance and holds data in memory When the key is pressed again the PAUSE Indicator POWER goes out and printing is resumed TAKE LABEL FEED Key In order to prev
25. this procedure continues on page 5 29 Page 5 30 Xill Series Maintenance Manual 48452L Rev 2 TENUL ooutuojure A souog IIX AON 7126787 16 oSuq POWER SUPPLY ASSEMBLY MAIN LOGIC BOARD AND REAR PANEL HEAT CONDUCTION PAD Figure 5 15 AC Power Supply Board a ar eM lt e 5 Corrective Maintenance 5 Atthe Rear of the printer install the 3 Phillips Screws which hold the rear panel to the back of the printer 6 Use the hex nut to install the ground lead from the Power Entry Module to the printer chassis 7 Refer to Figure 5 13 Install all Ribbon Cable Connectors and Small Wire Connectors onto the Main Logic Board and AC Power Supply Board Reconnect the AC Power Cord and the Signal Interface Cable 9 Hold in the PAUSE Key while turning the AC Power ON Observe the printer Power ON Self Test and examine the test labels which print for proper print quality 10 Reinstall the Left Side Panel 11 The printer should now be ready for operation Program ROM Installation To replace the program ROMs follow the procedure below A PLCC Plastic Leaded Chip Carrier Extraction Tool is included in the upgrade kit CAUTION The printer electronics are susceptible to static discharge Before proceeding it is recommende
26. Panel Left Side 46039 Cover Media 170Xill 46040 Panel Door No Window 46049 1 Support Frame 170Xill 48272 Label Media Load 170Xill 46342 Bracket Front Cover 170Xill 46396 006 Screw Truss Head Phillips 6 32 x 3 8 46491 1 Panel Lower Media Trim 170 Xill 46491 2 Panel Lower Media Trim 140 Xill 46491 3 Panel Lower Media Trim 90 46492M Trim Switch Panel w Logo 46755M LCD Backlit 46836 Spacer 47037 1 Cover Front 90Xill 47039 Cover Media 90Xill 47049 1 Support Frame 90Xill 47267 Spacer 140Xill 47342 Bracket Front Cover 90 Xill 48037 1 Cover Front 140X11 48039 Cover Media 140 Xill 48049 1 Support Frame 140 Xill 48267 Spacer 90Xill amp 170Xill 48272 Label Media Load 90Xill amp 140 48342 Bracket Front Cover 140Xill 48490 1 Panel Upper Media Trim 170 Xill 48490 2 Panel Upper Media Trim 140 Xill 48490 3 Panel Upper Media Trim 90 a NNDD NAN NN Ce 8 4 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists 48452L Rev 2 48490 3 _ 48490 2 140 48490 1 170Xil 48267 90xill 47267 140Xill 47037 1
27. fonts and formats with data compression s UPCHHAN at nominal 10055 mapaitication Bit image data transfer and printing Object copying between memory areas including mixing of text and graphics RAM and memory card Format inversion Code Page 850 character set Mirror image printing Adjustable print cache Four position field rotation Automatic virtual input buffer management s e Automatic memory allocation e e User programmable password Programmable quantity with print pause a Higtupinessase to host apos s quest e Communicates in printable ASCII characters Error Checking Protocol e Object copying between memory areas e Controlled via mainframe mini PC RAM and Memory Card Zebra Mate or other data entry device Serialized fields Bar Codes The following bar codes are available Code 11 Code 49 Code 93 e LOGMARS Plessey and MSI Code 39 Supports ratios of 2 1 3 1 5 2 Interleaved 2 of 5 Supports ratios of 2 1 and 7 3 3 1 and 5 2 also supports Modulus 10 e Code 128 Supports serialization in all sub Check Digit sets B and C and UCC Case C Codes e Industrial 2 of 5 Standard 2 of 5 e CODABAR Supports ratios of 2 1 3 1 and e EAN 8 EAN 13 EAN EXTENSIONS 5 2 e UPC A UPC E UPC EXTENSIONS e CODABLOCK and MAXICODE PDF 417 and POSTNET e Check digit calculation where applicable Page 2 2 Xill Series Maintenance Manual 48452L Rev 2 The XiII Series System
28. 90 46755M 48037 1 140xill 46037 1 170Xill 46492M 22492M 46491 3 90 46491 2 140 46491 1 170 D n d 7 30392 003 3 va 7 7 xm 44114 2 07257 NOT x aw a ang B 30269 2 1 1 6 DN I 1 I I 101130 I 441141 07257 ET a Ts I 07257 441141 lt lt 7 01130 46836 2 Y 46038 1 48272 90 48272 140 46272 170 d 48039 140 46039 170 30392 004 46396 006 2 lt 30407 008 4 gt 1 30392 004 5 47049 1 90 48049 1 140 46049 1 170 30392 004 4 22246 _ 47342 90 I 48342 140Xill 46342 170Xill 90Xill 140 amp 170Xill FINAL ASSEMBLY PG 1 OF 2 Xill Series Maintenance Manual 8 5 Drawings and Parts Lists PRINTER MODEL 90Xill 140XIiI 170 Xill Final Assembly page 2 of 2 PART NUMBER DESCRIPTION QUANTITY 01117 Clamp Cable 312 Nylon 01130 Nut 6 32 Hex Washer Head 04393 Tiewrap Beaded 06222 Clamp Cable 5 30336 1M Pulley Ribbon Take Up 30336 2M Pulley Media Take Up 30357M Pulley Stepper Motor 90Xill amp 170 XIII 30392 004 Screw 6
29. Configuration or ZPL II Modes Disabled Configuration or ZPL II 48452L Rev 2 Resolution Configuration or ZPL II Table continued on following page Table 3 1 Configuration Parameter Controls Xill Series Maintenance Manual Page 3 7 Printer Diagnostics Parameter Controlled By Socket 1 ID Hardware Firmware Hardware Configuration Hardware Memory Hardware B Memory Hardware J12 Interface Hardware 111 Interface Hardware J10 Interface Hardware J9 Interface Hardware J8 Interface Hardware J7 Interface Hardware Table 3 1 Configuration Parameter Controls con t PAUSE Key and CANCEL Key Self Test This self test can be used to verify proper printer operation after parts have been replaced or adjusted When activated the printer prints a maximum of 500 Head Test Labels Each label backfeeds prior to printing and feeds forward to the rest position after printing A serialized number will print on each label Press the PAUSE key or turn the printer power OFF to stop printing See Figure 3 5 for a sample label 12345678980123456789012345678901234567890123456789012345678901234567 Figure 3 5 PAUSE Key and CANCEL Key Self Test Label FEED Key and CANCEL Key Page 3 8 This self test is normally performed during the manufacturing process or after a major overhaul of the mechanical assemblies This test prints seven pre programmed label
30. Drawings and Parts Lists 8 48 Xill Series Maintenance Manual 48452L Rev 2 9 lt ASCII Code Chart American Standard Code for Information Interchange HEX CHAR HEX CHAR HEX CHAR HEX CHAR 00 NUL 20 space 40 60 01 SOH 21 41 A 61 a 02 STX 22 42 B 62 b 03 ETX 23 43 C 63 04 EOT 24 44 D 64 d 05 ENQ 25 45 65 e 06 ACK 26 amp 46 F 66 f 07 BEL 27 47 G 67 g 08 BS 28 48 H 68 h 09 HT 29 49 69 i OA LF 2A 4A J 6A j 0B VT 2B 4B K 6B k 0C FF 2C 4 L 6 0D CR 2D 4D M 6D m SO 2E 4E N 6E n OF Sl 2 4 6F 10 BLE 30 0 50 70 11 DC1 31 1 51 Q 71 q 12 DC2 32 2 52 R 72 r 13 DC3 33 3 53 S 73 S 14 DC4 34 4 54 T 74 t 15 NAK 35 5 55 U 75 16 SYN 36 6 56 V 76 17 37 7 57 W 77 w 18 CAN 38 8 58 X 78 X 19 EM 39 9 59 Y 79 y 1A SUB 3A 2 2 1B ESC 3B 5 7 1 FS 3C lt 5 7 1D GS 3D 5D 7D RS gt ZE 1F US _ 7F DEL NOTE Shaded codes NOT recomme
31. PAUSE Key Self Test Head Alignment and Run in Tests This test starts with a check of the hardware handshake lines When a loopback connector is not detected the following printhead test labels print When the printer pauses during these formats pressing the PAUSE Key re starts printing While paused pressing the CANCEL Key switches to the next set of labels This test can be performed without a loopback connector Eight dots per millimeter test sequence e 9999 labels at two inches second pausing every 15 labels e 9999 labels at eight inches second pausing every 15 labels e 9999 labels at two inches second pausing every 50 labels e 9999 labels at eight inches second pausing every 50 labels Twelve dots per millimeter test sequence e 9999 labels at two inches second pausing every 15 labels e 9999 labels at six inches second pausing every 15 labels e 9999 labels at two inches second pausing every 50 labels e 9999 labels at six inches second pausing every 50 labels When the loopback connector is detected 500 Head Test labels are printed at six inches per second The printer places the ZPL data for these labels into the printer s transmit buffer The data is then fed back into the printer by the loopback connector A serialized number is printed on the standard head test label Each label backfeeds prior to printing and feeds out to the rest position after printing FEED Key Self Test Print Quality Tests This test starts with a c
32. parallel port is powered up and the parallel port is enabled In the non default condition Select will go active LOW whenever the printer is printing nAutoFd Not defined Logic Ground Frame Ground is at the same potential as Logic Ground pin 16 Fused 5 VDC Supply 750 mA maximum Internal Fuse Protected SIGNAL GROUNDS are the Logic Grounds and Returns for all Input and Output signals NOT USED These leads should be left unconnected nSelectIn Optional Interface Boards For information about the plug compatible Twinax Interface the IBM plug compatible Coax Interface the ZebraNet Ethernet Interface the RS 485 Network Interface or the Applicator Interface refer to the instructions which accompany the Interface Option Kits Page 2 10 Xill Series Maintenance Manual 48452L Rev 2 The XilIl Series System Front Panel Controls and Indicators Front Panel Status Indicators The Status Indicators of the XilI Series printer are located on the Front Panel POWER Status Indicator Controlled by the Power ON OFF Switch located at the rear of the printer Normally ON to indicate that Primary Power is applied to the printer When OFF indicates Power is removed TAKE LABEL Status Indicator Peel Off Mode Only This Indicator is operative only in the Peel Off Mode The Indicator will Flash when a label has been printed and is ready to be removed from the XiII Series printer Th
33. 2 46396 006 2 30392 004 48490 4 47267 2 46755M 30392 004 5 22037 46492M 22492M 22491 Y i AA I oe 2 g 7101130 2 277 22 344402 _ P a _ lt M oy t7 30392 004 4 22246 Cy BD 30256 2 Xill Series Maintenance Manual 220 FINAL ASSEMBLY PG 1 OF 2 Drawings and Parts Lists PRINTER MODEL 220 Final Assembly page 2 of 2 PART NUMBER DESCRIPTION QUANTITY 01117 Clamp Cable 312 Nylon 01130 Nut 6 32 Hex Washer Head 04393 Tiewrap Beaded 06222 Clamp Cable 5 30336 1M Pulley Ribbon Take Up 30336 2M Pulley Media Take Up 30392 004 Screw 6 32 25 30914M Pulley Peel Off 38226M Assembly Reflective Sensor 40355M Pulley Main Platen 40357M Pulley Stepper Motor 220 XIII 45189 2 Belt Conductive 255T 45189 5 Belt Conductive 235T 46392 006 Screw Truss Head Phillips 46677 Cable AC to DC Power 49600 010 Cable SP Comm 49604 010 Cable Power Distribution 49700M Main Logic Board 49780M AC Power Supply 49790M DC Power Supply Q06020 Tiewrap 09 x 3 62 N 8 10 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists
34. 2 Drawings and Parts Lists PRINTER MODEL 220Xill Print Mechanism Assembly Page 2 of 3 QUANTITY PART NUMBER DESCRIPTION 01130 Nut 6 32 Hex Washer Head 06250 E Ring 312 22150M Spindle Ribbon Take up 22151M Spindle Ribbon Supply 22184 Hook Ribbon Take up Spindle 22207 Shaft Idler Pulley 22213M Assembly Compliance Roller 22253M Spindle Media Supply optional 22386 Support Media Supply 30106 Ring Crescent External 312 30114 Washer Flat 76 x 51 x 03 30115 Washer Wave 740 x 520 x 080 30118 E Ring 30239 Washer Crescent 415 x 323 x 062 30265 Pulley Idler 30336 1M Assembly Ribbon Take Up Pulley 30392 004 Screw 6 32 25 30392 014 Screw 6 32 87 30393 006 Screw 8 32 37 30395 012 Screw 1 4 20 75 Cap 30466 Washer 26 x 63 x 06 40027 Spring Torsion 40193 Washer Flat 406 x 172 x 048 A Se O m 8 20 Xill Series Maintenance Manual 48452L Rev 2 T 40027 30106 484521 Rev 2 PART 22213 30395 012 Drawings and Parts Lists 30466 Xill Series Maintenance Manual 22386 22253M OPTIONAL MEDIA SUPPLY SPINDLE SEE MEDIA SUPPLY HANGER ASSEMBLY SEE SPECIFIC PRINTER SUPPORT ASSEMBLY DRAWING 2215
35. 32 25 30914M Pulley Peel Off 38226M Assembly Reflective Sensor 40355M Pulley Main Platen 40357M Pulley Stepper Motor 140 ill 45189 2 Belt Conductive 255T 45189 5 Belt Conductive 235T 46392 006 Screw Truss Head Phillips 46677 Cable AC to DC Power 49600 010 Cable SP Comm 49604 010 Cable Power Distribution 49700M Main Logic Board 49780M AC Power Supply 49790M DC Power Supply Q06020 Tiewrap 09 x 3 62 N JN 8 6 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists LOCATION PULLEY DIMENSIONS FROM MAIN FRAME TO INSIDE GUIDING EDGE OF PULLEY 1 RIBBON TAKEUP 2 MAIN PLATEN STEPPER 4 MEDIA TAKEUP 5 PEELOFF s 49780M A A SECTION 48452L Rev 2 Xill Series Maintenance Manual 30336 1M 40355M 30357M 90Xill 170 40357M 140 30336 2M 30914M TYPICAL CABLE CLAMP INSTALLATION FIXED IN SUB ASSY 11MM 433 IN 10MM 40 IN FIXED IN SUB ASSY 8MM 28 IN 40185 140 30815 170 9 40484 40815 45189 5 45189 2 40357M 140X ll
36. Figure 5 4 during this procedure 1 Using a 7 64 Allen wrench or 7 64 Hex driver loosen the four Allen screws at the top rear of the Print Mechanism 2 Adjust the parallel location of the uppermost lines by turning one of the two flat head screws located at the back of the Print Mechanism NOTE Only small adjustments should be required 3 To move the Printhead forward turn the adjustment screw clockwise as viewed from the rear of the printer 4 move the Printhead backward turn the adjustment screw counterclockwise as viewed from the rear of the printer 5 Adjust each side as necessary to align the uppermost line of the test label in parallel with the top edge of the label 6 check the results of your adjustments run additional PAUSE Key Self Test labels and check for proper parallelism 7 Tighten the four top Allen screws and run more PAUSE Key Self Test labels to verify proper positioning TOGGLE KNURLED NOTE LOOSEN 4 HEX CAP SCREWS ADJUSTING NUT BEFORE ADJUSTING HEAD WEAR PLATE ADJUSTMENT SCREWS PARALLELISM ADJUSTMENT SCREWS NOTE THE RIBBON TAKE UP SPINDLE IS NOT SHOWN IN THIS ILLUSTRATION Figure 5 3 Printhead Adjustment Illustration Page 5 12 Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance Wear Plate Position Adjustment This adjustment is performed in conjunction with the Printhead Parallism Printhead Position and Printhead Pressure Adjustm
37. OUT OF MEMORY TORING GRAPHIC STORING FONT Front Panel LEDs LEDs on the front panel are a quick indication of the printer s status Whenever an LED should be ON and Flashing at the same time the LED will Flash Refer to the Xill Printer s user s guide for further details Communications A separate process handles the data communications with the host system as well as other printers and devices connected to a secondary port This process determines whether the received data should be transmitted by the secondary port or discarded as invalid before adding it to the label generator s input buffer Any data received by the secondary port is automatically re transmitted by the host port data transfers follow the selected hardware and software protocols However data received by the printer is not checked for parity framing or overrun errors except when the printer is in the communications diagnostic mode Optional Ports Host Port The standard printer configuration is a single RS232 RS422 RS485 serial port and a Centronics compatible parallel port Other interface options include an IBM twinax interface and an IBM coax interface A hardware check at power up determines which communications option is installed The main serial port is normally the primary port The parallel port or any of the optional ports may be selected as the primary port The primary port is the interface to the host system It receives ZP
38. SLOTS PRINTHEAD ALIGNMENT SLOTS 90Xill PRINTHEAD Figure 5 2 Printhead Replacement Page 5 10 Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance Printhead Adjustments Print Quality Adjustments There are five interrelated adjustments that lead to optimum print quality with increased Printhead life e Printhead Parallelism e Wear Plate Balance Position Printhead Position Printhead Pressure e Strip Plate Positioning To achieve optimum results with print quality adjustments install full width media and ribbon Prior to performing Printhead Adjustments 1 Position the toggle s as follows 90XilI Position the Toggle in the center of the upper print mechanism 140Xill 170 and220XiII Reference the Printhead Mounting Screw as the center of two halves of the print mechanism and position each toggle at the center of each half 2 Compress the Toggle spring by turning the lower knurled nut clockwise until the distance from the top of the toggle foot to the bottom of the lower knurled nut equals 30mm 1 and 3 16 3 Activate the PAUSE Key Self Test by pressing the PAUSE Key while turning the printer power ON NOTE The order in which the adjustments are performed depends on the print quality of the labels printed during the PAUSE Test above The first two Printhead Adjustments Parallelism and Wear Plate must be completed prior to attempting to locate the optimum print po
39. Section if the printer stops during the Power On Self Test due to failing a test Printer Self Tests Introduction Page 3 2 These Self Tests produce sample labels and provide specific information which helps determine the operating conditions for the printer Each Self Test is enabled by pressing in a specific front panel key while turning the Power Switch ON Keep the key pressed until the front panel LEDs turn ON Xill Series Maintenance Manual 48452L Rev 2 Printer Diagnostics When the Power On Self Test is completed the selected Printer Self Test will automatically start NOTE When performing Self Tests all Data Interface Cables should be disconnected from the printer It is recommended that Full Width media be used when performing these Tests Labels less than full width in size will lose printing on the right side Label length will determine the amount of printing starting at the top of the label In the Peel Off mode the printer does not pause while performing these Self Tests The Operator must remove the labels as they become available When Canceling a Self Test prior to its actual completion always turn the printer Power OFF and then back ON to reset the printer CANCEL Key Self Test This Self Test prints a single label which contains a listing of the printer s current configuration parameters stored in Configuration EEPROM Memory Press the CANCEL key while turning the AC Power Switch ON See Figure 3 1
40. Standard Printer Fonts 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 A and OCR B 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 Maximum character size depends on the available memory IBM Code Page 850 international character sets are available in fonts A B C D E F G and through software control Note Refer to the Options Section for available printer font options Font Matrices for 8 dots mm Printhead J L D Character Size Inches Millimeters 0 044 Char inch 33 90 U 0 054 22 60 L D 0 088 16 95 CR B 0 138 10 17 L D 0 128 12 71 J L D 0 295 4 24 CR A 0 103 10 71 W r2 tS character GS SYMBOL 0 118 8 48 Default 15 x 12 U L D Scalable U Uppercase L Lowercase D Descenders 5 J L D Character Size Inches Millimeters 0 030 50 00 7 U 0 037 33 33 10 J L D 0 060 25 00 20 CR B 0 137 11 54 13 J L D 0 087 18 75 40 J L D 0 200 6 25 19 CR A 0 100 10 71 C no oo O S S
41. all future fields or formats updates both the current definition and the proper default definition Each Field Separator command ends the current field and starts the next In standard ZPL mode the current field is saved in a list of field definitions In ZPL II mode all fields are formatted as soon as possible The only field definitions not formatted are fields with a field number and without field data A field definition that has a field number serialized field data or is a variable field must be saved for later reference Since all fields with field numbers are saved the field will be formatted the first time the same field number appears with field data After saving and possibly formatting the current field the current field definition is reset with the default field values Commands are then decoded for the next field Since some commands can affect the entire label it is VERY important with ZPL II that these commands are specified first While the order is less critical in standard ZPL these commands have traditionally been at the start of a format Command decoding continues to update the format and field definitions until the end of format command is decoded This command causes the current field definition to be processed as described above In standard ZPL mode all of the fields that have been defined are now formatted one at a time In ZPL II mode the formatting has already been completed and the images are ready to be que
42. character GS 24 MBOL 0 080 12 50 Default 15 x 12 L D Scalable U Uppercase L Lowercase D Descenders 48452L Rev 2 Xill Series Maintenance Manual Page 2 3 The XiIl Series System FONT ABCDwxyz 12345 FONT B ABCDHXVZ 12345 FONT D BCDuxuz 12345 FONT E OCR B ABCDwxyz 12345 FONT F ABCDwxyz 12345 FONT G 24 FONT H COCR A UPPER CASE ONLY FONT 0 Scalable ABCDwxyz 12345 FONT GS Figure 2 1 Default Fonts Examples Media Considerations Media Specifications 140XIII 170Xill 220 Total media width Maximum 90 mm 5 59 142 mm 182 mm 8 8 224 mm Minimum 20mm 1 57 40 mm 50 8 mm 4 25 108 mm Total Maximum f above thickness 0 01 printhead position 0 30mm 0 012 0 30 mm 0 30mm 0 012 0 30 mm includes may need adjustment liner Minimum 0 076 mm 0 003 0 076 mm 0 076 mm_ 0 003 0 076 mm Core size 76 2mm 3 0 76 2 mm 76 2 mm 3 0 76 2 mm Maximum roll diameter 203mm 8 0 203 mm 203 mm 8 0 203 mm Interlabel gap 2 4mm 0 079 2 4 mm 2 4mm 0 079 2 4 mm 0 118 3 mm preferred 0 157 0 157 Black Minimum mark length 3mm 1118 3 mm 3 mm 1187 3 mm mark thickness sensing Minimum mark width 10mm 393 10mm 10 mm 393 10mm extending in from the edge Maximum internal fanfold 203x90 8 0 x 1203x142 203x182 8 0 x 203 x224 media pack size L
43. formats first at a speed of 6 per second then the same formats at a speed of 2 per second The printer will automatically PAUSE after each format The sequence of label formats is shown in Table 3 2 Refer to Figures 3 7 through 3 13 for sample labels Xill Series Maintenance Manual 48452L Rev 2 Printer Diagnostics FORMAT PRINTING TEST FUNCTION E 20 at 6 per second Left Ribbon Wrinkle Test 20 at 6 per second Right Ribbon Wrinkle Test 20 at 6 per second Bar Code Wrinkle Test Code 39 20 at 2 per second Left Ribbon Wrinkle Test 20 at 2 per second Right Ribbon Wrinkle Test 20 at 2 per second Bar Code Wrinkle Test Code 39 10 at 6 per second Useable Area Test 10 at 6 per second Head Temperature Test MN S 0 10 at 6 per second Upper Smear Test 10 at 6 per second Lower Smear Test 10 at 2 second Useable Area Test N 10 at 2 per second Head Temperature Test 10 at 2 per second Upper Smear Test 10 at 2 per second Lower Smear Test Table 3 2 FEED Key and CANCEL Key Label Formats Extended Printer Diagnostics Additional Diagnostic Tests are available for Printhead Assembly Adjustments These Diagnostic Tests are only accessible when the Data Interface Cable is disconnected from the printer and a Loopback Connector is attached in it
44. of 2 Drawing 8 7 220Xill Final Assembly Page 1 of 2 Parts List 8 8 220Xill Final Assembly Page 1 of 2 Drawing 8 9 220Xill Final Assembly Page 2 of 2 Parts List 8 10 220Xill Final Assembly Page 2 of 2 Drawing 8 11 90 140 170XilI Print Mechanism Assy Page 1 of 3 Parts List 8 12 90 140 170XilI Print Mechanism Assy Page 1 of 3 Drawing 8 13 90 140 170 Print Mechanism Assy Page 2 of 3 Parts List 8 14 90 140 170XilI Print Mechanism Assy Page 2 of 3 Drawing 8 15 90 140 170XilI Print Mechanism Assy Page 3 of 3 Parts List 8 16 90 140 170XilI Print Mechanism Assy Page 3 of 3 Drawing 8 17 iv Xill Series Maintenance Manual 48452L Rev 2 Table of Contents 220Xill Print Mechanism Assy Page 1 of 3 Parts List 8 18 220Xill Print Mechanism Assy Page 1 of 3 Drawing 8 19 220Xill Print Mechanism Assy Page 2 of 3 Parts List 8 20 220Xill Print Mechanism Assy Page 2 of 3 Drawing 8 21 220XilI Print Mechanism Assy Page 3 of 3 Parts List 8 22 220Xill Print Mechanism Assy Page 3 of 3 Drawing 8 23 90XiII Printhead Support Assembly Parts List 8 24 90XilI Printhead Support Assembly Drawing 8 25 140XilI Printhead Support Assembly Parts List 8 26 140 Printhead Support Assembly Drawing 8 27 170XiII Printhead Support Assembly Parts List 8 28 170XiII Printhead Support Ass
