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Genicom 140 TM User's Manual

1. A parallel data communication port is also provided This port allows data to be sent to the printer at a higher speed than serial communications and still permits printer status information to be sent back to the host via the RS 232 serial port Zebra printers comply with international regulations governing radiated emissions when using fully shielded data cables Data cables must be fully shielded and fitted with metal or metalized connector shells Shielded data cables and connectors are required to prevent radiation and reception of electrical noise Use of unshielded data cables may increase radiated emis sions above the regulated limits Loading Media Introduction to Media Loading Note Note A Calibration must be performed when media and ribbon if used are first installed in the printer and when a different type of media or ribbon is installed See Media and Ribbon Sensor Calibration on page 38 Media widths and thicknesses vary between applications To maintain print quality from one application to another refer to Adjustments on page 61 Zebra Xill Printer User s Guide 7 Getting Started Non Continuous Media This type of media has some type of physical characteristic gap notch per foration etc which indicates the start end of each label The Media Sensor must be properly positioned to sense these indicators See Adjusting the Transmissive Media Sensor Assembly Position on page 15 Co
2. 9 Pin to 25 Pin Interconnecting Cable Figure 108 A AC Power Fuse 59 Adjustment Lower Media Sensor 17 Adjustments Adjusting for In Spec Bar Codes 113 Media Sensor Assembly Position 15 Printhead Pressure 62 Applicator Interface 77 ASCII Code Chart 112 Auxiliary Port Setting 47 B Backfeed Setting 45 Baud Rate Setting 40 BBS Technical Support Bulletin Board Service 94 Black Oval keys 2 27 C Cables interconnection 9 to 25 pin 108 null modem 108 RS 422 RS 485 109 Zebra Xill Printer User s Guide Cabling Requirements 111 Calibrate key 27 Calibration Media and Ribbon Sensor 38 Cancel key 27 Cancel Key Self Test 70 Figure 70 Changing Password Protected Parameters 32 Check Ribbon light 28 Cleaning Cutter Module 58 Extenor 56 Interior 56 Media Sensors 57 Platen Roller 56 57 Print Elements 57 Printhead 56 Cleaning Diagram 57 Cleaning Schedule 55 Cleaning Solvent 56 Communication Parameters Setting Baud 40 Communications Mode 42 Data Bits 40 Host Handshake 41 Host Port 40 Network ID 41 Parity 40 Protocol 41 121 Stop Bits 40 Communications LCD Setting 42 Communications Code 105 Communications Diagnostics Mode 72 Configuration and Calibration 31 Configuration Label 70 Continuous Media Loading 11 Control Prefix Character 42 Control Prefix Setting 42 Cutter Cleaning 58 Cutter Mode 25 Darkness setting 34 Data light 28 Data Specifications 106 Defaults loading factory 3
3. 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 or no ribbon which determines the print mode Thermal Direct or Thermal Transfer This type of calibration also occurs as part of the Sensor Profile and Media and Ribbon Calibrate procedures below 2 Media and Ribbon Sensor Sensitivity Calibration Performing the Media and Ribbon Calibrate procedure below first resets the sensitiv ity of the sensors to better detect the media and ribbon you are using With the sensors at their new sensitivity the printer then performs the standard calibration described above Changing the type of ribbon and or media may require resetting the sensitivity of the Media and Rib bon 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 Sensor Profile Press the right oval key to initiate the standard calibration procedure and print a media sensor profile See Figure 10 Media and Ribbon Sensor Profile Sample Printout on page 50 SENSOR PROFILE The Media Sensor Profile may be used to troubleshoot registration problems that may be caused when the Media Sensor detects p
4. Xill S eries User s Guide For the Zebra 90Xill 140xil 170XM and 220XilI Printers f Zebra Xill Series Printer User s Guide Customer order 48460L Manufacturer part 48460LB Rev 1 E Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation It is intended solely for the information and use of par ties operating and maintaining the equipment described herein Such proprietary information may not be used reproduced or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Corporation Product Improvements Continuous improvement of products is a policy of Zebra Technologies Corporation All specifications and signs are subject to change without notice FCC Compliance Statement Note This equipment has been tested and found to comply with the limits for a Class A digital Device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a com mercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the inte