45. printer continue to work normally This includes printing which should heat the printhead to the desired temperature While the Under Temperature condition exists print quality will be reduced due to insufficient heating of the print elements Darkness of Print The print process controls the amount of energy required to print each dot in the label The amount of energy required depends on the setting of the DARKNESS parameter the ZPL relative darkness setting the current printhead temperature the type of media direct thermal thermal transfer the speed of the media the speed of the ribbon the resistance of the elements of the printhead and the dots around the dot being printed These factors combine to determine the energy required by a printhead element to print one dot Printhead Element Test Since a dot cannot be printed by a damaged printhead element the printer performs a periodic test of each element This test is controlled by ZPL commands This test is always performed between printed labels The printer may be configured to stop all printing when a head element failure is detected or it may only display the error and continue printing The printhead test only tests the elements within the print width selected from the LCD menu 7 16 Xill Series Maintenance Manual 48452L Rev 2 System Repair Printing Queued Labels Without any errors a calibration request or a feed request the printer is ready to print labels The
46. prior to this Self Test Information on the printed Configuration Label CANCEL key Self Test will 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 Label will print out at various PLUS or MINUS Darkness settings relative to the Darkness value shown on the Configuration Label Inspect these labels and determine which one has the best darkness setting for the application This value can be entered into the printer by configuring the Setting Darkness parameter found in Configuration Section of the User Guide See the label example in Figure 3 3 below The value printed on the selected test 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 and should be entered as the Darkness parameter Relative Darkness 0 Print Speed 2 Lap m xocprzlIs ZAXMANLSYOdONW DIC 4303898 zhxmenisabdouuT3L szlaes scprzls te m pU ni 123456789 ABCDEFGHI JKLMNOPQRSTUVURYZ abcdefghijklmnopqrstuvwxyz Figure 3 3 Feed Key Test Sample Label 48452L Rev 2 Xill Series Maintenance Manual Page 3 5 Printer Diagnostics Communications Diagnostics Test This test is controlled by conf
47. slew requested until no backfeed is required The printer changes print speed without stopping It simply decelerates or accelerates until the new speed is reached ZPL Commands Supported All ZPL and ZPL commands are explained in full detail in the ZPL I Programming Guide part 46469L Refer to this guide for further information Power Up Diagnostics The Diagnostic Tests may be helpful when troubleshooting the Main Logic Board and ancillary hardware Individual circuits are enabled providing the Technician with the means of checking for proper operation CAUTION THESE TESTS MAY DAMAGE THE PRINTER Main Logic Board Diagnostic Testing set up requirements e To perform these tests rotary switch SW1 must be placed in the ZERO 0 position e Use an Xill Series printer as a test fixture when troubleshooting a Main Logic Board e The printhead connecting cable must remain disconnected from the Main Logic Board e Both a Serial Loopback Connector and a Parallel Loopback Connector must be installed on the Serial and Parallel Data Connectors on the Main Logic Board Refer to section 3 for information on these connectors When the power is turned ON the printer will repeatedly perform the following series of tests until an error is detected LED Ripple Test The LCD displays the phrase LED Test Each LED is turned ON and then OFF in sequence This test is repeated after each of the other tests The opera
48. the calibration process will assume that continuous media is in the printer Sensor Profile 1 Press the Setup Exit key to enter the programming mode 2 Press the Next Save key multiple times until the printer s LCD displays SENSOR PROFILE 3 Press the right oval key to initiate the standard calibration procedure and print a Media Sensor Profile See Figure 5 1 for a media and ribbon sensor profile sample printout 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 Media and or Ribbon Sensors sensitivity needs to be adjusted press the Next Save key to access the Media and Ribbon Calibrate procedure below Media and Ribbon Calibrate NOTE The following procedure is used to adjust the sensitivity of the Media and Ribbon Sensors It must be followed exactly as presented All steps must be performed even if only one of the sensors requires adjustment 1 Press the Next Save key to skip this procedure and go to the Setting Host Port function or Press the right oval key to start the calibration procedure The front panel LCD should show LOAD BACKING ANCEL CONTINUE Page 5 4 Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance 2 Press the left oval key to cancel the operation or Open the Printhead and remove as many labels as n
49. the printer The size of the buffer is 5000 characters As data is received by the XillI Series printer the processor monitors the number of characters in the buffer If the buffer is filled beyond 4744 characters the Xill will turn the control lead to the OFF condition negative voltage or transmit an X OFF DC 3 control character to the host When the buffer empties below 4250 characters the Xill will turn DTR to the ON condition positive voltage or transmit an X ON DC 1 control character to the host Page 2 6 Xill Series Maintenance Manual 48452L Rev 2 The Xill Series System Standard Serial Communication Connector The DTE port is a DB25S connector located at the rear of the XiII Series printer It provides connection to a host via RS 232 RS 422 or RS 485 signalling Refer to Figure 2 2 for wiring diagrams The pinouts and signal descriptions for the DTE port are as follows Pin 1 Frame Ground for cable shield Pin 2 TXD RS 232 Transmit Data This lead is the serial data output from the XilI Series printer It is on this lead that printer status or XON XOFF information is relayed to the host Pin 3 RXD RS 232 Receive Data This is the serial data input to the Xill Series printer from the host Pin 4 RTS RS 232 Request To Send This is a control output from the XiII Series printer to the host RTS is active positive voltage when the printer is powered ON An Active RTS indicates that the printer i
50. zn IN Figure 5 23 AC Power Fuse Replacement 9 955 GG 9 006 S e S D QD EI Figure 5 24 International Safety Organizations 48452L Rev 2 Xill Series Maintenance Manual Page 5 39 FUSE HOLDER Corrective Maintenance NOTES Page 5 40 Xill Series Maintenance Manual 48452L Rev 2 6 Troubleshooting OO In this section Page Basic isie a 6 1 Trogblesh ootine Charts sss aquqa 6 1 Sample Labels isanne neno 6 7 Factory iind uet rit qi p 6 14 Returning Urdu icq eiiie seiss 6 14 Basic Troubleshooting Consult the Troubleshooting Tables which follow and compare the printer output to the sample labels provided on the following pages to improve the quality of your labels Troubleshooting Charts Table 6 1 Power On Troubleshooting SYMPTOM DIAGNOSIS ACTION All LEDs light but nothing displays on LCD and printer will not operate Main Logic Board or Program ROM faulty Insure Program ROMs are properly installed or Replace the Main Logic Board All LEDs Flash ON and OFF No significant amount of DRAM tested good Replace the Main Logic Board Take Label LED Flashing Printer misconfigured for Peel Off Mode If Peel Off is desired check Take Label Senso
51. 0 1 Blade Ribbon Supply Outer 40070 2 Blade Ribbon Supply Inner 46151M Assembly Spindle Replacement 170Xill 46211 Spring Compression 53 x 660 x 62 46397 375 Nut Jam 47151M Assembly Spindle Replacement 90Xill 47171 Housing Ribbon Supply Spring 48151M Assembly Spindle Replacement 140XIll 8 38 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists 220Xill TN Complete Spindle Assemblies dni II 47151M 140Xi II 48151M 170Xi Il 46151M 220Xi Il 22151M 170Xill 40070 2 30401 002 6 140Xill LONG END 38042 99 9 90Xiil 30070 2 a 30401 002 4 LN 30070 1 SS M 46397 375 NOTES 1 ALL COMPONENTS MUST BE OIL FREE 2 O RINGS WEAR PLATES AND FRICTION CLUTCHES MUST HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION RIBBON SUPPLY SPINDLE ASSEMBLY 48452L Rev 2 Xill Series Maintenance Manual 8 39 Drawings and Parts Lists PRINTER MODEL All Xill Series Printers Ribbon Take Up Spindle Assembly PART NUMBER DESCRIPTION QUANTITY 22150M Assembly Spindle Replacement 220 1 38015 Screw Set 10 24 187 47081 Spring Compression 56 x 720 x 1 0 47150M Assembly Spindle Replacement 90 XIII 47158 Nut 50 75 48150M Assembly Spindle Replacement 140 Xill 46150M Assembly Spindle Replacement 170 11
52. 0123456789801234567 Figure 3 6 PAUSE Key Loopback Test Label FEED Key Loopback Test With the Loopback Connector in place press the FEED key while turning the AC Power Switch ON After the POST the printer will begin printing the same series of label formats as shown in Table 3 2 for the FEED Key CANCEL Key test The printer will PAUSE at the end of each printed format Press the PAUSE key to begin printing the next format Refer to the label examples in Figures 3 7 through 3 13 The PAUSE Key can be used to stop and restart the printing operation When the printer is paused the CANCEL key can be used to move to the next label format LEFT WRINKLE TEST PRINTING SPEED A E Q o Figure 3 7 Format 1 4 Test Label Page 3 10 Xill Series Maintenance Manual 48452L Rev 2 Printer Diagnostics RIGHT WRINKLE TEST PRINTING SPEED R m o Figure 3 8 Format 2 5 Test Label 39 359 ZETE SPEED Figure 3 9 Format 3 6 Test Label USE BLE RE 012345678901234567890123456 PRINTING SPEED Figure 3 10 Formatl 7 11 Test Label 48452L Rev 2 Xill Series Maintenance Manual Page 3 11 Printer Diagnostics HERD TEMP TEST PRINTING AT SPEED COUNT 0001 Figure 3 11 Format 8 12 Test Label ETE EE EE EE EL ELLE 0123456789012345678901234 UPPER SME
53. 0402 006 Screw 6 32 37 30494 Washer 320 x 119 x 062 30781 Cable Printhead Ground 31899 Brush Static 40013 Plate Washer 40193 Washer Flat 406 x 172 x 048 40194 Washer Curved 312 x 144 x 016 46481 1 Screw Adjustment 6 32 46665 Assembly Ribbon Sensor 46682 Cable Assy Printhead Data 46882 003 Screw 4 40 3 16 48000M Printhead 140 Xll 48003 Bracket Head Mounting 48014 Plate Guard 48017 Plate Ribbon Strip 48099 5 Roller 48162 Bar Head Pivot 48181 Pad Pressure 48182 Rivet Plastic 48212 Plate Pressure 48289 Label 49640 021 Cable Assy Printhead Power Q06020 Tiewrap 8 26 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists 30392 004 48289 48181 AROUND 49040 021 30314R ADHESIVE THIS SIDE ONLY 49641 46665 CABLES NOTE 30391 00 1 POSITION RIBBON SENSOR 46665 TAB 1 2 3 4 FLUSH WITH TOP EDGE OF PIVOT BAR 48162 ur GAP 010 MIN 030 MAX 2 REMOVE TAB AS SHOWN FROM PRINTHEAD DATA CONNECTOR 3 REMAINING PRINTHEAD DATA CONNECTOR TAB MUST SNAP OVER CONNECTOR 4 SCREW TIGH OTHERWISE OTHER VALU TENING TORQUES UNLESS SPECIFIED TO BE 10 12 IN LBS ES APPEAR IN BOXES IN IN LBS X Y 48452L Rev 2 3
54. 0M Assembly Main Logic Board 49780M Assembly AC Power Supply 49790M Assembly DC Power Supply 8 16 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists 30391 003 4 49669 AA BB amp CC INDICATE MOUNTING HARDWARE POSITIONS 48452L Rev 2 30406 006 2 49036 1 2 30236 06319 4 46392 006 30393 006 3 46392 006 lt asas Zy T 49699 01 BROWN 4 30407 004 pu 30393 006 I IE e oM 46325 5 n lt 2 30407 004 I P Mt 22 i 49313 2 XS 30393 006 47268 GL eet m 01130 2 01822 UN a 90X ll a 48035 1 140 46035 1 170 i 46015 4 49790M 08754 4 07435 4 90Xill 140Xill amp 170Xill PRINT MECHANISM ASSEMBLY PG 3 OF Xill Series Maintenance Manual 8 17 Drawings and Parts Lists Print Mechanism Assembly Page 1 of 3 Print Mechanism Assembly Page 1 of 3 PART NUMBER DESCRIPTION QUANTITY PART NUMBER DESCRIPTION QUANTITY 01159 Washer Lock 6 40031 Cover Sensor Wire 02252 Ring Crescent 250 40154 Pin Eccentric 06268 Washer Lock 6 40248 Plate Shaft Wear 07229 Washer Curved 49 x 33 x 0075 40355M Assembly Platen Pulley 22001 1 Rol
55. 1M 9 22184 um PART 22213 N 20 PRINT MECHANISM ASSEMBLY 2 OF 3 8 21 PRINTER MODEL 220 Print Mechanism Assembly Page 3 of 3 PART NUMBER DESCRIPTION QUANTITY 01130 Nut 6 32 Hex Washer Head 01155 Washer Lock 4 01159 Washer Lock 6 01822 Nut 4 40 06319 Screw Lock Hex 10 32 37 07435 Screw Lock Hex 6 32 37 07696 Screw 4 40 31 08754 Eye 183 x 157 x 187 22035 Base Printer 22416 Standoff 4 40 Hex 30236 Screw 4 40 30253 Plate Options Cover 30391 003 Screw 4 40 19 30393 006 Screw 8 32 37 30393 010 Screw 8 32 62 30405 006 Screw 1 4 20 38 Media Hanger Mounting 30406 006 Screw 4 40 38 30407 004 Screw 6 32 25 30466 Washer N N OO N N N O IN Drawings and Parts Lists PRINTER MODEL 220 Print Mechanism Assembly Page 3 of 3 PART NUMBER DESCRIPTION QUANTITY 46015 Foot 4 46102 1 Panel Rear 46238 Panel Mounting 46254 Plate Cover Cutter 46325 4 Spacer 6 32 46325 5 Spacer 6 32 46392 006 Screw Truss Head Phillips 6 32 x 38 46646 Spacer Locking PCB 5 16 x 125 46647 Spacer Support PCB 5 16 46648 Assembly Cable Ground 47268 Plate Cov
56. 2L Rev 2 Corrective Maintenance Media Sensor Profile 48452L Rev 2 The Media Sensor Profile is a graphical representation of the calculated sensor values The limitations associated with successfully printing the profile are that the label stock must be wide enough and long enough to allow the whole display to be viewed An incorrect label length may inadvertently allow the peaks to print in the interlabel gap The following profile represents these sensor values for a typical 1 1 2 6A label stock with 5319 Ribbon used in a 140XiII Sm Web Sensor apuqa Media Sensor atau asa Qa Ribbon Sensor 19 Media LED Ribbon LED DOF tenta Label Length 100 MEDIA RIBBON MEDIA MEDIA MEDIA MEDIA MEDIA Figure 5 1 Typical Media Sensor Profile NOTE A Paper Out condition will occur during normal printing functions if the sensed level is above 75 3 75 volts for 1 2 of media movement However if the sensed value is above 75 after recovering from an error condition i e Head Open Paper Out Ribbon Out the printer will indicate PAPER OUT immediately Thus there is no attempt to feed a label any distance until the sensed value is below the Media Sensor value Xill Series Maintenance Manual Page 5 7 Corrective Maintenance Sensing Continuous Media Continuous media does not p
57. 2nd Processor Test The LCD displays Processor Test The CRC value for the shared SRAM space is calculated by the second processor and compared to the expected value The second processor is operational when the two CRC values match If the test fails the LCD displays FAILED and all testing stops 2 E Test The LCD displays E Cubed Test Test patterns are written to the E circuit The E circuits response is checked for proper results If the test fails the LCD displays FAILED and all testing stops 3 EEPROM Test The LCD displays Test At the start of this test the factory default values are written to the EEPROM These initial values are then verified during the test cycle If the test fails the LCD displays FAILED and all testing stops 4 Head Sensor Test The LCD displays Head Sensor Test This test checks for a head open condition If the head is closed the LCD displays FAILED and all testing stops 5 Head Relay Test The printhead power relay is opened and closed several times with a very short delay between movements 6 Media Sensor Test The LCD displays Media Sensor Test This test checks for a Media out condition If media is detected the LCD displays FAILED and all testing stops 7 Ribbon Sensor Test The LCD displays Ribbon Sensor Test This test checks for a ribbon out condition If ribbon is detected the LCD displays FAILED and all testing stops
58. 30357M 90 170 3 WO REWIND 3 WITH REWIND 40357M 140 30357M 90 170 90Xill 140XiII amp 170Xill FINAL ASSEMBLY ELECTRICAL PG 2 OF 2 8 7 Drawings and Parts Lists PRINTER MODEL 220Xill Final Assembly page 1 of 2 QUANTITY PART NUMBER DESCRIPTION 01130 Nut 6 32 Hex Washer Head A 01861 Label Supplies w Logo 07257 Washer Flat 438 x 188 x 065 22037 Cover PCB CE 22039 Cover Media 22049 1 Support Frame 22246 Support Cover 22254 Label Tip Over 22342 Bracket Front Cover 22491 Panel Lower Media Trim 22492M Switch Membrane 30256 Nut Thumb 6 32 50 30269 Pad PVC 30363 Panel Door with Window NIN ma oa a co 30392 004 Screw 6 32 25 44114 Screw Hi Lo Hex M4 2 8 46038 1 Panel Left Side 46060 Panel Door No Window 46272 Label Load Media 46392 006 Screw Truss Head Phillips Black 6 32 x 3 8 46396 006 Screw Truss Head Phillips 6 32 x 3 8 46492M Trim Switch Panel w Logo 46755M LCD Backlit 46836 Spacer 47267 Spacer 48490 4 Panel Upper Media Trim Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists 48452L Rev 2 22254 46272 30363 CLEAR 46060 SOLID 30269
59. 5 Reconnect the AC Power Cord Press and hold the FEED Key while turning the printer Power Switch ON 7 Verify the presence of additional Memory or optional Fonts by checking the information indicated on the Configuration Label printed during the Power ON sequence 8 printer is now ready to operate with the additional Memory option 4 INSERT TO SIMM ON ANGLE i hA S p Figure 5 19 SIMM Installation 48452L Rev 2 Xill Series Maintenance Manual Page 5 35 Corrective Maintenance Main Drive Belt Removal Replacement amp Adjustment 90Xill 140Xill and 170Xill for 220Xill refer to the following page 1 2 5 36 Turn the printer OFF and remove Power Cord Remove the Left Side Panel of the printer by removing the Phillips Screws which hold it on Refer to Figure 5 20 and rotate the Ribbon Take Up Pulley until the 3 holes in the Pulley are aligned with the 3 mounting screws which hold the Ribbon Take Up Spindle Assembly to the Printer Frame Use a 9 64 Allen Wrench to reach through the holes in the Ribbon Take Up Pulley and loosen the 3 Spindle Assembly mounting screws Slide the Ribbon Take Up Spindle Assembly to the right to relieve the tension on the Main Drive Belt Remove the old Main Drive Belt and install the new one Hook a 2200 gram spring scale to the belt as shown in Figure 5 20 and carefully slide the Ribbon Take Up Spindle Assembl
60. 59 5 2 0392706 ep 4 30392 008 30392 004 30956 7 N MR UN gt 0 30392 004 30392 004 lt gt 30392 004 77 N 47101 90Xill 47808 90X 48904 140 48808 140 46001 1 170Xill s 46808 170Xill 44001 6 _ 30826 2 48007 30393 006 4 46196 90Xill 140XiII amp 170Xill PRINT MECHANISM ASSEMBLY PG 1 OF 3 48452L Rev 2 Xill Series Maintenance Manual 8 13 Drawings and Parts Lists PRINTER MODEL 90Xill 140 Xill 170 Print Mechanism Assembly Page 2 of 3 PART NUMBER DESCRIPTION QUANTITY 01130 Nut 6 32 Hex Washer Head 06250 E Ring 312 30106 Ring Crescent External 312 30114 Washer Flat 76 x 51 x 03 30115 Washer Wave 740 x 520 x 080 30118 E Ring 30239 Washer Crescent 415 x 323 x 062 30336 1M Assembly Ribbon Take Up Pulley 30393 006 Screw 8 32 37 30395 012 Screw 1 4 20 75 Cap 30466 Washer 26 x 63 x 06 40027 Spring Torsion 40193 Washer Flat 406 x 172 x 048 40490 1 Hook Ribbon Take up Spindle 90 XiIl 40490 2 Hook Ribbon Take up Spindle 14 Xill 40490 3 Hook Ribbon Take up Spindle 170 46150M Spindle Ribbon Take up 170Xill 46151M Spindle Ribbon Supply 170 Xill 46253M Spindle Media Supply optional 170Xill 46386 Support Media Supply 46813M Assembly Compliance Roller 170 11 47150M Spindle Ribbon Take up 90Xill 47151M Spindle Ribbon Supply 90Xill 47253M Spindle Media Su
61. 9 ERROR Messages The error message display cycles through each of the error conditions that have occurred since the first error condition was detected It also shows the printing of display When an error condition is corrected the top line of that error display indicates ERROR CLEARED Once all of the errors have been cleared the display indicates PRINTER IDLE The pause key may be pressed to resume printing The possible error conditions are ERROR CONDITION ERROR CONDITION PAPER OUT HEAD ELEMENT BAD ERROR CONDITION ERROR CONDITION HEAD OPEN CUTTER JAMMED Warning Messages The Head Overtemp warning will cause printing to stop The printer will resume printing after the head cools unless another error has also occurred The Ribbon In Out Warnings will cause printing to stop until the condition is corrected and the PAUSE Key is pressed The Head Undertemp condition does not stop printing WARNING WARNING HEAD OVERTEMP HEAD UNDERTEMP WARNING RIBBON IN OUT 48452L Rev 2 Xill Series Maintenance Manual 7 7 System Repair Out Of Memory Messages The OUT OF MEMORY conditions require the operator to press the PAUSE Key to clear the error condition and continue operation OUT OF MEMORY OUT OF MEMORY REATING BITMAP TORING BITMAP OUT OF MEMORY OUT OF MEMORY UILDING FORMAT STORING FORMAT OUT OF MEMORY
62. AR TEST PRINTING AT SPEED A Figure 3 12 Format 9 13 Test Label LOWER SMEAR TEST PRINTING AT SPEED A 0 1234567896 12345678901234 III EIER IEEE DELL UBL Figure 3 13 Format 10 14 Test Label Page 3 12 Xill Series Maintenance Manual 48452L Rev 2 Preventive Maintenance In this section Page Maintenance ro ec etico 4 1 Tools Reggired ias 4 1 Cleaning The Zebra Xill 4 2 Cleaning the 4 2 Cleaning the Upper Media Guide Plate 4 4 Recommended Preventive Maintenance Schedule 4 5 Maintenance Concepts Maintenance for the Zebra Xill Thermal Transfer Demand Printer can be divided into two basic categories This section of the manual contains Preventive Maintenance procedures and Operator Care instructions These procedures may be performed by the operator as well as the Service Technician and should be performed on a regular basis Preventive Maintenance consists of a visual inspection and general cleaning of the interior and exterior of the printer Preventive Maintenance also includes cleaning the printhead and the associated media and ribbon paths Corrective Maintenance provides the Service Technician with detailed steps for resolving faults by adjustment or the replacement of components or modules The next section Section 5 o
63. I Series DC Power Supply Assembly may require removal when replacement is necessary or when installing various options in the field Follow the procedure below to remove the XilI Series DC Power Supply Assembly CAUTION The printer electronics are susceptible to static discharge Before proceeding it is highly recommended that the Technician wear an anti static wrist strap connected to the printer chassis 1 Be sure the printer is OFF and the AC Power Cord and Signal Interface Cable are disconnected 2 Remove the Left Side Panel of the printer by removing the Phillips Screws which hold it on 3 Refer to Figure 5 13 Unplug all Ribbon Cable Connectors and Small Wire Connectors from the DC Power Supply Board note their positions 4 Refer to Figure 5 14 Remove the mounting screw and two hex nuts holding the DC Power Supply Assembly against the printer chassis 5 Remove the DC Power Supply Assembly from the printer The black heat conduction pad need not be removed 6 Perform the Installation Procedure below being very careful with all cables Installing the DC Power Supply Assembly Follow the procedure below to install the XilI Series DC Power Supply Assembly 1 Refer to Figure 5 14 Position the cables out of the way while placing the DC Power Supply Assembly into the printer Insure the heat conduction pad is in powition 2 Refer to Figure 5 14 Install the mounting screw and two hex nuts which hold the DC Po
64. L or ZPL II commands from the host and with the exception of the parallel port transmits information back to the host Port Configuration 7 8 The host port is specified during the printer configuration process Any of the ports will function as the host port Xill Series Maintenance Manual 48452L Rev 2 System Repair Serial port settings for baud rate data bits stop bits flow control and parity are also configured from the LCD menu The host port is configured with the same port settings The printer supports three software protocols for the serial port ZebraNet Ack Nak and Zebra Packet ZebraNet Protocol ZebraNet protocol connects Zebra printers together in an ethernet arrangement Label formats can be sent to only one or a multiple number of printers at the same time through the use of a Network ID code which is unique to each printer The Network ID is configured via the LCD Menu or by a ZPL command Whenever the proper ID number follows a connect command the printer processes the data received Additional information about ZebraNet operation may be found in the XilI printers user s guides Zebra Packet Protocol The main serial port supports a packet protocol The packet is received and checked for accuracy prior to processing by the printer If the packet is received correctly an acknowledge packet is returned to the host If an error occurs while receiving the packet a negative acknowledge packet may be s
65. Lu a 7 9 Label ei 7 12 Memory Manager 7 14 Print Process ge u 7 15 uu aee AUREAM eri E heu 7 18 ZPL Commands eiii 7 20 Power LUp DIagnostEeS UR NON PREDA 7 20 Printer Test Overview This Maintenance Manual does not contain a Circuit Description section Instead this section of the manual provides in depth explanations of the operation and testing features of the XilI Series printers Faulty Electronic Assemblies should be easily located by board swapping Further diagnostic testing of the faulty electronic assembly should be performed at a depot level style repair facility Power ON Self Tests The printer performs a complete self test sequence each time power is turned ON This sequence of tests verifies that the printer will perform as required Failing a critical test stops the printer from completing the self test and stops normal printer operation The following are the tests and their results LED Test LEDs are turned ON Visual inspection by the operator is required to verify that all LEDs are operational Program ROM CRC Test This test takes less than 5 seconds to execute The CRC value for programming code memory space is calculated and compared to the last few bytes of
66. Maintenance Schedule METHOD INTERVAL After every roll of Media PRINTHEAD Solvent or 500 feet of Fanfold PLATEN ROLLER Solvent Medis bon pride ut Direct Thermal Mode and TRANSMISSIVE Air Blow after every Roll of Ribbon MEDIA SENSOR Wwe when printing in the Thermal Transfer Mode REFLECTIVE BLACK Solvent MARK SENSOR MEDIA PATH Solvent Once Per Six Months LABEL AVAILABLE Air Blow SENSOR Once Per Six Months RIBBON SENSOR Air Blow Visual Once Per 3 Months RIBBON FEEDING Inspection Visual Inspection 6 Months 500 Rolls BELTS look for belt wear MEDIA SUPPLY Formal Preventive Maintenance is not required SPINDLE The Spindle Torques should be tested every MEDIA TAKE UP year or 500 rolls of Media for the Media Take up SPINDLE and optional Media Supply Spindles or every 200 rolls of Ribbon for the Ribbon o Supply and Ribbon Take up Spindles RIBBON TAKE UP The Spindle Torques need not be readjusted SPINDLE unless the printer is malfunctioning Clean stationary cutter blade with solvent when it becomes gummed up with label adhesive and cut debris CUTTER OPTION After cleaning apply a small amount of grease to the moving cutter parts Table 4 1 Preventive Maintenance Schedule 48452L Rev 2 Xill Series Maintenance Manual Page 4 5 Preventive Maintenance NOTES Page 4 6 Xill Series Maintenance Manual 48452L Rev 2 5 Corrective Maintenance I
67. Mounting Screw Replace the Left Side Panel and reapply AC Power SPRING SCALE Figure 5 21 220Xill Main Drive Belt Xill Series Maintenance Manual Page 5 37 Corrective Maintenance Rewind Drive Belt Removal Replacement amp Adjustment Turn the printer OFF and remove the AC Power Cord Refer to page 5 26 and remove the DC Power Supply from the Printer 3 Refer to Figure 5 22 and note the position of the Idler Gear used to adjust the tension of the Rewind Drive Belt 4 the Media Side of the printer locate the lower access hole in the Side Frame and remove the hole plug Use a 7 64 Allen Wrench with a 10 minimum shaft length 90 140 170XiII or a 12 minimum shaft length 220Xill to reach through the hole and loosen the Idler Gear Mounting Screw 5 Slide the Idler Gear Assembly toward the front of the printer to relieve the tension on the Rewind Drive Belt 6 Remove the old Rewind Drive Belt and install the new one Hook a 2200 gram spring scale to the belt as shown in Figure 5 19 and carefully slide the Idler Gear Assembly to the left to increase belt tension 8 When a scale reading of 2000 grams 250 grams 4 5 lbs 5 Ibs creates a deflection of 1 4 tighten the Idler Gear Mounting Screw a torque of 20 inch pounds 9 Refer to page 5 26 and perform the DC Power Supply Installation procedure
68. ON QUANTITY 01153 Washer Flat 250 x 125 x 028 1 01159 Washer 6 Lock 06268 Washer 6 Split Lock 22000M Printhead 220 22002 Bar Head Pivot 22003 Bracket Head Mounting 22013 Plate Washer 22015 Spring Printhead Mounting 22016 Screw Printhead Mounting 22017 Plate Ribbon Strip 22174 Plate Guard 22180 Plate Pressure 22181 P Pad Pressure 22191 Brush Static 22602 Cable Assy Printhead Data 22640 020 Cable Assy Printhead Power 22640 025 Cable Assy Printhead Power 30007 8 Shaft Roller 30009 9 Roller 30314R Adhesive 30391 003 Screw 4 40 19 30392 004 Screw 6 32 25 k h h k uuu mt 30402 006 Screw 6 32 37 30494 Washer 320 x 119 x 062 30781 Cable Printhead Ground 40193 Washer Flat 406 x 172 x 048 40194 Washer Curved 312 x 144 x 016 48023 Bearing 313 190 375 46481 1 Screw Adjustment 6 32 46665 Assembly Ribbon Sensor 46882 003 Screw 4 40 3 16 48182 Rivet Plastic 48289 Label Q06020 Tiewrap N N N NI N N N 8 30 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Pa
69. Power Cord Press and hold the FEED Key while turning the printer Power Switch ON 7 Verify the version of software printed on the Configuration Label during the Power ON sequence 8 Install the Left Side Panel of the printer by using the Phillips Screws Refer to the printer s user s guide and program the Printer Parameters 10 During the programming process you must perform a complete Printer Calibration Pressing the Front Panel CALIBRATE Key will not provide the full calibration required when new printer software is first installed 11 When the Printer Parameters are programmed and SAVED turn the printer OFF and back ON to activate the new parameters Option Installation Font ROM Installation Optional scalable and bit mapped Fonts are available in ROMs To install the Font ROMs refer to Figure 5 17 below and substitute Font ROM for Program ROM as you follow the Program ROM Installation procedure previously discussed H t3 d Figure 5 17 Font ROM Installation 48452L Rev 2 Xill Series Maintenance Manual Page 5 33 Corrective Maintenance Memory Card and Font Card Installation To replace the Memory Card or Font Card read the instructions included in the option kit The general installation procedure is as follows Turn the AC Power OFF before installing the card 2 Refer to Figure 5 18 and remove the Option Card Shield from the rear of the printer 3 Insert the Memory Car
70. S J3 Frame Ground TXD Transmit Data Output RXD Receive Data Input RTS Request To Send Output INN DSR Data Set Ready Input Signal Ground lt 5 VDC Source DTR Data Terminal Ready Output gt 3 RS 422 RS 485 Connector Rear Panel DB 25S J3 OOOOOOOOOOOQ Oooooooooood VDC Source Output B Output Input B Input Signal Ground Ref Frame Ground AC POWER ON OFF SWITCH 1 POWER CABLE CONNECTION Page 2 8 Figure 2 2 Interface Connections Xill Series Maintenance Manual 48452L Rev 2 The XiII Series System Serial Communication Signal Levels Refer to Figure 2 3 RS 232 Data Signals are defined as either MARK or SPACE while Control Signals are either ON Active Positive Voltage or OFF Inactive Negative Voltage Although the permitted voltage levels can range from 3VDC to 25VDC the levels for the XilI Series printer are as follows RS 232 Transmit and Receive Data MARK or OFF 7 to 10 VDC SPACE or ON 7 to 10 VDC START PARITY BIT DATA BITS BIT sA 25V LOGIC 1 STOP LOGIC BIT Figure 2 3 RS 232 Signalling Refer to Figure 2 4 RS 422 and RS 485 Data Signals are also either MARK or SPACE The voltage levels are 5 VDC and 0 VDC when monitored from a specifie
71. VIEW SIDE VIEW STOPPED BY THE OPTICAL SENSOR WHEN amp SQUARENESS TO MEDIA THE POWER IS ON IN THE CUTTER MODE 02133 x M _ _ gt O 30199 43604 019 49600 012 30214 ee je r 02133 1 y9 ennt t pi 30392 004 2 Q10019 6 s 30210 2 gt 2 Illu 30217 1 ed ni ZI V oou 01660 NU GREASE E 30208 30199 c 02133 30313 30181 90 A 40181 140 46181 170 01822 2 c 2 22193 220Xill 5 90 46618 30196 100 90 30320 90 40382RM 140 30405 006 90Xill 30196 150 140X ll 40320 140 46382M 170Xill 30405 006 140 41 30196 200 170Xill 46320 170 22382M 220Xill SEE DETAIL A 30196 251 220Xill 22320 220Xill SEE NO E 30405 006 170Xill 46224 30405 008 220xXill 30819 90 NOTE 40193 2 10421 4 40819 140 46819 170 WRAP WIRES THRU TOROID 44632 22819 220Xill 1 IF REWIND OPTION IS INSTALLED ON CUTTER CENTER 5 TIMES WILL WRAP REF 30392 004 2 MACHINE BE SURE TO ORDER CUTTER REWIND 4 TIMES AROUND OUTSIDE Mui PLATE ORDER BY MODEL S PART NO 2 POSITION BRUSH SO THAT APPROXIMATELY 1 8 OF THE BRUSH S BRISTLES RUB AGAINST EACH MOVING LABEL AND THE BRUSH S BRISTLES ARE PARALLEL TO THE LABEL EDGE DETAIL A CUTTER OPTION ASSEMBLY 48452L Rev 2 Xill Series Maintenance Manual 8 47
72. Xill Final Assembly Page of 2 Drawing 8 5 90 140 170 Final Assembly Page 2 of 2 Parts List 8 5 90 140 170 Final Assembly Page 2 of 2 Drawing 8 7 220XilI Final Assembly Page of 2 Parts List 8 8 220XillI Final Assembly Page 1 of 2 Drawing 8 0 220XilI Final Assembly Page 2 of 2 Parts List 8 10 220XIII Final Assembly Page 2 of 2 Drawing 8 11 90 140 170XiII Print Mech Assy Page of 3 Parts List 8 12 90 140 170XiII Print Mech Assy Page of 3 Drawing 8 13 90 140 170XiII Print Mech Assy Page 2 of 3 Parts List 8 14 90 140 170XiII Print Mech Assy Page 2 of 3 Drawing 8 15 90 140 170XiII Print Mech Assy Page 3 of 3 Parts List 8 16 90 140 170XilI Print Mech Assy Page 3 of 3 Drawing 8 17 220XilI Print Mechanism Assy Page of 3 Parts List 8 18 220XilI Print Mechanism Assy Page of 3 Drawing 8 19 220XilI Print Mechanism Assy Page 2 of 3 Parts List 8 20 220XilI Print Mechanism Assy Page 2 of 3 Drawing 8 21 220XilI Print Mechanism Assy Page 3 of 3 Parts List 8 22 220 Print Mechanism Assy Page 3 of 3 Drawing 8 23 90XilI Printhead Support Assembly Parts List 8 24 90XilI Printhead Support Assembly Drawing
73. Zebra XIll Series Miaintenance Manual 48452L Rev 2 Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation It is intended solely for the infor mation 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 designs 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 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 product manuals may cause harmful interfer ence to radio communications Operation of this equipment in a residential area is likely to cause harmful interfer ence 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
74. a new value based on the presence of media and backing and determines the label length The ribbon sensor determines a new value based on the presence of ribbon puts the printer in thermal direct or thermal transfer print mode Once media stops feeding from the printer the calibration process is complete 10 To see the new settings press PREVIOUS and print a Sensor Profile 11 Press the Setup Exit key to leave the programming mode When asked to SAVE CHANGES select Permanent 48452L Rev 2 Xill Series Maintenance Manual Page 5 5 Corrective Maintenance Sensor Sensitivity The detailed information which follows amplifies the Media and Ribbon Sensor Calibration description and procedure just performed procedure prompts the user to load just the liner backing material in the media sensor path and remove the ribbon from the ribbon sensor area This step prepares the printer to automatically adjust the gain of the media amplifier to produce a 3 volt output while sensing just the label liner This step also prepares the printer to adjust the gain of the ribbon amplifier to produce a 2 volt output while no ribbon is in the path of the ribbon sensor Sensing Typical Thermal Transfer Non Continuous Diecut Labels Once the user has loaded backing and removed the ribbon continuing the process adjusts the gain of the sensor amplifiers The end results of this process are subsequently indicated on the Printer Config
75. are printed in a vertical format 4 Compare the test label printed to the Bar Codes in Figure E 1 If the test label appears underburnedor overburned Refer to section 4 1 and increase or decrease the BURN TEMP Setting accordingly 9 Resume printing by pressing the PAUSE Key again Print a few labels at the new setting and verify that proper IN SPEC Bar Codes are being printed Repeat steps 3 4 and 5 until satisfied 6 To terminate the printing of the test labels depress the PAUSE Key then depress the CANCEL Key Printing Conditions Overburned Overburned labels are fairly obvious The normal Bar Code bars increase in size and the openings in small alphanumeric characters may fill in with ink It may be readable but not IN SPEC Rotated Bar Code bars and spaces will run together 9 2 Xill Series Maintenance Manual 48452L Rev 2 Appendices Slightly Overburned Slightly overburned labels are not as obvious The normal Bar Code will be IN SPEC Small character alphanumerics will be bold and could be slightly filled in The rotated Bar Code spaces are small when compared to the IN SPEC Code possibly making the code unreadable Slig htly Underburned Slightly underburned labels are in some cases preferred to slightly overburned for IN SPEC Bar Codes Both normal and rotated Bar Codes will be IN SPEC but small alphanumeric characters may not be complete Underburned Underburned labels are very obvious Both normal and rotate
76. ata may be stored in all of these devices Since it is possible to have the same name for data stored in several different devices each device has a unique name When the device name is not specified the memory manager searches each device for the data item in the following order RAM Space Memory Card Optional ROMs Font ROM This same search order is followed at power up for the AUTOEXEC ZPL label format and for automatically installed fonts Fonts are automatically installed when they have a single character name A font such as D FNT could exist in the memory card the option ROMs and in Zebra s font ROM Since the memory card has the highest priority this is the font that is installed for the AD command The AUTOEXEC ZPL format may override this with a font alias command Font ROM The printer s standard fonts and bar codes are stored in the Font ROM space part of the code EPROMs This device must be present for the printer to pass the Power On Self Test This ROM is referred to as the Z device Optional ROM Since the ROM space is read only memory it must be pre programmed with fonts formats or graphics At Power On the printer determines if the optional ROMs are installed When present the ROMs are referred to as the E device Optional Memory Card The optional memory card may be writable or read only memory At Power On the printer determines if a memory card is installed and the type of card Read onl
77. bel images from it The memory required to store the data and label images comes from a memory pool managed by the label generator Once a label image is created it is queued for printing Since a single format can create several different labels this process also modifies the initial image to create the other label images needed Creating a label image from the data in the input buffer is a two step process First the data must be processed for commands and the parameters associated with them The second step is to create a dot pattern from these commands Processing and Formatting Standard ZPL processes all of the commands in a format before it starts to create the dot pattern Since data is placed into the input buffer as it is received by the communications process there may be times when the label generator is waiting for more input data ZPL II decodes all of the commands for a single area or field and then generates the dot pattern for just that area This allows the label generator to fill the idle time when it would be waiting for the communications process ZPL II also supports a command that allows the label generator to queue a portion of the label image so the printing process may start earlier The input data is decoded to determine what data is valid and where to store the information The parser receives two types of commands Format commands are decoded to create label images while control commands perform some other functi
78. d Bar Codes have incomplete bars and spaces Small alphanumeric characters are unreadable In Spec The IN SPEC bar code can only be confirmed by a verifier but it should exhibit some very visible characteristics The normal Bar Code will have complete even bars and clear distinct spaces The rotated Bar Code will also have complete bars and clear distinct spaces though it may not look as good as a slightly overburned Bar Code it will be IN SPEC In both normal and rotated styles small alphanumeric characters will look complete ROTATED BAR CODES ma Lll EZ gt S gt srl Vae mE APTE USES TOO LIGHT 1 1 er OE suemvueer _ xCODE 39x gt INSPEC 39 5 SLIGHTLY DARK lli Figure 9 1 Bar Code Examples 484521 Rev 2 Xill Series Maintenance Manual 9 3 Appendices NOTES 9 4 Xill Series Maintenance Manual 48452L Rev 2
79. d open error condition stops the printer immediately The label being printed when the error condition occurs is only partially printed The PAUSE LED is turned ON and the printer waits for the PAUSE Key to be pressed If all three error conditions are cleared when the PAUSE Key is pressed the PAUSE LED turns OFF Media registration occurs for non continuous media and then the printing process resumes Printing resumes by reprinting the label that was in process when the error occurred All other printer features e g communications decoding formatting and cancel function normally during the error condition and while the printer is recovering The feature of reprinting a label after an error condition occurs can be turned off by a ZPL command Media registration is also controlled by a ZPL command Head Over Temperature When the printhead becomes too hot gt 60 C all printing stops the Error LED turns ON and the LCD displays HEAD OVERTEMP The printer will wait until the printhead has returned to an acceptable temperature lt 55 C prior to restarting All other printer features including calibration function normally while the printhead is over temperature Head Under Temperature A similar condition occurs when the printhead is cooler than desired 15 C The printer does NOT stop but the ERROR LED turns ON and the LCD displays HEAD UNDERTEMP to indicate the error condition of the other features of the
80. d or Font Card with the notch UP into the card slot as shown Insert far enough to cause the eject button to pop out Reinstall the Option Card Shield over the Option Card and card slot 5 Press and hold the FEED Key while turning the printer Power Switch ON 6 Verify the presence of additional Memory or optional Fonts by checking the information indicated on the Configuration Label printed during the Power ON sequence 7 printer is now ready to operate with the additional Memory or Font option CARD EJECT BUTTON MEMORY FONT OPTION CARD E OPTION CARD SHIELD Figure 5 18 Memory Card and Font Card Installation Page 5 34 Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance SIMM Installation To replace the Memory Card or Font Card read the instructions included in the option kit The general installation procedure is as follows CAUTION The printer electronics are susceptible to static discharge Before proceeding it is recommended the Technician wear an anti static wrist strap connected to the printer chassis Be sure the printer is OFF and the AC Power Cord is disconnected 2 Remove the Left Side Panel of the printer by removing the Phillips screws which hold it on 3 Referto Figure 5 19 and locate the SIMM Socket on the Main Logic Board Install the SIMM into the socket as illustrated in Figure 5 19 Make sure the SIMM is locked securely into position
81. d reference point The levels for the Xill Series printer when referenced to Signal Ground are RS 422 and RS 485 Transmit and Receive Data MARK Output Input A 5V and Output Input B 0V SPACE Output Input A OV and Output Input B 5V i i BIT MARK 5 VDC DLE SPACE 0 VDC _ r s START DATA BITS PARITY BIT BIT Figure 2 4 RS 422 RS485 Signalling Communication Code The Xill Series printer sends and receives ASCII American Standard Code for Information Interchange characters in either a Serial Data or Parallel Data format NOTE When using the Serial Data format the baud rate number of data and stop bits per character and parity are selectable Parity only applies to data transmitted by the XilI Series printer For received data the Parity bit is ignored 48452L Rev 2 Xill Series Maintenance Manual Page 2 9 The Xill Series System Parallel Data Communications Interface Overview Refer to Figure 2 2 A standard 36 pin Centronics Parallel Interface Connector is available at the rear of the printer for connection to a parallel data source The Parallel Interface receives data from the data source but cannot send back printer status information over this port When the Parallel Data Port is used the standard RS 232 Port will not function as an Input Port However if the XilI Series printer receives a Printer Status Request command over the Parallel Port it will send informatio
82. d the Technician wear an anti static wrist strap connected to the printer chassis Turn the AC Power OFF and disconnect the Power Cord Remove the Left Side Panel of the printer by removing the Phillips Screws 3 Refer to Figure 5 16 Insert the tines at the bottom of the Extraction Tool firmly into the slots in the chip socket Make sure the tines catch under the ROM chip as you gently squeeze and the program ROM will raise out of the socket Repeat for positions U4 U12 U20 and U27 4 Insert the new program ROMs with the notched corner positioned to the upper right or the positioning dot pointing up Match the Main Logic Board U position with the position specified on each ROM label Make sure all pins are properly aligned before pressing the chips into place This procedure continues on page 5 30 GENTLY SQUEEZE ex lt ASSY P N el 966 Zebra Technologies Corporation 5 13 5 13 5 13 5 Figure 5 16 Program ROM Replacement Page 5 32 Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance CAUTION Permanent damage to the ROM will result if you power up the printer with it installed in the wrong direction Before you apply Power double check that all ROMs are in the proper socket and properly aligned If you have any doubts contact your Distributor or Zebra Technical Support 5 Reconnect the AC
83. dia Rewind e Media Cutter Rewind e Fan Folded Media Supply Bin SIMM Memory Modules 1 2 4 8 Mbyte Memory Cards Font Cards e Font ROMs Communication Specifications IBM Twinax Interface IBM Coax Interface RS 485 Network Interface ZebraNet Ethernet Interface 10Base T and 10Base 2 Applicator Interface Media Supply Spindle KMT printhead only available for the 140Xill printer Serial Data Communication Interface Overview The Zebra Xill has a single Data Terminal Equipment DTE port which supports RS 232 RS 422 and RS 485 serial data communications Baud rate parity data length stop bits and XON XOFF or DTR control protocols are front panel selectable Refer to Figure 2 2 A 25 pin DB25S connector at the rear of the printer provides the Data and Control Leads necessary to communicate through all three signalling methods The method used is specific to the application of the printer For all RS 232 Data and Control input and output signals the Zebra Xill follows both the Electronic Industries Association s EIA RS 232 and the Consultative Committee for International Telegraph and Telephone CCITT V 24 specifications Communication Buffer The XilI Series printer has a communication buffer that stores the incoming data until that information can be acted upon imaged Communication Handshaking DTR DSR control signals or X ON X OFF control codes is used to control when the host can send data to
84. ditional memory Bar code modulus X dimension 3 33 mil to 33 3 mil 5 mil to 50 mil 3 33 mil to 33 3 mil 5 mil to 50 mil Printing Speeds Configurable from 2 sec 50 8 mm sec to 12 sec 305 0 mm sec depending the specific Xill printer Thin film printhead with Element Energy Equalizer Printers Physical Sizes Physical Charac 140Xill 170 220Xill teristics Height Width Depth Weight w o options Electrical Requirements e Autoselect 90 264 48 62 Hz e 5 Amps for entire AC voltage range e 25 Watts standby power consumption e 200 300 350 450 Watts maximum power consumption for 90Xill 140XiII 170Xi1I 220Xill respectively printing 100 black at 6 ips e UL 1950 Listed Certified to CAN CS A C22 2 No 950 M89 and 950 e Complies with CISPR22B and with FCC and Canadian DOC class A rules e Carries the CE mark of compliance Environmental Operating Ranges Operating Temperature Thermal Transfer 41 F to 104 F 45 C to 40 C Direct Thermal 32 F to 104 F 0 C to 40 C Storage 4 F to 140 F 20 C to 60 C Non condensing Operating 20 to 85 relative humidity Storage 5 to 85 48452L Rev 2 Xill Series Maintenance Manual Page 2 5 The XilIl Series System Printer Options e Media Cutter Cutter Tray e Me
85. e 4 5 5 Corrective Maintenance orrective Maintenance Functions 5 1 Tools Required x9 ssa peda pomad EUER ewes 5 2 Test Equipment Required 5 2 Optional Cutter 5 2 CODBBEUPIDOD 4 ha 5 2 Calibration nox 9o 9 9 OX k e a 3 q 5 4 Standard KST Printhead Replacement 5 9 Printhead Adjustments 5 11 Darkness Adjustment se ode doe OS aa ey x9 3 5 16 Media Tear Off Position Adjustment 5 17 Transmissive Media Sensor Position Adjustment 5 18 Reflective Media Sensor Adjustment 5 19 LCD Viewing Adjustment 5 20 Motor Balance Adjustment 5 20 Take Label Sensor Alignment saad ya RR Ss 5 20 Media Tracking Adjustments 5 21 Spindle Adjustment and Maintenance 5 23 Removing Main Logic Board 5 25 Installing the Mam Logic Board 5 25 Removing the DC Power Supply Assembly 5 29 Installing the DC Power Supply Assembly 5 29 Xill Series Maintenance Manual iii Table of Contents Removing the AC Power Supply Assembly 5 30 Installing the AC Power Supply Assembly 5 30 Program ROM Installation 5 32 Option
86. e Figure 5 10 Rewind Spindle Positioning Peel Off Mode Page 5 22 In PEEL OFF MODE the Lower Roller alignment has the same affect on media tracking as the Rewind Plate alignment does in REWIND MODE Refer to Figure 5 11 and perform the following procedure l Usea 7 64 Hex Allen wrench to loosen the two Allen Head screws which attach the Platen Support Bracket to the Side Plate 2 Moving the Bracket toward the front of the machine moves the label backing material away from the Rewind Tracking Plate Moving the Bracket toward the rear of the machine moves the label backing toward the Tracking Plate Adjust Bracket position as required and tighten the Allen Head Screws 3 Repeat steps 1 and 2 until required results are achieved SCREWS ROLLER PLATEN SUPPORT BRACKET Figure 5 11 Peel Off Lower Roller Alignment Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance Spindle Adjustment and Maintenance There are four spindles which require periodic tension measurement and adjustment Measuring spindle tension should be done at least once each year unless required more often due to high printer use Tension should be adjusted whenever it is not within the tolerance range associated with that spindle Tension Measurement Procedure The procedure for measuring spindle tension is similar for all four spindles Refer to the Spindle Tension Adjustment Diagram in Figure 5 12 for any specific requirem
87. e Xill will not print until the label is taken It may however accept label formats if the buffer is not yet full When the label is taken the Indicator will stop flashing and the next label if any will be printed ERROR Status Indicator Normally OFF Flashes ON and OFF when a printer error occurs Read the Front Panel LCD for diagnostic information CHECK RIBBON Status Indicator Normally OFF Direct Thermal Mode ON if Ribbon is installed in the printer Thermal Transfer Mode ON if Ribbon is not installed or when the end of the ribbon has advanced beyond the ribbon sensor The Indicator turns OFF when the printer detects a ribbon in the printhead PAPER OUT Status Indicator Normally OFF ON if Media is not installed or when the media has advanced beyond the programmed or learned label length and no label edge or marker has been detected The Indicator turns OFF when the printer detects a media edge or marker AFTER the PAUSE switch is pressed when media is reloaded PAUSE Status Indicator Normally OFF When the PAUSE Key is pressed the PAUSE Indicator will light and printing will stop When the PAUSE Key is pressed again the PAUSE Indicator turns OFF and printing resumes The PAUSE Indicator will light under the following conditions Pressing the PAUSE Key Detection of a PAPER OUT condition programmed PAUSE is encountered in the label program Detection of a RIBBON OUT condition e Printhead is opened
88. e label generator wait for labels to finish printing When data needs to be stored for graphics fonts and stored formats the memory manager waits for enough memory to become free and then stores the data Memory Full Conditions While downloading a graphic font or stored format the memory manager determines the amount of memory needed to store the data It then waits until enough memory is free or until all of the bitmaps are printed Once all of the bitmaps are printed if there is still not enough memory to store the data the LCD displays the message Out of Memory Saving Image Font or Format The graphic image font or stored format is then discarded It is possible to run out of memory when attempting to create a bitmap If there are other bitmaps in memory the printer waits until the other bitmaps are printed Once all of the other bitmaps have been printed if there is still not enough memory the printer pauses and displays a message Out of Memory Creating Label The format is then discarded Print Process The print process controls media motion and physical printing It performs three different tasks printing a label from the label queue feeding blank labels and calibrating the media sensors The highest priority task is media sensor calibration followed by feeding blank labels and then printing labels The print process never interrupts one of these tasks to start another It simply completes the current tas
89. e 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 via the ZPL ZPL II command re enable the password protection feature send the ZPL ZPL II command KPx where can be any number 1 4 digits in length except 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 Press the left or right black oval key to display the sequence of choices When your choice is displayed on the LCD press the Next Save key to save settings PERMANENT saves the current settings Values are stored in the printer even when power is turned OFF TEMPORARY saves the current settings until changed again or until power is turned OFF CANCEL cancels all setting changes made since entering the programming mode except the Darkness and Tear Off settings if they were changed LOAD DEFAULTS loads factory defaults settings Refer to the user s guide for default values NOTE If you load factory defaults serttings you will have to perform a Media and Ribbon Sensor Calibration and reset the Head Resistor value before operating the printer LOAD LAST SAVE reloads the settings made during the last Permanent Save 48452L Rev 2 Xill Series Maintenance Manual Page 5 3 Corrective Mai
90. e the ribbon for possible problems such as wrinkling 3 Loosen the two Phillips screws holding the Strip Plate to the front of the Printhead Assembly 4 While running the PAUSE Key Self Test lower the Strip Plate so that the ribbon is flat and smooth and tracks properly when fed to the Ribbon Take up Spindle 5 Tighten the Strip Plate Phillips screws and print a minimum of 25 labels while checking for ribbon wrinkle tracking and media ribbon separation problems If ribbon problems persist check the torque settings of the Ribbon Supply Spindle and adjust tension if required Darkness Adjustment Due to differences in types of media ribbon and wear on Thermal Printhead Elements it may be necessary to adjust the Darkness Setting Burn Tempera ture of the Xill Printhead to achieve proper printing This adjustment is accom plished by using the LCD Display and the Membrane Keys NOTE Turning the Printer OFF is not required for the new setting to take effect To adjust the Darkness follow the procedure below CAUTION Set the Darkness to the lowest setting possible for the desired print quality Darkness set too high for a given ribbon may cause ink smearing ribbon wrinkle and or burning through of the ribbon as well as reduced printhead life l Begin printing a batch of labels Refer to Section 3 and use the Pause Key and Cancel Key Self Test Label or preferably one of your own formats 2 Refer to the Printer Confi
91. ear Off Adjust parameter of the LCD menu adjusts the final rest position of the media without affecting the position of the printed image relative to the media Tear Off Mode The media is at the rest position for tear off mode when the web is over the tear bar To print a label the printer backfeeds the media until the start or bottom of the next label is directly under the printhead The printer then prints the entire bitmap After the bitmap is completely printed the printer either feeds to the tear bar feeds until the start of the next label is under the head or stops at the top of the current bitmap The final position for the label is controlled by ZPL commands and when the next format is ready to be printed If there is another label in the print queue the printer feeds until the start of the next label is under the head 48452L Rev 2 Xill Series Maintenance Manual 7 17 System Repair Peel Off Mode The media is at the rest position for peel off mode when the web is slightly in front of the printhead To print a label the printer backfeeds the media until the start or bottom of the next label is directly under the printhead The printer then prints the entire bitmap After the bitmap is completely printed the printer either feeds to the take label position or just to the top of the current bitmap When the label is completely printed the printer feeds the label to the take label position The label is in the take label pos
92. ed setting Both the printer configuration and a ZPL command can set the media feed value to one of four possible values e No Motion this indicates that the media is correctly positioned and no motion is required e Feed Default this causes the media to feed to the first web notch hole or mark that passes the media sensor e Length the printer measures the length of one label and then feeds to the start of the next label e Calibrate the printer performs a full calibration where the media type label length and sensor settings are determined prior to feeding the next label to the rest position The proper rest position is determined by the print mode which is described later Self Test Labels Self test labels if requested are generated once the media registration is completed These self test labels are requested by pressing a key while turning the printer power ON The key must be held in before the power is turned on and not released until the first LED turns OFF The PAUSE Key Self Test and the FEED Key Self Test both cause labels to print The label formats change when a loopback connector is detected PAUSE Key and FEED Key Self Test Reset Defaults Pressing the PAUSE and FEED Keys while turning printer power ON resets the printer to the Default settings These values are not saved in EEPROM but may be saved from the LCD menu 7 4 Xill Series Maintenance Manual 48452L Rev 2 System Repair
93. eeded to load a section of blank backing material under the Media Sensor If you are unsure of the Media Sensor location refer to Figure 5 6 3 Press the right oval key to continue The front panel LCD should show REMOVE RIBBON CANCEL CONTINUE 4 Press the left oval key to cancel the operation or Remove the ribbon sliding it as far to the right as possible will have the same effect as removing it and close the Printhead 5 Press the right oval key to continue The front panel LCD should show CALIBRATING PLEASE WAIT The printer automatically adjusts the base settings as determined by the media and ribbon sensors due to 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 this part of the calibration process is completed the front panel LCD should show RELOAD ALL CONTINUE 6 Open the Printhead and pull the media forward until a label is positioned under the Media Sensor 7 Move the ribbon back to its proper position 8 Close the Printhead 9 Press the right oval key to continue The printer performs the second part of the calibration process and the front panel LCD shows MEDIA AND RIBBON CALIBRATE This part of the calibration is equivalent to pressing the Calibrate key on the printer s front panel The media sensor determines
94. eived 48452L Rev 2 Xill Series Maintenance Manual 7 9 System Repair Flow Control The printer will accept data and place it into the label generator s input buffer until the buffer is full Then the printer will only process commands that can be handled in the communications process All other data is ignored When the label generator s 5000 character input buffer only has enough room for another 256 characters a signal is sent to the host to stop the data transmission This is done by either hardware DTR DSR or software Xon Xoff flow control as selected from the LCD menu The label generator will remove data from it s input buffer as it is processed Once the buffer has room for another 512 characters the printer will signal the host to resume sending data This guarantees that valid data will never be ignored Data transmissions from the printer are controlled in the same manner When the printer receives a signal to stop sending data it starts collecting data internally Once the signal to resume data transmission is received the printer will resume transmitting data If the printer needs to transmit data and its internal transmit buffer is full the printer will drop the data rather than wait for the buffer to empty The flow control for the secondary port is handled in the same manner as the host port described above The secondary port has its own set of receive and transmit buffers The data received by the secondary p
95. els at a speed of 2 second then automatically PAUSES the printer Each time the PAUSE key is pressed an additional 15 labels will print While the printer is PAUSED pressing the CANCEL key once alters the Self Test Now each time the PAUSE key is pressed the printer prints 15 labels at a speed of 6 per second While the printer is PAUSED pressing the CANCEL key a second time alters the Self Test again Now each time the PAUSE key is pressed the printer prints 50 labels at a speed of 2 per second 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 a speed of 6 per second 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 the printer s fastest speed 8 per second for the 90Xill and 170XiII 10 per second for the 220XiII 12 per second for the 140Xill This Self Test can be used to provide the Test Labels required when making adjustments to the Printer s Mechanical Assemblies See the label example in Figure 3 2 1234567890123456789012345678901234567890123456789012345678901234567 Page 3 4 Figure 3 2 Pause Key Test Sample Label Xill Series Maintenance Manual 484521 Rev 2 Printer Diagnostics FEED Key Self Test NOTE The CANCEL Key Self Test should be performed
96. em Repair CANCEL Key Self Test Printer Configuration The CANCEL Key self test prints a Configuration Label This label shows the active printer configuration information about options and the software version number A copyright notice also prints on this label When a single label is not long enough the configuration information prints over several labels Automatically Executed Format The printer is ready to print label formats once the Power ON Self Test and Media Registration are finished The first labels printed are the self test labels previously described Once the self test labels are printed a check is made in the optional memory card and then the optional EPROM for a stored format named AUTOEXEC ZPL The first AUTOEXEC ZPL format encountered is recalled and printed Printer Ready Once the automatic format AUTOEXEC ZPL has printed the printer enters an idle state The printer waits for operator interaction or ZPL input to determine its next operation While in this idle state the printer continuously checks for error conditions head open head over temperature head under temperature ribbon out or media out in addition to ZPL input and Front Panel Key closures The printer is capable of handling data communications operator interactions printing and formatting all at the same time These are all basically independent processes which are performed simultaneously by the printer In the following paragraphs when
97. embly Media Supply Hanger 140 1 48417 Block Bearing 8 32 Xill Series Maintenance Manual 48452L Rev 2 484521 Rev 2 Drawings and Parts Lists 48417 2 ow n um 22152M Xill Series Maintenance Manual Complete Hanger Assemblies 90Xi II 140Xi 170Xi 220Xi 11 47153M 48153M 46153M 22153M MEDIA SUPPLY HANGER ASSEMBLY 8 33 Drawings and Parts Lists PRINTER MODEL All Xill Series Printers Media Rewind Spindle Assembly QUANTITY PART NUMBER DESCRIPTION 22062 J Hook 220 Xill 22090 Blade Media Take Up 220 Xill 22155M Assembly Spindle Replacement 220 30062 J Hook 90 Xill 30433 004 Screw 8 32 250 38210 Spring Compression 56 x 720 x 1 0 40062 J Hook 140 Xill 45090 1 Blade Media Take Up 90Xill 45090 2 Blade Media Take Up 140 Xill 46062 J Hook 170 Xill 46090 Blade Media Take Up 170 ill 46249M Assembly Spindle Replacement 170 Xill 46397 500 Nut Locking Thin Hex 47155M Assembly Spindle Replacement 90 XIII 48155M Assembly Spindle Replacement 140 ill 8 34 Xill Series Maintenance Manual 48452L Rev 2 484521 Rev 2 Drawings and Parts Lists Complete Spindle Assemblies 90Xi I 47155M 30433 004 6 140Xill 48155M
98. embly Drawing 8 29 220 Printhead Support Assembly Parts List 8 30 220 Printhead Support Assembly Drawing 8 31 Media Supply Hanger Assembly Parts List 8 32 Media Supply Hanger Assembly Drawing 8 33 Media Rewind Spindle Assembly Parts List 8 34 Media Rewind Spindle Assembly 8 35 220 Compliance Roller Assembly Parts List 8 36 220Xill Compliance Roller Assembly Drawing 8 37 Ribbon Supply Spindle Assembly Parts List 8 38 Ribbon Supply Spindle Assembly Drawing 8 39 Ribbon Take Up Spindle Assembly Parts List 8 40 Ribbon Take Up Spindle Assembly Drawing 8 41 Optional Media Supply Spindle Assembly Parts List 8 42 Optional Media Supply Spindle Assembly Drawing 8 43 Media Rewind Option Assembly Parts List 8 44 Media Rewind Option Assembly Drawing 8 45 Cutter Option Assembly Parts List 8 46 Cutter Option Assembly 8 47 ASCH Cod Chart duu e dou He 9 Setting Burn Temperature For IN SPEC Codes 9 2 Printing Conditions 9 2 48452L Rev 2 Xill Series Maintenance Manual Table of Contents NOTES vi Xill Series Maintenance Manual 48452L Rev 2 Introduction In this section Page Ibi uude io P
99. ent accidental loss of ERROR data this key is ignored unless the printer is not printing is between formats or is first PAUSED CHECK RIBBON see PAUSE Key above Pressing this key causes the media to advance until one of the following PAPER OUT occurs e The media advances to the start of the next label e A Paper Out condition is encountered Pressing the FEED Key while turning the power ON causes a printer Self Test Label to be automatically printed at end of the Power ON Self Test FEED CANCEL Key This key is ignored unless the printer is first PAUSED see PAUSE Key above in order to prevent accidental loss of data Pressing the DATA CANCEL Key removes the current batch printing from the Print Data Buffer CANCEL CALIBRATE Each subsequent pressing of the CANCEL Key clears the next batch if any from the Print Data Buffer until the Buffer is empty Pressing the CANCEL Key while turning the power ON causes the printer Configuration Label to be automatically printed at the end of the Power ON Self Test Figure 2 5 Front Panel Controls Page 2 12 Xill Series Maintenance Manual 48452L Rev 2 The Xill Series System CALIBRATE Key This key is ignored unless the printer is first PAUSED see PAUSE Key above in order to prevent accidental loss of data Pressing this key once causes the printer to recalibrate the Media and Ribbon Sensors for proper Media Length set media type continuous or non continu
100. ent to the host or no response at all Once a packet is received and verified the data in the packet is processed normally A complete explanation of the Packet protocol is found in the ZPL II Programming Guide Ack Nak Packet Protocol Another version of Zebra packet protocol is supported to maintain compatibility with earlier printer models Since this is not a reliable packet protocol the Zebra protocol should be implemented in its place where possible Errors Conditions The packet protocol responds with a negative acknowledge packet when an error is detected This is the only communications method that attempts to correct detected errors Standard communications errors such as parity and overrun errors should cause packets to be invalid Normal Mode During normal printer operations framing overrun and parity errors are ignored The printer attempts to print labels from the data values it receives The printer always transmits data with the specified parity data bits and stop bits The printer may print labels even when it is improperly configured If the host is not receiving responses it may be due to an incorrect setting Diagnostic Mode This mode is very beneficial as a troubleshooting aid Each character received is printed as a hex value Its ASCII interpretation is printed directly above the hex value Any framing overrun or parity errors are indicated just below the hex value if the character was incorrectly rec
101. ents Adjusting the Wear Plate position produces even pressure across the full width of the printhead and platen roller Refer to Figure 5 3 for the location of the adjustment screws used in the following procedure 1 Using a 1 Phillips screwdriver loosen the 2 screws on the front of the Strip Plate 2 Activate the PAUSE Key Self Test by pressing the PAUSE Key while turning the Printer Power ON 3 After printing a few labels PAUSE the printer and reduce the DARKNESS value until the test labels are a charcoal gray color Print additional PAUSE Key Self Test labels and observe the print quality 5 If lighter or no printing is observed on one side of the label as compared with the other continue with this adjustment 6 Using a 7 64 Allen wrench slightly loosen the 2 Allen Set Screws mounted on the Wear Plate 7 Continue to print PAUSE Test labels while adjusting the Wear Plate Eccentric for even printing 8 Adjust the Wear Plate Eccentric by turning it by hand or with a 7 16 open end wrench or with a pair of utility pliers 9 Adjust the Wear Plate Eccentric clockwise to increase pressure on the Main Frame side of the label or adjust it counter clockwise to increase pressure on the outboard side of the printer 10 When even print quality is achieved hold the Wear Plate in position and tighten the 2 Wear Plate Set Screws 11 Continue to print PAUSE Test labels and verify Parallelism is correct 12 If Parallel
102. ents l Use adhesive tape to attach a 2 wide strip of polyester film part 01776 to the Spindle Shaft or Core where required as illustrated in Figure 5 12 Wind the polyester film around the Spindle or Core about 5 times in the direction indicated 2 Measure tension by slowly pulling the film with a springscale Pull ONLY in the direction shown The pull rate should typically be 2 per second 3 Compare the springscale reading with the force values provided in Figure 5 12 Perform the Spindle Adjustment only if the reading is out of spec 4 If adjustment is made recheck the tension after running a full roll of labels Spindle Tension Adjustment Refer to the Spindle Tension Adjustment Diagram in Figure 5 12 and adjust the Spindle Tension as follows 1 Loosen the set screw s if present in the Adjustment Nut at the end of the Spindle 2 Turn the Adjustment Nut clockwise to increase the tension or counter clockwise to decrease the tension Tighten the set screws if present NOTE If the shaft of the Ribbon Take Up Media Take Up or optional Media Supply Spindle turns when attempting to turn the Adjustment Nut refer to Figure 5 10 and insert an Allen wrench through the access hole on the inner end of the spindle and into the set screw in the shaft collar DO NOT TURN THE ALLEN WRENCH Simply hold the shaft in place with the Allen wrench while turning the Adjustment Nut 3 Measure the spindle tension as performed above Com
103. er 49013 Cover Memory Card PCMCIA 49036 1 Cover PCB Option 49285 Pad Insulation AC Power Supply 49286 Pad Insulation DC Power Supply 49313 Spacer Top AC Power Supply 49605 009 Assembly Cable Power Supply 49669 Switch Power Entry 49673 Assembly Power Entry w Fuse amp Gnd Wire 49699 01 Assembly Cable Short Brown 49699 06 Assembly Cable Short Blue 49700M Assembly Main Logic Board 49780M Assembly AC Power Supply 49790M Assembly DC Power Supply 1 1 1 2 1 2 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 8 22 Xill Series Maintenance Manual 48452L Rev 2 49036 1 2 30391 003 UN 49605 009 49669 30406 006 2 77 _ 49699 01 BROW AA BB amp CC INDICATE MOUNTING HARDWARE POSITIONS 48452L Rev 2 Drawings and Parts Lists 49013 30236 zn t 46392 006 E E 07696 2 1 46392 006 2 1 L 46392 00677 gt lc y gt 49699 06 BLUE Xill Series Maintenance Manual lt 49780M 06319 4 2 4 2 I 46325 51 icm 5 4 08754 4 30393 010 3 994 30407 004 vd 30393 006 a 7 PA 30407 004 30393 006
104. er to Figure 5 14 Position the cables out of the way while placing the Main Logic Board onto the plastic stand offs at the top and bottom right hand corners of the board 3 Atthe rear of the printer install the 4 Phillips Screws which hold the serial and parallel interface connectors to the back of the printer 4 Refer to Figure 5 13 Carefully connect all the Ribbon Cables and Small Wire Cables to the proper connectors on the Main Logic Board 5 Refer to Figures 5 14 If required install the optional interface board through the rear of the printer Insure the data cable is properly connected between the Main Logic Board and the Interface Board 6 If required install any Font Card or Memory Card into the card slot located at the rear of the printer 7 the AC Power Cord and the Signal Interface Cable 8 Turn the printer ON and configure the printer parameters Be sure to enter the Printhead Resistance value indicated on the label attached to the printhead 9 Hold in the PAUSE Key while turning the AC Power ON Observe the printer Power ON Self Test and examine the test labels which print for proper print quality 10 Reinstall the Left Side Panel 11 Refer to the printer s user s guide and program the Printer Parameters NOTE During the programming process you must perform a complete Printer Calibration Pressing the Front Panel CALIBRATE Key will not provide the full calibration process required when a Ma
105. ers Media Rewind Option Assembly PART NUMBER DESCRIPTION QUANTITY PRINTER MODEL All Xill Series Printers Media Rewind Option Assembly QUANTITY PART NUMBER DESCRIPTION 02252 Ring Crescent 25 N 07435 Screw 22001 1 Roller Platen Lower 220 Xill 22207 Shaft Idler Pulley 220 22155M Assembly Media Rewind Spindle 220Xill 22265 Pulley Idler 220Xill 22383M Plate Rewind 220 Xill 30104 Flange Ball Bearing 30114 Washer Flat 76 x 51 x 03 30115 Washer Wave 740 x 520 x 080 30118 E Ring External 500 x 042 30207 Shaft Idler Pulley 90Xill 140 Xill 170 XilI 30247 Washer Flat 30261 Washer Flat 30265 Pulley Idler 90Xill 140 Xill 170 XIII 30336 2M Assembly Media Take up Pulley 30392 004 Screw 6 32 30393 006 Screw 8 32 31 30914M Assembly Peel off Pulley 40019 Plate Roller Adjust 40193 Washer Flat 45189 2 Belt Drive Rewind 46001 1 Roller Platen Lower 170 Xll 46249M Assembly Media Rewind Spindle 170Xill 46383M Plate Rewind 170 Xill 46673 Assembly Take Label Sensor Lower 46674 Assembly Take Label Sensor Upper 47101 Roller Platen Lower 90 XIII 47155M Assembly Media Rewind Spindle 90 47383M Plate Rewind 90Xi
106. essary or when installing various options in the field Follow the procedure below to remove the XilI Series Main Logic Board CAUTION The printer electronics are susceptible to static discharge Before proceeding it is highly recommended the Technician wear an anti static wrist strap connected to the printer chassis 1 Be sure the printer is OFF and the AC Power Cord and Signal Interface Cable are disconnected 2 Remove the Left Side Panel of the printer by removing the Phillips screws which hold it on 3 Remove any Font Card or Memory Card from the card slot located at the rear of the printer by pressing the card release button 4 If an optional interface board is installed in the printer refer to the removal instructions for that board before continuing this procedure 5 Refer to Figure 5 13 Unplug all Ribbon Cable Connectors and Small Wire Connectors from the Main Logic Board note their positions 6 Referto Figure 5 14 At the rear of the printer remove the 4 Phillips screws holding the serial and parallel interface connectors to the back of the printer 7 Remove the Main Logic Board by squeezing the tips of the plastic stand offs at the top and bottom right hand corners of the board 8 Software is not included with the replacement Main Logic Board Refer to the Program ROM Installation topic covered later in this section and use a Zebra approved PLCC Plastic Leaded Chip Carrier Extraction Tool to carefully remove
107. f this manual provides detailed Corrective Maintenance procedures Tools Required 48452L Rev 2 A Preventive Maintenance Kit part 01429 containing six cleaning swabs soaked in solvent alcohol is available from Zebra Technologies Corporation WARNING Unless indicated otherwise turn printer power OFF before performing maintenance procedures Xill Series Maintenance Manual Page 4 1 Preventive Maintenance Cleaning The Zebra Xill Printer CAUTION Use only the cleaning agents described in the following procedures Zebra Technologies will not be responsible for any other fluids being used on this printer EXTERIOR The exterior surfaces of the XiII Series printer may be cleaned as required by using a lint free cloth DO NOT use solvents or harsh cleaning agents If the unit is excessively dirty a mild detergent solution or desktop cleaner may be used sparingly INTERIOR As required remove any dirt lint accumulated in the interior of the printer using a soft bristle brush and or vacuum cleaner It is a good practice to inspect these areas after every fourth roll of media WARNING The use of certain lubricants such as Penetrating Oil and Silicone Oil will damage the printer s spindles and inhibit proper operation DO NOT LUBRICATE any parts in this printer unless called for in the installation and adjustment procedures CLEANING SUPPLIES When cleaning supplies are required reorder the Preven tive Maintenance K
108. functioning If the test finishes successfully then the entire SRAM space is initialized to zero and the Paper Out LED is turned OFF After memory is cleared the code for the second processor is loaded into memory and the second processor starts executing the code Should the SRAM test fail the system will not advance beyond this test The failed SRAM area will be read repeatedly until power is turned OFF Second Processor Test This test takes less than 5 seconds to execute The LCD displays Processor Test The CRC value for shared SRAM space is calculated by the second processor and compared to the expected value The second processor is operational when the CRC values match The main processor will wait for the second processor to finish this test Should this test fail the system will not advance beyond this CRC test Optional ROM CRC Test This test takes less than 5 seconds to execute The LCD displays the phrase Option ROM Test The CRC for each object in the optional ROM is calculated and compared to the expected CRC All of the object CRCs must match for the optional ROM to be valid Should the option ROM CRCs not match the display will show Not Installed and the system will pause for one second EEPROM Checksum Test The LCD displays the phrase EEPROM Test A checksum is calculated for each value stored in the EEPROM If the checksum is correct the corresponding printer parameter is updated Sho
109. ges of Horizontal Bars Splotchy on Right Side Toggles Balanced Equal Pressure On Left and Right Sides 48452L Rev 2 Troubleshooting 34 789212345678301234567890123456 28921234 IIIIIII 48452L Rev 2 Xill Series Maintenance Manual Unacceptable Label Darkness Properly Set Printhead Position Correct on Right Side Too Far Forward on Left Side Noisy Printing Breakup on Leading Edges of Horizontal Bars Splotchy on Left Side Toggles Balanced Equal Pressure On Left and Right Sides Unacceptable Label Darkness Properly Set Printhead Position Correct on Left Side Too Far Forward on Right Side Noisy Printing Breakup on Leading Edges of Horizontal Bars Splotchy on Right Side Toggles Balanced Equal Pressure On Left and Right Sides Page 6 13 Troubleshooting Factory Assistance Should any problem be encountered which cannot be corrected with the aid of this manual immediately contact your Distributor or the Zebra Technical Support Department to minimize downtime and or assist in returning the equipment Returning Equipment Should it become necessary to ship your XillI Series printer carefully pack it in a suitable container to avoid damage during transit A note describing the failure must be enclosed with the unit Whenever possible the original shipping container should be
110. gs for S1 This switch should not be set to the ZERO 0 position unless a faulty Main Logic Board is being tested Refer to page 7 20 for further information on the Diagnostic Tests CAUTION Insure this switch is properly positioned before applying Power to the printer If this switch is set incorrectly the Printhead or the Main Logic Board could be damaged Table 7 1 S1 Switch Settings Switch Switch Position Function Position Function 0 Diagnostics 8 140XilI KMT 8 dots mm 8 sec 1 170PAX Left Hand 12dots mm 9 140Xill KST 8 dots mm 8 sec 2 170PAX Right Hand 12dots mm A 140 KMT 8 dots mm 12 sec 3 170PAX Left Hand 8dots mm B 140XilI KST 8 dots mm 12 sec 4 170PAX Right Hand 8dots mm C Undefined 5 Undefined D Undefined 6 90 Printhead 12 dots mm E 220 XilI Printhead 8 dots mm 7 Undefined F 170XilI Printhead 12 dots mm 7 2 Xill Series Maintenance Manual 48452L Rev 2 System Repair LCD Display Test The LCD Liquid Crystal Display shows all the displayable characters The display then shows solid boxes at each character position allowing the operator to visually insure all dot positions are displayable Shared SRAM Test This test takes less than 2 seconds The LCD displays SRAM test The shared SRAM Static RAM operation is verified by reading and writing to the SRAM area The test is successful when the full 128k of SRAM is properly
111. guration discussion in the User Guide Using the Front Panel Display and the Membrane Keys adjust the Darkness Setting to obtain the desired print quality Decreasing the value in the display causes a lighter less black image Increasing the value causes a darker more black image Page 5 16 Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance Media Tear Off Position Adjustment Refer to Figure 5 5 This adjustment sets the rest position of the media over the Tear Bar after printing To achieve the desired Tear Off position refer to the user s guide Power need not be turned OFF to set this parameter Nominal factory set tear line location will usually be 00 LABEL MOTION This illustration shows how higher values move the label further out from the printer moves the tear line closer to the leading edge of the next label while lower values move the label into the printer moves the tear line closer to the edge of the printed label Figure 5 5 Tear Off Position Adjustment 48452L Rev 2 Xill Series Maintenance Manual Page 5 17 Corrective Maintenance Transmissive Media Sensor Position Adjustment Page 5 18 The Transmissive Media Sensor senses either the web between labels or a hole or notch in the print media to determine the length of the label or ticket The factory set position should be sufficient for any width label when using media with a web so little or no repositioning s
112. he Main Logic Board Missing LCD characters or parts of characters LCD may need replacing Run the Power On Self Test and check that LCD display is showing all characters ZPL was sent to printer but not recognized Buffer light remains ON Page 6 6 Communications parameters are incorrect Print a Communications Diagnostic Label Check for Format or Overrun Errors Reset Communication parameters Prefix and Delimiter characters set in printer do not match the ones used in ZPL Xill Series Maintenance Manual Set the characters in the printer to match ZPL format If problem continues check the ZPL format for changed and CD 48452L Rev 2 Troubleshooting Sample Labels The following pages contain labels to be used with the preceeding troubleshooting charts These labels illustrate conditions which could be seen if mechanical adjustments are necessary Zebra type 3P Media Stock and type 5319 Ribbon were used to obtain these labels Any other Label and Ribbon stock combinations may produce sample labels with similar but not necessarily the same indications The size of these example labels has been adjusted to permit good visibility of the effects of the mechanical problem being illustrated 48452L Rev 2 Xill Series Maintenance Manual Page 6 7 Troubleshooting Acceptable Label 123456789012345678901234567890123456783012345578901234567890123456
113. heck of the hardware handshake lines for a loop back connector If a loopback connector is not present 14 Print Quality labels are printed One label is printed for each darkness setting at the slowest and fastest print speeds The darkness starts at three settings below the currently configured value and continues to increase until it is three settings darker than the configuration value The relative darkness and speed are printed on each label The bar codes on these labels can then be ANSI graded to check print quality This test can be performed without a loopback connector If a loopback connector is detected the following set of formats print with a pause after each format refer to page 3 9 for more information on loopback connectors 1 20 Fastest Speed Left Ribbon Wrinkle labels 2 20 Fastest Speed Right Ribbon Wrinkle labels 3 20 Fastest Speed C39 Wrinkle test labels 4 10 Fastest Speed Useable Area labels 5 10 Fastest Speed Head Temp Test labels 6 10 Fastest Speed Upper Smear labels 7 10 Fastest Speed Lower Smear labels 8 20 Slowest Speed Left Ribbon Wrinkle labels 9 20 Slowest Speed Right Ribbon Wrinkle labels 10 20 Slowest Speed C39 Wrinkle Test labels 11 10 Slowest Speed Useable Area labels 12 10 Slowest Speed Head Temp Test labels 13 10 Slowest Speed Upper Smear labels 14 10 Slowest Speed Lower Smear labels 48452L Rev 2 Xill Series Maintenance Manual 7 5 Syst
114. hillips No 2 Nut Driver 1 4 Nut Driver 5 16 Long nose pliers Set of inch combination Open End Box End wrenches must include a 7 16 Set of inch Allen wrenches 1 16 3 32 5 64 7 64 9 64 Hex Head Driver 3 32 Hex Head Driver 7 64 Hex Head Driver 7 64 Extended Reach 10 shaft part HT368 Hex Head Driver 7 64 Extended Reach 15 shaft part 46482 Springscale 0 2250 g part HT344 Wire Cutters Spindle Torque Adjustment Kit part 01773 Test Equipment Required Multimeter and Test Leads Anti Static Mat and Anti Static Wrist Strap used when removing Electronic Circuit Boards or updating Firmware WARNING Unless indicated otherwise turn printer power OFF before performing maintenance procedures Optional Cutter Module The Cutter Module should NOT be disassembled but replaced as a unit Any disassembly of the Cutter Module voids the warranty Configuration Page 5 2 After you have installed the media and ribbon and the POST Power On Self Test is complete the front panel display shows PRINTER READY You may now set printer parameters for your application using the front panel display and the five keys directly below it Refer to the Zebra 1 Printer User s Guide for further details on configuring the printer for your application If it becomes necessary to restore the initial printer defaults see the Feed Key and Pause Key Self Test in the Printer Diagnostics section
115. hould be required If it does become necessary to reposition the Transmissive Media Sensor refer to Figures 5 6 and 5 7 and perform the Upper Media Sensor Adjustment followed by the Lower Media Sensor Adjustment To adjust the Upper Media Sensor for the inside half of the media width follow these steps 1 Remove the ribbon and locate the Upper Media Sensor 2 90XilI 140Xill 170XiII Carefully loosen the Phillips screw located at the top of the sensor 220XiIT DO NOT loosen the Phillips screw 3 Slide the Upper Sensor along the slot to the desired position When using label stock that has a web between labels position the Upper Media Sensor anywhere along the web except where the rounded corners of the label are detected When using tag stock position the Upper Sensor directly over the hole or notch 4 Tighten the Phillips screw To adjust the Upper Media Sensor for the outside half of the media width follow these steps 1 Remove the ribbon and locate the Upper Sensor 2 Remove the Phillips screw This releases the Upper Sensor and the Sensor Wire Cover 3 Lift the Upper Media Sensor Assembly and move the sensor and the wire cover to the outside half of the mounting bracket Carefully pull the wires through the tie wrap You may need to set aside the Sensor Wire Cover if the adjustment is far to the outside 4 Replace and tighten the Phillips screw To adjust the Lower Media Sensor follow these steps 1 L
116. iguring the Setting Communications Mode parameter found in the Configuration Section of the printer s user s guide Refer to Figure 3 4 for a sample label resulting from this test NOTE This label will be inverted when printed FS FO394 25 AA DE 46 53 5E 46 33 39 34 2C 32 35 41 41 N 18 10 FDCOO00 4E 2C 31 38 2C 31 30 5E 46 44 28 30 30 30 30 0999 9999 FS 29 39 39 39 2D 39 39 39 39 SE 46 53 D A 18 46 30 2C 35 41 41 4E 2C 31 38 2C 1O0 FDCENTER STA 31 30 46 44 43 45 4E 54 45 52 20 53 54 41 Figure 3 4 Results of Communications Diagnostic Test FEED Key and PAUSE Key To temporarily reset the Printer Configuration to the Factory Default values press these two keys at the same time while turning the Power ON The Factory Default values will be active until power is turned OFF If Factory Default values are Saved during configuration a Media Calibration procedure must be performed and some parameters must be reconfigured Refer to the printer s user s guide for more details Table 3 1 indicates which printer function controls each of the configuration parameters Page 3 6 Xill Series Maintenance Manual 48452L Rev 2 Printer Diagnostics Parameter Controlled By Darkness Configuration or ZPL II Tear Off Configuration or ZPL II Print Mode Configuration or ZPL II Media Type Configuration or ZPL II Senso
117. in Logic Board is first installed Refer to page 5 2 to begin the Configuration and Calibration process 12 When the Printer Parameters are programmed and SAVED turn the printer OFF and back ON to activate the new parameters Table 5 1 S1 Switch Settings Switch Switch Position Function Position Function 0 Diagnostics 8 140Xill KMT 8 dots mm 8 max 1 170PAX Left Hand 12dots mm 9 140 KST 8 dots mm 8 sec max 2 170PAX Right Hand 12dots mm A 140 KMT 8 dots mm 12 sec max 3 170PAX Left Hand 8dots mm B 140XilI KST 8 dots mm 12 sec max 4 170PAX Right Hand 8dots mm C Undefined 5 Undefined D Undefined 6 90 Printhead 12 dots mm E 220 Xill Printhead 8 dots mm 7 Undefined F 170XilI Printhead 12 dots mm 48452L Rev 2 Xill Series Maintenance Manual Page 5 27 ST S 98 4 SIIS X AA 7106787 OPTIONAL INTERFACE BOARD MAIN PROGRAM ROMS 4 ROTARY SWITCHES v lt PDC POWER SUPPLY ASSEMBLY HEAT CONDUCTOR PAD Figure 5 14 Main Logic Board amp Power Supply Board ar eM lt oO 5 e 5 Corrective Maintenance Removing the DC Power Supply Assembly The Xil
118. in its edges the inside toggle should be centered above the media and the outside toggle should be reduced to a minimum Print PAUSE Key Self Test labels to check print quality 2 increase Printhead Pressure loosen the Upper Knurled Nut on the Toggle and adjust the Lower Toggle Adjusting Nut downwards 3 decrease Printhead Pressure loosen the Upper Knurled Nut and adjust the Lower Toggle Adjusting Nut upwards Adjust Printhead Pressure for optimum print quality To lock the toggle pressure tighten the Upper Knurled Nut against the Lower Toggle Adjusting Nut 6 Though different media and ribbon combinations may require different Toggle settings a suggested initial distance between the flat area at the bottom of the Printhead Pressure Bracket and the top of the upper knurled adjustment nut is 8mm 7 Enter the configuration mode and set the Darkness to the optimum level for the installed media 0 ERN SS 0 ADJUSTING NUTS Figure 5 4 Printhead Pressure Adjustment 48452L Rev 2 Xill Series Maintenance Manual Page 5 15 Corrective Maintenance Strip Plate Adjustment The Strip Plate Adjustment is a very important part of total printhead adjustment procedure The Strip Plate can be adjusted for proper tracking and separation of the ribbon from the media after printing Refer to Figure 5 3 Print PAUSE Key Self Test labels 2 Press the PAUSE Key and after the printer pauses observ
119. inter Section 10 is available for the technician to add additional printed materials such as installation instructions provided with Option Kits and Replacement Parts Kits To ensure that you receive documentation updates refer to the registration form at the front of this manual Complete the registration form and return it to Zebra Technologies In this way we can provide better service directly to the repair technician Related Manuals The ZPL Programming Guide Part 464691 provides information on printer commands and label formatting instructions Printer front panel operation and printer calibration procedures are provided in the Xill Series User s Guide Part 48460L and are not repeated in this maintenance manual Refer to the user s guide for this type of information Page 1 2 Xill Series Maintenance Manual 48452L Rev 2 2 The Zebra Xill Series System In this section Page Printer Specifications 2 1 Meurs Handle teret teneo ul P x Ud au beet open 2 1 Operator uiii poetis QU E Edu Ies 2 2 Zebra Programming Language II ZPL 2 2 Codes ace ironia e M EL as 2 2 Standard Printer Fonts 2 3 Media Considerations e 2 4 Ribbon Considerations eese 2 4 Printing ONS yee 2 5 Pri
120. inthead Data Cable into each connector The Holding Tabs must snap into place around the cable connectors 13 Carefully position the alignment slots in the new Printhead over the alignment posts on the underside of the mounting bracket 14 Once the Printhead is seated properly carefully tighten the mounting screw to a value of 5 6 inch pounds If any problems occur during this installation contact your distributor or Zebra Technologies Corporation for technical support 15 Refer to Figure 4 1 Use a cleaning swab to thoroughly clean the print element gray area of the new Printhead 16 Reinstall media and ribbon 17 Connect the AC Power Cord and turn the printer power ON 18 After the POST enter the Configuration Mode enter the new Printhead Resistance value then permanently save the configuration 19 Turn the printer OFF then activate the PAUSE Key Self Test and check print quality 20 The printer should be ready for operation If problems arise refer to the Troubleshooting Section 48452L Rev 2 Xill Series Maintenance Manual Page 5 9 Corrective Maintenance DO NOT LOOSEN THESE SCREWS PRINTHEAD MECHANISM ASSEMBLY PRINTHEAD MOUNTING SCREW PRINTHEAD ALIGNMENT POSTS PRINTHEAD DATA CONNECTOR POWER CABLE LOCKING TAB 22 PRINTHEAD EGA ALIGNMENT 23 SLOTS PRINTHEAD 3 POWER m 140Xill and 170Xill CONNECTOR D PRINTHEAD PRINTHEAD ALIGNMENT
121. ism is out of tolerance perform the Printhead Parallelism Adjustment 13 If no other adjustment is required align the Strip Plate and tighten the 2 Phillips screws 48452L Rev 2 Xill Series Maintenance Manual Page 5 13 Corrective Maintenance Printhead Position Adjustment This adjustment is performed in conjunction with the Printhead Parallelism Wear Plate Position and Printhead Pressure Adjustments Adjusting the Printhead position aligns the head for optimum print quality Refer to Figure 5 3 for location of adjustment screws used in the following procedure The thermal elements of the Printhead should be aligned just behind the crest of the Platen Roller Print test labels using the PAUSE Key Self Test Set the Darkness to achieve as close to optimum print quality as possible Using a 7 64 Allen wrench loosen the four Allen screws at the top rear of the Print Mechanism CAUTION In step 5 to prevent Printhead damage loosen the four top screws before turning the two rear adjustment screws 10 Page 5 14 Adjust the Printhead position for optimum print quality by equally turning the two screws located at the back of the print mechanism Adjustments are made in very small increments Turn both screws one eighth turn clockwise and observe the changes in print quality Turn both screws 1 8 turn counter clockwise and observe the changes in print quality Due to spring pressure there may be a dead spot in
122. it part 01429 Cleaning The Printhead Page 4 2 Inconsistent print quality such as voids in the bar codes or graphics may indicate a dirty printhead For optimum performance the printhead should be cleaned regularly Zebra Technologies Corporation recommends performing the cleaning procedure when installing a new Roll of Ribbon when installing a new Roll of Direct Thermal Media or after having printed 500 feet of Continuous or Fanfold Media Xill Series Maintenance Manual 48452L Rev 2 Preventive Maintenance It is not necessary to turn the Printer Power OFF prior to cleaning If Power is turned OFF all label formats images and parameter settings stored in the printer s formatting RAM Memory will be lost Permanent parameter settings stored in EEPROM will be retained When Power is turned back ON it may be necessary to reload some items into the printer s memory Printhead Cleaning Procedure Open the Printhead by moving the Printhead Lever to the OPEN position Remove the media and ribbon if present 3 Refer to Figure 4 1 Use a cleaning swab and wipe the print elements from end to end The print elements are the grayish black strip just behind the chrome strip on the underside of the printhead Allow a few seconds for the solvent to evaporate Rotate the Platen Roller and clean thoroughly with a cleaning swab 5 Brush or vacuum any accumulated paper lint and dust away from the Rollers and the Media and Ribbon Senso
123. ition when it is still held on by only the portion of backing material that has not crossed the tear bar This allows the label to hang off of the printer After the label is pulled free the printer immediately backfeeds the media to the rest position Rewind Mode The media is in the rest position for rewind mode when the start of the next label is directly under the printhead The media never backfeeds in this mode The printer prints the entire bitmap After the bitmap is completely printed the printer either feeds to the rest position or to the top of the current bitmap This final position of the label is controlled by ZPL commands Cutter Mode Test Mode The media is at the rest position for cutter mode when the web is slightly in front of the printhead To print a label the printer backfeeds the media until the start or bottom of the next label is directly under the printhead The printer then prints the entire bitmap After the bitmap is completely printed the printer feeds the label to the cut position the rest position or just to the top of the current bitmap When the label is completely printed and a cut is required the printer feeds the next web the top of the label out into the cutter mechanism The cutter blade is activated and the printer waits for the cutter mechanism to complete its cycle After cutting the printer immediately backfeeds the media to the rest position If a cut is not requested by ZPL the printer simpl
124. k and then checks for the highest priority task 7 14 Xill Series Maintenance Manual 48452L Rev 2 System Repair Media Calibration Media calibration occurs either when the printer is paused and the CALIBRATE Key is pressed when the printer is turned ON and when the printhead is CLOSED A ZPL command determines the type of calibration performed for bot the Power ON and Head Closed conditions Media Sensor calibration may also be selected from the configuration menu or by a ZPL command The calibration always occurs at two inches per second the slowest speed supported e The simplest form of calibration moves the media looking for the first web that passes the Media Sensor This web is then placed at the proper rest position based on the print mode e A label length calibration moves the media until two webs pass the Media Sensor to measure the label length It then feeds the second web to the rest position Acomplete calibration moves the media and monitors the Media Sensor input to determine the voltage level associated with web only and the level associated with web plus media If no distinction can be made between these two voltage level readings the media type is set to continuous media After analyzing the data two webs are fed past the Media Sensor to measure the label length and then the second of these webs is fed to the rest position Prior to moving the media at all a check is made to determine if ribbon is present If
125. ler Main Platen 40462 Nut Expansion 8 10 22023 1 Plate Cutter Cover 44001 Screw Self Tap 3 5x11mm w 5mm Hex Head 22099M Assembly Toggle 44288 Washer 50 25 031 22249 Pin Pivot 44931 Ring E 218 22266 Stop Head Lift Spring 46091 Grommet for 1 25 x 625 cutout 22275 Screw 10 32 625 Flat Socket Cap 46105 Bearing Nylon 312 x 251 x 140 22302M Assembly Bracket Media Sensor 46128 Washer Flat Nylon 505 192 015 22304M Assembly Damper Cover 46224 Grommet Rubber 312 34 109 22305M Guide Media 46267 Plug Hole 5 dia x 125 thick 22391M Assembly Dancer Arm w Springs 46663 Assembly Upper Media Sensor 22444 Bar Toggle 46664 Assembly Lower Media Sensor 22808 Bar Peel Tear off 46896 Bushing 22825 Plate Upper Media Guide 48007 Side Plate 30007 9 Shaft Roller 48023 Bearing Rulon 313 x 190 x 375 30009 10 Roller 37 312 48404 Spring Torsion Inboard 30033 Guide Media Movable 48405 Spring Torsion Outboard 30104 Flange Ball Bearing 5 x 250 x 125 48411 Screw Thumb 30105 Bearing Nylon 312 x 251 x 078 48413 Standoff 30236 Screw 4 40 Q10019 Ring E Ext 250 30256 B Nut thumb Q10057 Washer 372 x 158 x 032 30296 Cover Media Take up Sensor 30307 Flag Head Open 30353 Assembly Head Open Opto Switch 30392 004 Screw 6 32 25 30392 006 Screw 6 32 37 30392 008 Screw 6 32 50 30393 006 Screw 8 32 37 30402 006 Screw 6 32 37 30423 003 Screw Set 8 32 187 30494 Washer 32 119 062 30826 Plug Hole 30827 H
126. ll 48001 Roller Platen Lower 140 11 48155M Assembly Media Rewind Spindle 140 Xill 48383M Plate Rewind 140 Xill QO 8 44 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists STEPPER MOTOR PULLEY REF 45189 5 40193 3 MAIN DRIVE BELT REF PN 07435 30336 2 30114 ad 46674 NOTE SPACERS MUST BE 2 GRN YELLOW POSITIONED ON BOTH SIDES 2 CS OF BELT 45189 5 a U 30265 90X ll 30265 140Xill 30265 170 22265 220 30914 47383M 90Xill 7 07435 48383 140Xill 30207 140Xill 30207 1 70Xill 47155M 90XiII 22207 220 m 48155M 140 46249M 170 22155M 220Xill 46383M 170Xill 22383M 220Xill REWIND VERSION x Ses N 40193 2 466737 BLK RED pi 2 47101 90 48001 140XilI 46001 1 170 30104 22001 1 220Xill 30247 30261 2 MEDIA REWIND OPTION ASSEMBLY 48452L Rev 2 Xill Series Maintenance Manual 8 45 Drawings and Parts Lists PRINTER MODEL Xill Series Printers Cutter Option Assembly PRINTER MODEL AII Xill Series Printers Cutter Option Assembly PART NUMBER DESCRIPTION QUANTITY 01155 Washer Lock 4 PART NUMBER DESCRIPTION QUANTITY 01660 Grease 40181
127. lly closed Close Printhead completely Printer stops and ERROR LED Flashes Head Open Sensor not detecting Position Flag or Flag not in the proper position Check Head Open Sensor and Flag for proper operation WARNING HEAD OVERTEMP Printer stops and ERROR LED Flashes Printhead element is overheated Printer resumes printing when the Printhead element cools to a normal operating temperature WARNING HEAD UNDERTEMP Printer stops and ERROR LED Flashes Printhead element is not hot enough to print properly Environment too cold for proper printing Relocate printer to warmer area ERROR CONDITION HEAD ELEMENT BAD Experiencing Print Quality Problems Printhead element is going bad To override this message 1 place JT in your format and then 2 JO to turn off the HEAD TEST Clean Printhead and test for proper printing Replace Printhead if necessary ERROR CONDITION CUTTER J AMMED Page 6 2 The Cutter blade is in the media path Xill Series Maintenance Manual Turn the Power OFF Remove the media reload the media and turn Power ON If the error condition still exists check Cutter Sensors and Control Board Replace if necessary 48452L Rev 2 SYMPTOM Troubleshooting Table 6 2 Error Messages Cont d DIAGNOSIS ACTION Printer stops and
128. n back over the Standard RS 232 Port Parallel Port Connector The following table shows the pin configuration and function of a standard PC to Printer Centronics Parallel cable Pin No Parallel Data Port Signal Description The nStrobe printer input has internal 3 3k ohm pull up resistors to 5V Ior 1 5mA and is designed to receive a signal driven open collector Vor lt 0 8V This pin is a signal from the host computer DATA inputs have TTL input characteristics with internal 3 3k ohm pullups and represent 1 TTL unit load or less The DATA inputs are positive logic with a HIGH voltage level corresponding to a logic 1 Pin 2 through Pin 9 DO through D7 respectively The nAck output is an active LOW pulse indicating that the printer is ready to accept data The active LOW state precedes BUSY by 7 microseconds nAck is driven open collector with a 3 3k ohm internal pull up The output sinks 7 mA to a Vor lt 0 4V The Busy output is active HIGH whenever the printer cannot accept data due to conditions such as Buffer Overflow Head Open Over Temperature and Media Error Busy is driven open collector with a 3 3k ohm internal pull up The output sinks 7 mA to a Vor 0 4V The PError signal is active HIGH whenever the printer is out of media or ribbon The Select signal function is determined by a configuration option which becomes active when the port is selected In the default condition Select is active HIGH whenever the
129. n this section Page Corrective Maintenance Functions eines 5 1 Tools e 5 2 Test Equipment Redg Ired ei 5 2 Optional Cutter Mod le se zu aint 5 2 ees o Qe RE ghe 5 2 CEE ARNO seein 5 4 Standard KST Printhead Replacement 5 9 Printhead AdJ0SUNM68DUS 5 11 Darkness 5 16 Media Tear Off Position Adjustment 5 17 Transmissive Media Sensor Position Adjustment 5 18 Reflective Media Sensor Adjustment 5 19 LCD Viewing AJIUSDQIIL ciini inet cates 5 20 Motor Balance orient 5 20 Take Label Sensor Aligntnent ci 5 20 Media Tracking Adjustments or rei eren un 5 21 Rewind Toro cen 5 21 Peel Off Mode 5 22 Spindle Adjustment and Maintenance 5 23 Tension Measurement Procedutre 5 23 Spindle Tension 2 5 23 Sti Le Wa MPS MAN CS aeo Renta eE EEE 5 23 Removing Main Logic Board
130. nded for use as a Command Prefix Format Prefix or Delimiter Character 484521 Rev 2 Xill Series Maintenance Manual 9 1 Appendices Setting Burn Temperature For IN SPEC Bar Codes All Direct Thermal and Thermal Transfer materials do not have the same Burn Temperature requirements The best way to check for the proper Burn Temperature 15 to use a Bar Code Verifier that actually measures bars spaces and will calculate the PCS ratio Without the assistance of a verifier your eyes and or the scanner to be used in the system are the best bet for picking the optimum burn setting What follows is a simple yet effective method for adjusting the burn temperature to print IN SPEC Bar Codes 1 Load media and Ribbon if required according to the appropriate Media Loading and Ribbon Loading Instructions found in the printer s User Guide Insure the Print Method is appropriately characterized for either Direct Thermal or Thermal Transfer 2 To print a label for evaluation use the following procedure A With Power OFF depress and Hold the FEED Key B Turn the Printer Power ON then release the FEED Key C The Printer will perform the Power ON Self Test POST calculate label length and then begin printing test labels 3 Print a label then depress the PAUSE Key The label will contain two Bar Codes as well as other printer information Normal Bar Codes are printed in a horizontal format as they feed out of the printer Rotated Bar Codes
131. nics are susceptible to static discharge The Technician must wear an anti static wrist strap connected to the printer chassis when removing and replacing the Printhead Turn the printer OFF and remove the Power Cord 2 Open the Printhead Assembly and remove the media and ribbon then close the Printhead Assembly 3 Properly connect yourself to an anti static protection system Locate the Spring loaded Printhead Mounting Screw on top of the Printhead Assembly 5 Loosen the Mounting Screw until it disengages from the Printhead CAUTION Use care to minimize any physical damage to the Printhead during the remainder of this procedure 6 Slowly open the Printhead Assembly The Printhead will be resting on the Platen while the rest of the Assembly pivots back out of the way 7 Spread apart the holding tabs on the sides of the Printhead Data Connectors to release the Data Cables 8 Grasp the outside edges of the Printhead Power Cable Connector and press down on the Power Cable Locking Tab 9 While maintaining pressure on the locking tab disconnect the Printhead Power Cable and remove the Printhead through the front of the printer 10 Prior to installing the new Printhead note the Resistance Value located on the right side of the new Printhead Label 11 Connect the Printhead Power Cable to the appropriate connector 12 Spread apart the holding tab on the top of the two data connectors and press the appropriate Pr
132. ntenance Calibration There are two different types of calibration that can be performed by the printer 1 Standard Calibration pressing the Calibrate key causes the 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 in out status which deter mines the print mode Thermal Direct or Thermal Transfer This form of calibration also occurs as part of the Sensor Profile and Media and Ribbon Calibrate procedures described below 2 Media and Ribbon Sensor Sensitivity Calibration using non continuous media Performing the Media and Ribbon 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 levels the printer then performs the standard calibration described above Changing the type of ribbon and or media may require this calibration process to reset 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 Media and Ribbon Sensor Sensitivity 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
133. nter Diagnostics All LEDs turn ON simultaneously then turn OFF in sequence starting at the bottom through the following steps SRAM Test SRAM functionality test performed Option ROM Test Option ROM functionality test is performed The words Not Installed will be added to the display if no ROM is used Printhead Test Printhead is checked for proper operation Processor Test Processor functionality test is performed The word Failed will be added to the display if the test does not pass E Cubed Test E Cubed functionality test is performed The word Failed will be added to the display if the test does not pass EEPROM Test EEPROM functionality test is performed The word Failed will be added to the display if the test does not pass Memory Card Test Optional Memory Card functionality test is performed The words Not Installed will be added to the display if no card is present The MF command causes the rinter to feed to the first web or abel length calibrate Ribbon and Media Sensors set Label Length and feed one or more labels PRINTER READY X X MB VX X X Printer Ready For Operation Refer to the Configuring to the Application Section to set specific parameters NOTE Refer to the Troubleshooting
134. nters Physical SIZ6 55i 2 5 Electrical Reguirements mad tea 2 5 Environmental Operating Range intei 2 5 Printer OpLOS 2 6 Communication Specifications esent 2 6 Serial Data Communications Interface Overview 2 6 Communication Buffer 2 6 Standard Serial Communication Connector 2 7 Rear Panel Interface Connections 2 8 Serial Communication Signal Levels 2 9 Communication Code eese eee 2 9 Parallel Data Communications Interface Overview 2 10 Parallel Port Connector essere 2 10 Optional Interface 8 eere 2 10 Front Panel Controls and Indicators 2 11 Front Panel Status Indicators 2 11 Front Panel Keys saan 2 12 Liquid Crystal Display and Membrane Keys 2 13 This section of the manual is intended to supplement the printer s user s guide by providing additional information to aid the service technician in troubleshooting and maintaining the printer Printer Specifications Media Handling e Tear Off mode Labels are produced in strip
135. ocate the Lower Media Sensor assembly a spring clip holding a circuit board under the Rear Idler Roller 2 Position the Sensor by sliding it in its slot so that the two brass colored infra red emitters are centered under the Upper Sensor 3 Gently pull wires out as required Wires should have a little slack NOTE If the Sensor is being moved inward and a large loop of wire results remove the cover from the Electronics side of the printer and gently pull the wires through It is important that the wires be properly clamped so that they do not rub any drive belts Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance UPPER MEDIA SENSOR ADJUSTMENT MEDIA SENSOR Figure 5 7 Lower Media Sensor Position Adjustment Reflective Media Sensor Adjustment 48452L Rev 2 The Reflective Media Sensor is placed into operation for those applications where the sensing of Black Marks on the underside of the media is desired For the XilI Series printers the position of the Reflective Media Sensor is fixed against the Mainframe and has no adjustment Refer to the printer user s guide to configure the printer for operation with either the Reflective Media Sensor or the Transmissive Media Sensor previously discussed Xill Series Maintenance Manual Page 5 19 Corrective Maintenance LCD Viewing Adjustment The brightness of the Liquid Crystal Display LCD may be adjusted for optimal
136. of this manual Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance 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 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 sequence 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 correctly entered it need not be entered again unless you leave and re enter th
137. older media Sensor PCB 30909 Handle Head 30956 Washer Flat 207 x 146 x 030 31493M Motor DC Stepper N N N JN N N N N N O aila 4 N N 8 18 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists REF 22039 COVER 30236 1 x I 1 1 1 1 1 1 144288 2 144931 1 1 1 22305M 004 30392 P UPPER MEDIA SENSOR SUB ASSEMBLY 22302M 22444 30392 004 004 30392 30392 004 30909 07229 30423 003 30392 008 06268 2 40154 30956 9 wes 7 9 30392 004 30956 7 30392 004 30392 004 RE vp LA kg Le pa MoS Ari ny ivy It 4 M 1 1741 sii Mel XA B yg n Fe fe 30392 004 Q10057 30307 5 46896 2 30392 008 44001 2 30296 30392 006 30007 9 30392 004 30826 2 30393 006 4 220 PRINT MECHANISM ASSEMBLY PG 1 OF 3 8 19 Xill Series Maintenance Manual 48452L Rev
138. on such as storing data as a graphic image or a font Line Printer Mode When in line printer mode any data that is received prior to the start of format command is formatted and printed except control commands The number of characters per line and the orientation of the text are all controlled by a ZPL command The default line printer mode is OFF and it must be activated to make text print When line printer mode is disabled the printer will ignore data prior to the start of format command except for control commands Control Commands A Control command may be received at any time It may be between formats or during a format The Control command will end the current Format command but has no other affect on the format Control commands may perform one of several functions i e storing or deleting graphics fonts or formats or printing informational labels 48452L Rev 2 Xill Series Maintenance Manual 7 11 System Repair Format Commands All Format commands in ZPL have a default value for each parameter These values are related to either the overall format or a field within the format The input data is searched until a start of format command is found It then copies the default format and field definitions to the current format and field definitions As each command is decoded the current format and field definitions are updated accordingly Any ZPL command that affects both the current field or format and
139. ons 4 Remove the hex nut holding the ground lead from the Power Entry Module to the printer chassis 5 Refer to Figure 5 15 Remove the 2 screws at the top and center right hand corners of the metal mounting plate directly behind the Main Logic Board 6 At the rear of the printer remove the 3 Phillips screws holding the rear panel to the back of the printer 7 Slide the Main Logic Board and Rear Panel Assembly out and away from the printer 8 Remove the AC Power Supply Assembly by removing the 5 hex nuts and 2 spacers which hold the Assembly against the mounting posts The black heat conduction pad need not be removed 9 Perform the AC Power Supply Assembly Installation Procedure below being very careful with all cables Installing the AC Power Supply Assembly Follow the procedure below to install the XiII Series DC Power Supply Assembly 1 Refer to Figure 5 15 Position the cables out of the way while placing the AC Power Supply Assembly into the printer Insure the heat conduction pad is in position 2 Refer to Figure 5 15 Install the 5 hex nuts and 2 spacers which hold the AC Power Supply Assembly against the printer chassis Insure the plastic spacers are installed on the two left posts 3 Slide the Main Logic Board and Rear Panel Assembly into the printer Refer to Figure 5 15 Install the 2 screws at the top and center right hand corners of the metal mounting plate directly behind the Main Logic Board
140. ons Perform Spindle Adjustments Improper ZPL Format Correct ZPL Format Misregistration and misprint of 1 to 3 labels 48452L Rev 2 Media was pulled when motor was not moving Open and close the printhead so it calibrates to find the label length Printer that is in Rewind or Peel Off mode was powered ON without media or backing around rewind spindle Load media correctly for Rewind or Peel Off Mode Misadjusted Media Sensor Xill Series Maintenance Manual Place Media Sensor in proper position Page 6 5 Troubleshooting SYMPTOM Table 6 3 Troubleshooting Cont d DIAGNOSIS ACTION Vertical drift in top of form registration A plus or minus imm vertical drift is allowable due to the tolerances of the mechanical parts and printer modes Use Top Position setting to reposition the top of form Label jam in rear area of the Printhead Upper Media Plate Snap Plate needs cleaning Clean Upper Media Plate Snap Plate Print label feeds out and then backfeeds immediately resting under the Printhead Printer set for Cutter Mode with no Cutter installed Set correct print mode Changes in Parameter Settings did not take effect Parameters are set incorrectly Cycle the power Reload factory defaults Then set parameters and save permanently If problem continues there may be a problem on the Main Logic Board Replace t
141. operator interface or a ZPL command may pause the printing process This keeps the print process from printing queued labels but does not stop the feed or calibration functions Once the print process is taken out of pause the first label queued is printed Print Speed The media speed for the label is determine by the APR ZPL command Speeds of 2 inches sec to 12 inches sec are available depending on the specific Xill printer under discussion Media Tracking All label images are printed completely After the entire image is printed the printer seeks the next web for non continuous media This is done by feeding up to twice the known label length while looking for a web If no web can be detected while feeding twice the label length an Out of Paper error will occur Once the web is detected the printer feeds the web to the correct position based on the print mode and related ZPL commands Continuous media is assumed to have the end of the label under the printhead after feeding the full label length The location of the label image on the physical label stock is controlled by the LCD menu and ZPL The LABEL TOP and LEFT SHIFT parameters move the image up and down or left and right without affecting media position relative to the printer Print Modes The print mode determines the media motion and the rest position of the media relative to the printer The print mode is selected by either a ZPL command or the LCD menu The T
142. ort is always retransmitted by the primary port The Command Processor The data received by the primary port is processed in several steps The first step is to remove all CR LF NULL XON and XOFF characters from the data stream The next step is to convert all command tilde format caret and delimiter comma prefixes to DLE RS and US characters respectively The SI STX and ETX characters are also expanded into a field separator command a start of format command and an end of format command respectively The command is then either processed or placed in the label generator s input buffer There are three types of commands in ZPL e Immediate commands start with a DLE character These commands are processed as soon as they are received All other commands are placed directly into the label generator s input buffer e Format commands start with an RS character These commands are only recognized when they are placed between the start of format and the end of format commands e The third type of command starts with either a DLE or an RS character These commands need not be a part of a format but are processed by the label generator along with the format commands in the order received 7 10 Xill Series Maintenance Manual 48452L Rev 2 System Repair Label Generator The label generator interprets the data found in its input buffer and either stores it for later recall or generates a set of la
143. ossible for good print quality Incorrect Printhead pressure or balance Set the pressure to the minimum needed Refer to the Printhead Balance Adjustment and Printhead Pressure Adjustment procedures Media not feeding properly it is walking from side to side Xill Series Maintenance Manual Make sure the media is snug by adjusting the media guide 48452L Rev 2 Troubleshooting SYMPTOM Table 6 3 Troubleshooting Cont d DIAGNOSIS ACTION Continued wrinkled ribbon Strip Plate needs adjusting Perform adjustments Ribbon Supply Spindle tension needs adjusting Perform adjustments Printhead shaft needs adjusting using the Wear Plate Perform adjustments Printhead needs realigning with Platen Roller Perform adjustments Ribbon Take Up Spindle tension needs adjusting Perform adjustments 3 point mount for Ribbon Supply Spindle needs adjusting Perform adjustments Ribbon Supply Core slipping Spindle Blades need adjusting Perform adjustments Light printing or no printing on the left or right side of the label Printhead needs balancing Adjust balance See Printhead Balance Adjustment procedures Printhead shaft needs adjusting using the Wear Plate Perform Wear Plate Adjustment Mis registration Skips Labels Misadjusted Media Sensors Perform Media Sensor Adjustments Improper Spindle Tensi
144. ostic tests are illustrated Section 4 Preventive Maintenance discusses the recommended cleaning procedures for the printer and the printhead Recommended cleaning agents and a preventive maintenance schedule are specified Section 5 Corrective Maintenance provides disassembly replacement and reassembly instructions for the XiII printers Required tools and test equipment are specified Adjustment procedures are provided along with the required tensions torques and tolerances Instructions on AC power fuse replacement are also contained in this section Xill Series Maintenance Manual Page 1 1 Introduction Section 6 Troubleshooting contains troubleshooting tables showing symptom diagnosis and action columns to assist the repair technician in quickly locating and repairing a printer fault Example labels illustrate several common mechanical misalignment conditions and the best methods of adjustment Section 7 System Repair provides in depth explanations of the operating and testing features of the XiII Series printers Section 8 Mechanical Drawings and Parts Lists contains mechanical assembly drawings and parts lists Parts and assemblies common to all Xill Series models are illustrated along with their maintenance part numbers Those parts that are specific to a particular model are individually identified Section 9 Appendices contains reference material which may assist the technician when installing and maintaining the pr
145. ous and set printer mode direct thermal or thermal transfer Liquid Crystal Display and Membrane Keys The two line sixteen character liquid crystal display LCD and five membrane keys below it are used to program print and communication parameters and to display operator messages The keys and their functions are BLACK OVAL KEYS The function of the two black oval keys depends on the parameter being displayed They are normally used to scroll through multiple setting choices or increase decrease variable parameters such as burn temperature PREVIOUS Scrolls back to the previous parameter NEXT SAVE Scrolls forward to the next parameter SETUP EXIT Enters and exits the Configuration Mode 48452L Rev 2 Xill Series Maintenance Manual Page 2 13 Xill Series System NOTES Page 2 14 Xill Series Maintenance Manual 48452L Rev 2 3 Printer Diagnostics In this section Page Power ON Self Vest eoo in 3 1 Printer Self T 3 2 3 2 CANCEL key Self Test sansaq deside bye 3 3 PAUSE key Self aq Ert un 3 4 FEED key Self Test e 3 5 Communications Diagnostics Test 3 6 FEED key and PAUSE Key i 3 6 PAUSE key and CANCEL Key 3 8 FEED key and CANCEL kKey
146. over Sensor Wire 02252 Ring Crescent 250 40154 Pin Eccentric 06268 Washer Lock 6 40248 Plate Shaft Wear 07229 Washer Curved 49 x 33 x 0075 40305RM Guide Media 140 ill 30007 1 Shaft Roller 90Xill 40355M Assembly Platen Pulley 30007 3 Shaft Roller 140 Xill 44001 Screw Self Tap 3 5x11mm w 5mm Hex Head 30007 6 Shaft Roller 170 Xill 46001 1 Roller Main Platen 170 11 30023 Plate Cutter Cover 46091 Grommet for 1 25 x 625 cutout 30033 Guide Media Movable 46105 Bearing Nylon 312 x 251 x 140 30104 Flange Ball Bearing 5 x 250 x 125 46196M Motor DC Stepper 30105 Bearing Nylon 312 x 251 x 078 46224 Grommet Rubber 312 34 109 30236 Screw 4 40 46267 Plug Hole 5 dia x 125 thick 30256 B Nut thumb 46302 4 Assembly Bracket Media Sensor 170Xill 30266 Stop Head Lift Spring 46305M Guide Media 170 11 30296 Cover Media Take up Sensor 46444 Bar Toggle 170 11 30305RM Guide Media 90 Xill 46663 Assembly Upper Media Sensor 30307 Flag Head Open 46664 Assembly Lower Media Sensor 30353 Assembly Head Open Opto Switch 46691 1M Assembly Dancer Arm w Springs 90 Xill 30392 004 Screw 6 32 25
147. pare the tension reading on the springscale with the appropriate force value provided in Figure 5 12 Repeat the adjustment procedure until the correct tension is obtained Spindle Maintenance Periodic spindle maintenance is not required on the 5 printers u WARNING DO NOT apply lubrication to any of the spindles in the XiII Series printers 48452L Rev 2 Xill Series Maintenance Manual Page 5 23 Corrective Maintenance ALIGN ALL THREE SECTIONS BEFORE INSTALLING RIBBON CORE RIBBON SUPPLY SPINDLE ASSY Xill 140Xil 220 SPINDLE FORCE 90 1 17041 GRAMS RIBBON SUPPLY F1 450 50 450 50 500 50 600 50 RIBBON TAKEUP F2 450 50 450 50 550 50 630 50 MEDIA SUPPLY 50 300 50 300 50 300 50 MEDIA REWIND 1450 100 1450 100 1650 100 1830 100 ATTACH POLYESTER FILM STRIP TO RIBBON CORE WITH TAPE MEDIA SUPPLY SPINDLE ASSY MEDIA CORE DETAIL A x CE SE SCREWS 1 551 1 or 2 LOOSEN THE SET SCREWS ON THE ADJUSTING NUT TURN THE NUT IN OUT TO INCREASE DECREASE z THE FORCE AFTER ADJUSTMENT MEDIA REWIND SECURE THE NUT TO THE SHAFT SPINDLE ASSY WITH THE SET SCREWS Figure 5 12 Spindle Tension Adjustments Page 5 24 Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance Removing the Main Logic Board The XilI Series Main Logic Board may require removal when replacement is nec
148. pply optional 90 48150M Spindle Ribbon Take up 140Xill 48151M Spindle Ribbon Supply 140 ill 48253M Spindle Media Supply optional 140 Xill Ss fs S S SE SS 8 14 Xill Series Maintenance Manual 48452L Rev 2 Drawings and Parts Lists PART OF 46813M 47253M 90 48253M 140X ll 46253M 170 30395 012 OPTIONAL MEDIA 30466 SUPPLY SPINDLE SEE MEDIA SUPPLY HANGER ASSEMBLY SEE SPECIFIC PRINTER PRINTHEAD SUPPORT ASSEMBLY DRAWING hs 06250 _ 40027 Te 30106 E 47151M 90 48151M 140 46151M 170 c 40490 1 90 40490 2 140 40490 3 170 47150 90 46813 48150M 140 46150M 170 140 amp 170Xill PRINT MECHANISM ASSEMBLY PG 2 OF 484521 Rev 2 Xill Series Maintenance Manual 8 15 Drawings and Parts Lists PRINTER MODEL 90 140Xill 170 Xill Print Mechanism Assembly Page 3 of 3 PRINTER MODEL 90Xill 140Xill 170 Xill Print Mechanism Assembly Page 3 of 3 PART NUMBER DESCRIPTION QUANTITY 01130 Nut 6 32 Hex Washer Head PART NUMBER DESCRIPTION QUANTITY 01155 Washer Lock 4 46015 Foot A 01159 Washer Lock 6 46035 1 Base Prin
149. r Printer locks up while running Power On Self Test Main Logic Board failure Replace Main Logic Board CHECKSUM FOR ROM SET n INVALID A Program ROM checksum is incorrect Turn the printer OFF and then ON If the fault reoccurs replace the Program ROMs EEPROM CHECKSUM INVALID 48452L Rev 2 EEPROM checksum is incorrect Xill Series Maintenance Manual Replace the Main Logic Board Page 6 1 Troubleshooting SYMPTOM Table 6 2 Error Messages DIAGNOSIS ACTION ERROR CONDITION PAPER OUT No media loaded or incorrectly loaded Load media correctly Printer stops and ERROR LED Flashes Misadjusted Media Sensor Check Media Sensor Position and Sensitivity Printer set for Non Continuous Media but Continuous Media is loaded Install proper Media or reset printer for current Media type WARNING RIBBON OUT Printer stops and ERROR LED Flashes For Thermal Transfer Ribbon not loaded or incorrectly loaded or Ribbon Sensor not sensing ribbon that is correctly loaded 1 Load ribbon correctly 2 Insure Snap Plate is properly installed 3 Perform Media and Ribbon Sensor Calibration WARNING RIBBON IN For Direct Thermal Ribbon loaded unnecessarily Remove Ribbon ERROR CONDITION HEAD OPEN Printhead is not fu
150. r Type Configuration or ZPL II Print Method Configuration or ZPL II Print Width Configuration or ZPL II Label Length Calibrate key configuration or ZPL II Maximum Length Configuration or ZPL II Host Port Configuration Baud Configuration Data Bits Configuration Parity Configuration Stop Bits Configuration Host Handshake Configuration Protocol Configuration Network ID Configuration or ZPL II Control Prefix Configuration or ZPL II Format Prefix Configuration or ZPL II Delimiter Char ZPL Mode Configuration or ZPL II Configuration or ZPL II Media Power Up Configuration or ZPL II Head Close Configuration or ZPL II Backfeed Label Top Configuration or ZPL II Configuration or ZPL II Left Position Configuration or ZPL II Head Test Count Configuration or ZPL II Head Resistor Configuration or ZPL II Verifier Port Configuration or ZPL II Applicator Port Configuration or ZPL II Web S Configuration or ZPL II Media S Configuration or ZPL II Ribbon S Configuration or ZPL II Mark S Configuration or ZPL II Mark Med S Configuration or ZPL II Media Led Configuration or ZPL II Ribbon Led Configuration or ZPL II Mark Led Configuration or ZPL II LCD Adjust Configuration Modes Enabled
151. resent a web to the Media Sensors When monitored the Web Sensor value will be greater than the Media Sensor value The printer then automatically reconfigures the Media Type to Continuous Sensing Tag Stock with a Notch The Media Sensors can be calibrated using no backing however this may allow one label length to feed during a paper out condition as if a label were missing from the liner This may occur if the adjusted level of the Media LED allows no backing condition to achieve 3 volts A better method of calibration is to use a strip of standard label liner to adjust the sensor sensitivity The only drawback to this method is that a Paper Out condition will result if the hole or notch is present at the Media Sensor Web Value exceeds the Media Sensor Value after an error condition See the previous NOTE regarding a Paper Out condition Direct Thermal Printing During the Ribbon LED adjustment if there is no ribbon in the printer no difference in the Ribbon In and Ribbon Out values is detected During direct thermal printing the printer continues to monitor the Ribbon Sensor input and will generate a Ribbon In error and stop printing if the Ribbon Sensor value increases during the printing process Page 5 8 Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance Standard KST Printhead Replacement Refer to Figure 5 32 while performing the following procedure CAUTION The printer electro
152. ribbon is present the printer is set to thermal transfer mode If the ribbon is not present the printer is set to direct thermal mode e The final calibration mode is the same as the complete calibration mode with one exception The Media Sensor values are printed on the media as a bar graph This allows the operator to analyze the same data the calibration task is analyzing Corrections can be made with a ZPL command to any of the values set by automatic calibration The values set by calibration are applied to any label that is then printed Since label images may already exist the images may appear to be truncated Media calibration always functions and may clear error conditions that prevented media movement As long as the printhead is closed a media calibration may be performed Ribbon and paper error conditions are cleared by calibration unless the Media Sensor never detects paper Print Error Conditions There are several error conditions that affect printing Some actually stop the printing process completely while others are only reported to the operator or host system For example a head open error condition stops all media movement while the head under temperature error has no effect on media movement Some error conditions must be corrected before the printer will feed or print labels again 48452L Rev 2 Xill Series Maintenance Manual 7 15 System Repair Paper Out Ribbon Out or Head Open A paper out ribbon out or hea
153. rs 6 Reload ribbon and or media close and latch the Printhead restore power if necessary and run the PAUSE Key self test to check print quality PRINTHEAD LABEL PLATEN PEEL TEAR AVAILABLE ROLLER BAR SENSORS Figure 4 1 Cleaning a Typical Printhead 48452L Rev 2 Xill Series Maintenance Manual Page 4 3 Preventive Maintenance Cleaning the Upper Media Guide Plate In the event of a label jam the Upper Media Guide Plate Snap Plate can be removed and cleaned following these steps 1 open the printhead to its fully open position rotate the lever counterclockwise The printhead pivots to almost vertical From the front of the printer pop up the front of the Snap Plate using your fingernail or a flat blade screwdriver Lift the front edge of the Snap Plate while pulling it up and out of the mechanism Clean the Snap Plate Remove any stuck on labels and remove all adhesive residue using the using swabs soaked in cleaning solvent alcohol Replace the Snap Plate by placing the back legs in the openings in the Main Media Guide while sliding it to the rear of the openings and snapping it down into position Refer to Figure 4 2 below NOTE Incorrect installation may disable the Ribbon Sensor or contribute to print quality problems Page 4 4 Figure 4 2 Typical Upper Media Guide Plate Snap Plate Xill Series Maintenance Manual 48452L Rev 2 Preventive Maintenance Recommended Preventive
154. rts Lists FRONT SURFACE OF PRESSURE PLATE 22180 SHOULD BE FLUSH TO BELOW ENDS OF MTG BRKT 22003 P DETAIL SCALE 2 1 30392 004 30392 004 2 2 01159 2 48289 22181 30781 WRAP GROUND STRAP AS SHOWN N 22191 BN 30314R ADHESIVE M THIS SIDE ONLY Nis 30007 8 a 06268 4 30392 004 4 22013 30009 9 22017 2 Q06020 30402 006 AROUND 3 2 2 N O Bo 49640 021 Asg4g4 M 6 8 22602 49640 026 CABLES WES 01153 XS 30391 003 1 a gt 1 POSITION RIBBON SENSOR 46665 TAB NOT 1 2 3 4 TO BE FLUSH WITH TOP EDGE OF PIVOT BAR XI 4 48162 GAP 010 030 22640 020 lt S 46481 1 2 2 PRINTHEAD DATA CONNECTOR TABS MUST SNAP OVER CONNECTOR EG 3 SCREW TIGHTENING TORQUES UNLESS p KF 40194 2 OTHERWISE SPECIFIED TO BE 10 12 IN LBS re S OTHER VALUES APPEAR IN BOXES IN S 25 40193 2 IN LBS X Y 22002 22640 025 30392 004 2 220Xill PRINTHEAD SUPPORT ASSEMBLY 48452L Rev 2 Xill Series Maintenance Manual 8 31 Drawings and Parts Lists PRINTER MODEL All Xill Series Printers Media Supply Hanger Assembly PART NUMBER DESCRIPTION QUANTITY 22152M Kit Hardware 1 22153M Assembly Media Supply Hanger 220Xill 22395 Guide Outer Edge 46153M Assembly Media Supply Hanger 170 11 47153M Assembly Media Supply Hanger 90Xill 48153M Ass
155. s Rewind mode Requires the Media Rewind option Labels are rewound internally onto a 3 inner diameter cardboard core e Peel Off mode Requires the Media Rewind option Labels are dispensed and peeled from the liner which is rewound within the printer e Cutter mode Requires the Cutter option Media is cut into individual labels after printing Applicator mode Requires the Applicator Interface option Labels peeled from the liner and presented for use by an external applicator device 48452L Rev 2 Xill Series Maintenance Manual Page 2 1 The XilIl Series System Operator Controls PAUSE FEED CALIBRATE and CANCEL Keys PAUSE pauses the printer and clears errors e CANCEL cancels the current batch FEED feeds a label CALIBRATE sets label length Liquid Crystal Display LCD with 5 Membrane Keys PREVIOUS displays the previous selection e NEXT SAVE displays the next selection e SETUP EXIT enters and exits the Configura 2 unlabeled Black Oval Keys change LCD tion Mode Settings The LCD and Membrane Keys are used to Set communication parameters Enable disable media and ribbon sensor diag J i nostics e Set printing parameters Ae mediamode Enable disable communication diagnostics Zebra Programming Language ZPL If ASCII data commands provide the following features e Downloadable graphics scalable and bitmap e n spec OCR A and OCR B
156. s place The Serial Loopback Connector is a 25 pin D Type DB25P Male style with the following pins tied together e pins 2 and 3 e pins 6 and 20 e pins 13 and 14 e pins 16 and 19 Solder Side of Connector The Parallel Loopback Connector is a standard 36 pin parallel connector mounted to a small Circuit Board This connector is available from Zebra Technologies as Part 44680 For each of these Diagnostic Tests the printer will Transmit the Test Label Format out of the Data Interface Connector to the Loopback Connector The Loopback Connector passes the Test Label Format back to the printer as Receive Data and the Test Label is printed PAUSE Key Loopback Test This test demonstrates the media movement capabilities of the printer and provides a test label to view while making print quality adjustments 48452L Rev 2 With the Loopback Connector in place press the PAUSE key while turning the AC Power Switch ON Xill Series Maintenance Manual Page 3 9 Printer Diagnostics After the Power On Self Test the printer will print 500 Head Test labels Each label will backfeed prior to printing and feed to the rest position after printing A serialized number will print on each label for label comparison purposes if required See the label example in Figure 3 6 below The PAUSE key can be used to stop and restart the printing operation 1234567898012345678901234567890120345678901234567898
157. s ready to receive data Pin 6 DSR RS 232 Data Set Ready This is a control input to the 5 from the host The printer monitors this lead to determine if the host is ready to receive data status from the printer Pin 7 Signal Ground for RS 232 This lead serves as the voltage reference between the interfaced devices and is DC coupled to Frame Ground inside the printer Pin 9 5VDC Source 750mA maximum Pin 11 RS 422 RS 485 Signal Ground Reference Pin 13 RS 422 RS 485 Data Input B Pin 14 RS 422 RS 485 Data Output B Pin 16 RS 422 RS 485 Data Input Pin 19 RS 422 RS 485 Data Output A Pin 20 DTR RS 232 Data Terminal Ready This lead is a control output from the XilI Series printer to the host When the DTR control line from the printer is active positive voltage the host is allowed to send data to the printer When DTR is inactive negative voltage the host may not send data to the XilI Series printer This condition occurs when the printer is configured for DTR DSR hardware handshaking and the communication buffer is within 256 characters of its capacity Pins 5 8 10 12 15 17 18 and 21 25 are not used and are unterminated 48452L Rev 2 Xill Series Maintenance Manual Page 2 7 The XilIl Series System Rear Panel Interface Connections PARALLEL INTERFACE CONNECTOR DB 25 SERIAL INTERFACE CONNECTOR RS 232 Connector DTE Rear Panel DB 25
158. sition As with the other adjustments Parallelism and Wear Plate adjustments are interrelated Adjusting one may have an effect on the position of the other Excessive toggle pressure will lead to increased Printhead wear and decreased Printhead life Increased Printhead life is possible by combining minimum toggle pressure and optimum Printhead position over the Platen Roller Printhead Parallelism Adjustment This adjustment is performed in conjunction with the Wear Plate Position Printhead Position and Printhead Pressure Adjustments Adjusting the Printhead Parallelism squares the Printhead in reference to the media Refer to Figure 5 4 for location of adjustment screws used in the following procedure 48452L Rev 2 Xill Series Maintenance Manual Page 5 11 Corrective Maintenance Printhead Parallelism Test 1 Prior to starting this test insure the installed media is squared with the Tear Off Bar 2 When the printer begins printing PAUSE Key Self Test labels refer to the user s guide and adjust the Darkness for a clear presentation of all lines on the test label 3 The uppermost line on the test label should be parallel to the top edge of the label within a tolerance of 0 020 4 Ifthe print lines are not parallel with the top of the label proceed to the Printhead Parallelism Adjustment If parallelism is within tolerance proceed to the Wear Plate Position Adjustment Printhead Parallelism Adjustment Refer to
159. tenance Manual 48452L Rev 2 Troubleshooting Unacceptable Label Darkness Properly Set Iii Printhead Too Far Back rl lili i Breakup on Trailing Edges AM Bet of Bars Opposite the 18234567892 Direction of Movement Black is Splotchy Printhead Needs to Come Forward On Both Sides Toggles Balanced Equal Pressure On Left and Right Sides Unacceptable Label Darkness Properly Set i Ir pp li Printhead Way Too Far Back 4 Breakup on Trailing Edges DAS cri Hi of Bars Opposite the SR bs Direction of Movement Black is Splotchy Printhead Needs to Come Forward On Both Sides Toggles Balanced Equal Pressure On Left and Right Sides 48452L Rev 2 Xill Series Maintenance Manual Page 6 11 Troubleshooting 3 lt 52788012345678901234567880123455 8901234567 Page 6 12 Xill Series Maintenance Manual Unacceptable Label Darkness Properly Set Printhead Position Correct on Right Side Way Too Far Back on Left Side Noisy Printing Breakup on Trailing Edges of Horizontal Bars Splotchy on Left Side Toggles Balanced Equal Pressure On Left and Right Sides Unacceptable Label Darkness Properly Set Printhead Position Correct on Left Side Way Too Far Back on Right Side Noisy Printing Breakup on Trailing Ed
160. ter CE 170 01822 Nut 4 40 46102 1 Panel Rear 06319 Screw Lock Hex 10 32 37 46238 Panel Mounting 07435 Screw Lock Hex 6 32 37 46254 Plate Cover Cutter 07696 Screw 4 40 31 46325 4 Spacer 6 32 08754 Eye 183 x 157 x 187 46325 5 Spacer 6 32 22416 Standoff 4 40 Hex 46392 006 Screw Truss Head Phillips 6 32 x 38 30236 Screw 4 40 46646 Spacer Locking PCB 5 16 x 125 30253 Plate Options Cover 46647 Spacer Support PCB 5 16 30391 003 Screw 4 40 19 46648 Assembly Cable Ground 30393 006 Screw 8 32 37 47035 1 Base Printer CE 90 XIII 30405 006 Screw 1 4 20 38 Media Hanger Mounting 47268 Plate Cover 30406 006 Screw 4 40 38 48035 1 Base Printer CE 140 Xill 30407 004 Screw 6 32 25 49013 Cover Memory Card PCMCIA 30466 Washer N N o O N 49036 1 Cover PCB Option 49285 Pad Insulation AC Power Supply 49286 Pad Insulation DC Power Supply 49313 Spacer Top AC Power Supply 49605 009 Assembly Cable Power Supply 49669 Switch Power Entry 49673 Assembly Power Entry w Fuse amp Gnd Wire 49699 01 Assembly Cable Short Brown 49699 06 Assembly Cable Short Blue 4970
161. the actual Printhead movement when switching adjustments from one direction to the other Enter the configuration mode and decrease the Darkness until the PAUSE Test labels a charcoal gray color Carefully look at the PAUSE Test labels for streaks flouring and other print quality problems If required adjust the hex head screws and observe if print quality problems are corrected Enter the configuration mode and increase the Darkness until the PAUSE Test labels are printed at optimum resolution and contrast Since Printhead parallelism Wear Plate position and Printhead position are interrelated carefully look at the test labels for changes in these settings and adjust if necessary Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance Printhead Pressure Adjustment Printhead Pressure is the fourth of the four interrelated adjustments Using lower Printhead Pressure and Darkness settings can extend Printhead life If printing is too light on one side or if thick media is used Printhead Pressure may require adjustment Refer to Figure 5 4 for the location of the Pressure Toggles The 90XiII printer uses only one toggle which should be positioned over the center of the media width The 140XilI 170XiII and 220XiII printers have two toggles These toggles are typically positioned at the 1 4 and 3 4 positions across the width of the media If the media is sufficiently narrow that both toggles will not fit with
162. the code itself The Program ROMs are operational when the calculated CRC value matches the CRC value stored at the end of the ROM memory Upon successful completion of the ROM test the Data LED is turned OFF Should the CRC test fail the system will not advance beyond this test 48452L Rev 2 Xill Series Maintenance Manual 7 1 System Repair DRAM Test This test takes less than 5 seconds to execute DRAM Dynamic RAM operation is verified by reading and writing to the DRAM area The test is successful if one megabyte or more of DRAM is properly functioning The DRAM size is rounded down to one two four or eight megabytes available If the test finishes successfully then the entire DRAM space is initialized to zero After the memory is initialized the Pause LED is turned OFF The Configuration Label and the LCD Idle Message show the amount of memory recognized This value is compared to what was installed in the unit to verify that all of the installed memory is functioning correctly Should the DRAM test fail the system will not advance beyond this test The failed DRAM area will be read repeatedly until power is turned OFF Printer Type Test This test checks the settings of the Printer Type Selector Switches S1 and S2 located on the Main Logic Board When the Main Logic Board is installed S1 must be positioned according to the type of printer 52 must be in the zero 0 position Table 7 1 shows the valid settin
163. the program ROMs and any optional Font ROMs from the faulty Main Logic Board Carefully install the ROMs on the replacement board The label on each ROM specifies the chip location on the Main Logic Board 9 Perform the Installation Procedure below being very careful with all cables Installing the Main Logic Board Follow the procedure below to install the XiII Series Main Logic Board 1 Refer to Figure 5 13 and Table 5 1 and place Rotary Switch S1 in the proper position for the printer under repair Rotary Switch S2 must remain in the zero 0 position this procedure continues on page 5 24 48452L Rev 2 Xill Series Maintenance Manual Page 5 25 9 98 4 SIIS X AON 7106787 SWITCHES BUTTER MAIN LOGIC P OPTION DC POWER PCB LCD DISPLAY LOWER MEDIA SENSOR UPPER MEDIA SENSOR LOWER LABEL AVAILABLE SENSOR UPPER LABEL AVAILABLE SENSOR RIBBON SENSOR HEAD OPEN SENSOR z SS SIP J11 TO J10 ON DC POWER PCB PRINTHEAD PRINTHEAD ADDITIONAL STEPPER DATA POWER PRINTHEAD POWER MOTOR ALL Xill PRINTERS FOR 220Xill PRINTERS LCD DISPLAY CUTTER OPTION Figure 5 13 Circuit Board Location and Interconnection a ar eM lt oO 5 e 5 Corrective Maintenance 2 Ref
164. there are interactions between processes these interactions are described in detail Otherwise each operation functions independently so it is described separately Operator Interfaces The Front Panel Keys LCD and LEDs are the interfaces to the operator The LEDs provide a very quick overview of the printer s current status while the LCD provides more detailed feedback about the printer The keyboard supports features such as Pause Feed and Cancel independent of the LCD The other keys along with the LCD display allow the operator to configure the printer Front Panel Keys The operator has complete control over the printer with the front panel keys The black keys along with the LCD are used to configure the printer Refer to the Xill printer s user s guide for further details Liquid Crystal Display The LCD display shows several types of information The display starts with the printer ready message shown below For each format printed it displays the printing message with a label counter as shown below The LCD also indicates error conditions when they occur and allows the printer to be configured The message priority for the LCD display is therefore configuration messages first then error messages printing messages and finally the idle message Xill Series Maintenance Manual 48452L Rev 2 System Repair IDLE Message PRINTER READY 1024K Vx x x PRINTING Message PRINTING 000001 OF 99999
165. this manual and the label printer described therein are owned by Zebra Technologies Corporation 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 BAR ONE SCAN ONE TRACK ONE Zebra ZPL and ZPL II are registered trademarks WEDGE ONE and are trademarks of Zebra Technologies Corporation Centronics is a registered trademark of Genicom Corporation IBM is a registered trademark of IBM Corporation Windows is a registered trademark of Microsoft Corporation 1996 1997 Zebra Technologies Corporation All rights reserved 484521 Rev 2 TABLE OF CONTENTS SCOPE eRe eae te et Su 1 1 Related 1 2 Communication Specifications 2 6 Front Panel Controls and Indicators 2 11 3 Printer Diagnostics Power On Self Test 3 Printer Self Tests 3 2 Extended Printer Diagnostics x x 3 9 Tools v9 9 ox e modo dox 64964544 4 Cleaning The 7 4 2 Cleaning The 4 2 Cleaning the Upper Media Guide Plate 4 4 Recommended Preventive Maintenance Schedul
166. tinues to the next label format Turn Power OFF to Clear printer memory and start all over again Page 6 3 Troubleshooting SYMPTOM Table 6 3 Troubleshooting DIAGNOSIS ACTION Poor Print Quality Darkness set too low Reconfigure Darkness setting Incorrect Media and Ribbon Replace Media and Ribbon Printhead just replaced Insure Printhead is installed properly with no wires or debris caught underneath Printhead Adjustments incorrect Perform required adjustments Printhead Resistance not configured to proper value Reconfigure Printhead Resistance Truncated print no print or Feed button operates incorrectly while using non continuous media Maximum label length parameter set less than the actual label length Set the correct label length Printer that is in Rewind or Peel Off Mode was powered ON without media or backing around the Rewind Spindle Load media correctly for Rewind or Peel Off Mode Long tracks of missing print on several labels Wrinkled ribbon See Wrinkled Ribbon in this Table Print Element damaged Replace printhead Fine gray lines on blank labels at angles Wrinkled ribbon See Wrinkled Ribbon in this Table Wrinkled ribbon Page 6 4 Ribbon fed through machine incorrectly Load ribbon correctly Incorrect Burn Temperature Set the Burn Temperature to the lowest setting p
167. tor must visually inspect the LED operation Program ROM CRC Test The LCD displays the phrase ROM Test This is the same test as the one performed during the Power ON Self Test If the test fails the LCD displays the phrase FAILED and all testing stops DRAM Test The LCD displays the phrase DRAM Test This is a walking zero and walking one test a more complete test than the Power ON Self Test The DRAM is good when 1Mbyte passes the test The amount of functioning memory is displayed in the lower right hand corner of the display This value remains displayed throughout the testing cycle If less than 1 Mbyte passes the test the LCD displays the word FAILED and all testing stops 48452L Rev 2 Xill Series Maintenance Manual 7 19 System Repair 7 20 Keyboard Test The LCD displays Keyboard Test The test looks for pressed keys If any key is pressed the LCD displays FAILED Keyname and all testing stops SRAM Test The LCD displays the phrase 5 Test This is a walking zero and walking one test a more complete test than the Power On Self Test The SRAM is good when 128KB passes the test If less than 128KB passes the test the LCD displays the word FAILED and all testing stops Second Processor Test After passing the SRAM Test the SRAM is loaded with test code for the second processor The following eight tests are run by the second processor while the main processor waits 1
168. ued for printing The first label image is queued once for each label to be printed from that image The label generator then determines if additional label images are required These additional images are created one at a time by erasing old field data values and replacing them with new data values The new image is then queued as many times as required This process is repeated for all of the label images that are printed by the current format Once the labels are all queued the current image is either partially or fully erased for the next format If a field was defined as a host verify field the label generator will wait for the label image to be printed before continuing Once the image is printed the label generator returns the field header data and the field data value to the host through the communications process The parser is now ready to start searching for the next start of format command 7 12 Xill Series Maintenance Manual 48452L Rev 2 System Repair Memory Manager The label generator has several memory areas available A font ROM RAM space an optional ROM area and optional memory card are available for stored information The memory manager determines when these memory areas are available and what type of memory is available in each area The ROM area and read only memory cards must be pre programmed The format of the pre programmed data is determined by Zebra s PC based tools for generating these ROMs and cards D
169. uld any value be incorrect the factory default setting is loaded for that value and the LCD displays the phrase Failed for one second See the LCD Menu operation described later Printhead Test The LCD displays the phrase Print Head Test The printhead test determines the width and dot density of the printhead The printer operation is then adjusted accordingly This test actually checks rotary switches SWland SW2 and not the printhead itself 48452L Rev 2 Xill Series Maintenance Manual 7 3 System Repair Memory Card Test This test takes less than 5 seconds to execute The LCD displays the phrase Memory Card Test The CRCs for objects in the optional memory card are calculated and compared to the CRCs in the card All of the object CRCs must match for the option card to be valid Should the option card CRCs not match the display will show Not Installed and the system will pause for one second Test Completion The final action of the Power On Self Tet is to turn all of the LEDs OFF except the Power LED At this time the LCD displays the phrase Printer Ready Power Up Media Registration Once the Power On Self Test is complete if the Printhead Type Selector Switch 51 is not 0 the media is advanced to the proper rest position Continuous media is assumed to be at the proper rest position The motion required to place non continuous media at the rest position is determined by the media fe
170. uration Label as Media LED Duty cycle applied to the media amplifier to achieve the 3 volt output while viewing backing material only Ribbon LED Duty cycle applied to the ribbon amplifier to achieve the 2 volt output while viewing only the reflector ribbon out condition Reinstalling the ribbon and media and continuing the process media is feeding automatically adjusts the remaining values needed to function properly These values are determined as follows The Max Label Length setting is read and the printer begins feeding labels to determine the Web Sensor value This value is indicated on the Printer Configuration Label as Web Sensor the voltage level distinguishing backing only from label plus backing specified as a percentage of 5 volts Media Sensor the Paper Out value equal to a certain percentage of 5 volts This is programmed to be at 75 5 volts x 75 3 75 volts The Ribbon Sensor value is calculated This value is indicated on the Printer Configuration Label as Ribbon Sensor determined by taking 7596 of the minimum ribbon in calculation This is displayed as a percentage of 5 volts The Label Length is now measured by feeding one label This value is indicated on the Printer Configuration Label as Label Length the distance in dot rows between the rising edge of consecutive peaks as it crosses the web value minus 2 millimeters Page 5 6 Xill Series Maintenance Manual 4845
171. used If the original shipping container is not available a replacement can be ordered by contacting the Technical Support Department If other containers are used a procedure similar to the original factory packaging should be followed Remove all media and ribbon from the printer Enclose the unit in a protective dust proof bag and insure that the unit floats in an outer carton of shock absorbing material A Return Materials Authorization RMA number is required for all equipment being returned Contact Zebra Technologies Corporation s Technical Support Department to obtain an RMA number Equipment returned for service without prior authorization may be refused CAUTION Before packing the printer remove any ribbon and paper rolls from the media compartment DO NOT package the printer in a rigid container without utilizing shockmounts or shock absorbing packing material A rigid container will allow shock on the outside to be transmitted undamped to the unit and may cause damage Page 6 14 Xill Series Maintenance Manual 48452L Rev 2 7 System Repair In this section Page Printer ERIT a ER 7 2 Power ON 7 2 Power Up Media Registration 7 5 SEIT RS nsn sm 7 5 Automatically Executed uu ttti i roS hee 7 7 Operator Interfag eS_ _asuassusnunsnsisya nusqas 7 7 DH
172. viewing Refer to the LCD ADJUST configuration parameter in the printer s user s guide Motor Balance Adjustment DO NOT ADJUST THIS SETTING It is for technical use only The motor balance is set at the factory Call Zebra Technical Support with any questions Take Label Sensor Alignment The Take Label Sensor activates only when the Zebra is set to Peel Off Mode This mode requires the media rewind spindle option The media sensor pair is NOT installed on Zebra printers without this option Refer to Figure 5 8 for the location of the Take Label Sensor components When the beam is broken XiII printer will be inhibited from printing or feeding Peel Off Mode only It may however accept additional label formats if the buffer is not full There is no sensitivity adjustment for the Take Label Sensor If you encounter problems make certain the printer is set to Peel Off mode using the front panel display and that the sensors are aligned Sensors are aligned at the factory or when the media rewind spindle option is installed No adjustments are required after installation AVAILABLE SENSORS Figure 5 8 Take Label Sensor Location Page 5 20 Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance Media Tracking Adjustments Rewind Mode If the media walks from side to side tears or wrinkles against the Media Rewind Tracking Plate it will be necessary to adjust the Rewind Plate Assembl
173. wer Supply Assembly against the printer chassis 3 Refer to Figure 5 13 Carefully connect all the Ribbon Cables and Small Wire Cables to the proper connectors on the DC Power Supply Board Reconnect the AC Power Cord and the Signal Interface Cable Hold in the PAUSE Key while turning the AC Power ON Observe the printer Power ON Self Test and examine the test labels which print for proper print quality If necessary refer to the user s guide to configure the Darkness setting Reinstall the Left Side Panel The printer should now be ready for operation 48452L Rev 2 Xill Series Maintenance Manual Page 5 29 Corrective Maintenance Removing the AC Power Supply Assembly The XilI Series AC Power Supply Assembly may require removal when replacement is necessary or when installing various options in the field Follow the procedure below to remove the XilI Series AC Power Supply Assembly CAUTION The printer electronics are susceptible to static discharge Before proceeding it is highly recommended that the Technician wear an anti static wrist strap connected to the printer chassis 1 Be sure the printer is OFF and the AC Power Cord and Signal Interface Cable are disconnected 2 Remove the Left Side Panel of the printer by removing the Phillips Screws which hold it on 3 Refer to Figure 5 13 Unplug all Ribbon Cable Connectors and Small Wire Connectors from the Main Logic Board and AC Power Supply Board note their positi
174. x W x H x 114 mm 5 59 x 114mm xll4mm 8 8 x 114mm x 4 5 x 4 5 Ribbon Considerations Ribbon Specifications 140 170 220 Ribbon width To protect the printhead Maximum 3 54 531 6 89 8 66 from wear Zebra recommends using ribbon at m Minimum 0 79 1 57 2 0 4 33 least as wide as the media you are using Standard 2 1 media to ribbon roll ratio 984 ft 984 ft 984 ft 984 ft lengths s media to ibbon tati 1476 ft 1476 ft 1476 ft 1476 ft Roll size Inner diameter of core 1 0 1 0 1 0 1 0 Outside diameter of full ribbon roll 3 2 3 2 3 2 3 2 Page 2 4 Xill Series Maintenance Manual 48452L Rev 2 The XiII Series System Printing Considerations Printing Specifications 140 170 220 Xill Resolution 300 dots per inch 203 dots per inch 300 dots per inch 203 dots per inch 12dots per mm 8 dots per mm 12 dots per mm 8 dots per mm Dot size square 0 0033 x0 0039 0 0049 x0 0049 0 0033 0 0039 0 0049 x0 0049 0 085 0 100 mm 0 125 0 125 0 085 0 100 mm 0 125 0 125 mm Maximum print width 3 42 87 mm 5 04 128 mm 6 61 168 mm 8 5 216 mm Maximum Standard memory 20 508 mm 30 762 mm 10 254 mm 16 406 mm s With 8 Mbyte 39 991 mm 39 991 39 991 mm 39 991 mm ad
175. y Refer to Figures 5 9 and 5 10 1 Remove the Rewind Plate Assembly and loosen the 5 16 Hex Nuts 01130 which attach the Hook Plate to the Rewind Plate Moving the outer end of the Hook Plate up will force the media towards the Rewind Tracking Plate while moving this end down will move the media away from the Tracking Plate The opposite effect will occur if the same adjustments are performed on the inner end of the Hook Plate 2 Reinstall the Rewind Plate Assembly and print a number of test labels If problems persist readjust the Hook Plate 3 the media cannot be made to track correctly with this adjustment check the distance from the outside of the Tracking Plate to the Main Frame This dimension is set at the factory and should be 0 547 13 9 mm to 0 567 14 4 mm If the distance needs to be reset refer to Figure 5 10 and proceed to step 4 below 4 Use a 1 16 Hex Allen Wrench to loosen the two set screws in the Collar located inside the Rewind Spindle Assembly The screws are accessible through a single hole in the Spindle Assembly as shown in Figure 5 10 Reposition the Spindle Assembly closer to or farther from the Main Frame as required and retighten the two collar set screws 5 Perform steps 1 and 2 until required results are achieved Figure 5 9 Rewind Plate Assembly 48452L Rev 2 Xill Series Maintenance Manual Page 5 21 Corrective Maintenance 1 16 Hex Allen Wrench Tracking Plat
176. y cards must be pre programmed similar to the optional ROMs If the printer detects a read only card it can not save data in the option card If the printer detects a writable card the printer may save data to this card When present the memory card is referred to as the B device 48452L Rev 2 Xill Series Maintenance Manual 7 13 System Repair Battery Failure A battery preserves the data on a writable card when the power is turned OFF If a writable card is detected and the card has invalid data the printer will display a Battery Dead message The card can be re initialized by the LCD menu or a ZPL command The LCD does provide a Battery Low warning message to alert the operator when the battery should be changed The battery status is also indicated on the Configuration Label by one of the following NONE s nasa Battery RAM Memory not detected Dead Battery RAM Memory not initialized Installed Battery RAM Memory and battery good RAM The printer s standard one megabyte of RAM space is expandable to a total of nine megabytes General printer operation requires 256 kilobytes of RAM The remainder of the memory 768K or 8192K from 9MB is in a single memory pool which is allocated for the storage of label images bitmaps graphics formats and fonts The printer creates as many bitmaps as possible from the memory pool when generating label images Only when the entire memory pool is exhausted does th
177. y feeds to the rest position or to the start of the next label when another label is in the print queue The media is at the rest position for test mode when the web is slightly in front of the printhead To print a label the printer backfeeds the media until the start or bottom of the next label is directly under the printhead The printer then prints the entire bitmap After the bitmap is completely printed the printer feeds the label completely out of the printer and then immediately backfeeds the media to the rest portion Feed Labels The print process feeds a blank label whenever the operator interface or ZPL indicates a blank label has been requested The feed occurs between label formats or while the printer is paused Multiple feed requests feed a single label A second blank label may be requested once the first label feed is completed Feed labels move the media at the slew or feed speed which is set by the second parameter of the ZPL command All printers support 2 3 4 5 6 7 and 8 inches sec printing speed The 220XiII printer supports speeds up to 10 inches sec The 140XiII printer supports speeds up to 12 inches sec Xill Series Maintenance Manual 48452L Rev 2 System Repair Optimized Motion The printer always determines the minimum motion required to perform each task Blank labels always feed forward and never backfeed first Labels with slew commands always reduce the backfeed distance by the amount of
178. y to the left to increase belt tension When a scale reading of 2000 grams 250 grams 4 5 16 0 5 165 creates a deflection of 1 4 inch tighten the 3 mounting screws to a torque of 20 inch pounds Replace the Left Side Panel and reapply AC Power ACCESS To MOUNTING S SCREWS SPRING SCALE Figure 5 20 90 140 170X1ll Main Drive Belt Xill Series Maintenance Manual 48452L Rev 2 Corrective Maintenance 220Xill for 90Xill 140Xill and 170Xill refer to the previous page 1 2 484521 Rev 2 Turn the printer OFF and remove the AC Power Cord Remove the Left Side Panel of the printer by removing the Phillips Screws which hold it on Refer to Figure 5 21 and note the position of the Idler Gear used to adjust the tension of the Main Drive Belt In the Media Compartment locate the Idler Gear Mounting Screw Use a 7 64 Allen Wrench to loosen the Idler Gear Mounting Screw Refer to Figure 5 21 and slide the Idler Gear Assembly toward the rear of the printer to relieve the tension on the Main Drive Belt Remove the old Main Drive Belt and install the new one Hook a 2200 gram spring scale to the belt as shown in Figure 5 21 and carefully slide the Idler Gear Assembly toward the front of the printer to increase belt tension When a scale reading of 2000 grams 200 grams 4 5 16 0 5 165 creates a deflection of 1 4 inch tighten the Idler Gear

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