5. fold and roll media sensor This sensor is located behind the printhead to detect the presence of media and for non con tinuous media the position of the web hole notch or mark that sepa rates each label media supply hanger The hanger that supports media rolls and provides consistent media feed to the print head non volatile memory Electronic memory that retains data even when power is removed print speed The speed at which printing occurs For thermal transfer printers this speed is expressed in terms of ips inches per second Zebra Xill Printer User s Guide Glossary printhead wear The degradation of the surface of the printhead and or the print elements over time Heat and abrasion can cause printhead wear Therefore to maximize the life of your printhead use the lowest print darkness setting sometimes called burn temperature or head tempera ture and the lowest printhead toggle pressure necessary Also use ribbon that is as wide as or wider than the media to protect the printhead of the Xill printer from the rougher surface of the media registration Alignment of printing with respect to the top of a label tag ribbon A band of inked material that is pressed against the media and heated to transfer an image onto the media which in turn is pressed against the platen A ribbon consists of a base film coated with wax or resin ink Zebra ribbons also have a back coat ing that prote
6. 23 Printer Operating Modes eerte viss nys bess Eesen EE eek 24 Tea Off Mode oven ge pee ee errr AN SN DRE 24 Peel Off MOdGe E Rewind Mode eee dc Cutter Mode eedem ern eter eo eur Pepe ebd 25 Operator e 25 Power E EE 25 Pront Panel Display teh PRG EeE 26 Front Panel K6ys ics ect 27 Front Panel Laghts orones 28 Printer Status Sensors 29 Initial Printer POW EL Ups gegen egene geesde RR DET te Ug Etui 30 Configuration and Calibration sess 31 Entering the Program Mode sees 31 Changing Password Protected Parameters sess 32 Leaving the Program Mode 32 Configuration and Calibration Sequence sess 34 Sample ZPL II Label Formats ve TEEN Format 1 Simple Text anid a i Barcode Er 52 Format 2 Saving a Label Format As a Graphic Image 52 Format 3 Using a Serialized Data Field s 33 ss CVC ADIN 55 Cleaning the brenge nere ettet tenetur opas 56 Cleaning the Interi r s sssssns vsssorsssssorsssssrrnstsskseses Det susse 56 Cleaning the Printhead and Platen Roller 56 vi Zebra Xill Printer User s Guide Cleaning the Sensors eem 57 Cleaning the Cutter Module suresi vevissisriresinresisivis 58 ET ee 58 Fuse Replacement rette pale ee retra epe neret dress e sna 59 ATI Mt Toggle EE 61 Printhead Pressure Adius
7. 3 1 Code 49 2 dimensional bar code Code 93 Code 128 Supports serialization in subsets B and C and UCC Case C Codes Codabar Supports ratios of 2 1 up to 3 1 CODABLOCK nterleaved 2 of 5 Supports ratios of 2 1 up to 3 1 Modulus 10 Check Digit Zebra Xill Printer User s Guide ndustrial 2 of 5 Standard 2 of 5 LOGMARS Plessey EAN 8 EAN 13 EAN EXTEN SIONS UPC A UPC E UPC EXTENSIONS MSI PDF 417 2 dimensional bar code POSTNET MaxiCode Check digit calculation where applica ble 83 v8 oprinz s 1os 1ojuuq IK e1qoz General Specifications General Specifications 90Xill 140Xill 170Xill 220Xill Wi tion printing 100 Complies with FCC class A and Canadian Doc class a rules Compliance Carries the CE mark of compliance pone 4l to 104 F 5 to40 C 41 to104 F 5 to40 C 4 1 to 104 Fs 5 to40 C 41 to 104 F_ 5 to 40 C Operating Temperature 32 to 1042 F 0 to 40 C 32 to104 F O to40 C 32 to 104 F 0 to 40 C 322 to 1042 F 0 to 40 C 4 to 140 F 20 to 60 C 4 to 140 F 20 to 602 C 1 4 to 140 F 20 to 602 C 1 4 to 140 F 20 to 60 C 20 to 85 non condensing 20 to 85 non condensing 20 to 85 non condensing 20 to 85 non condensing Storage 5 to 85 non condensing 5 to 85 non condensing 5 to 85 non condensing 5 to 85 non condensing suonBagnpvads WPMD s 1os IJUMA IK eJqoz S
8. Compare your results with those shown If your printout does not look like the one shown confirm that the file you created is identical to the format shown then repeat the printing procedure If nothing prints refer to Chapter 1 to make sure your system is set up correctly otherwise refer to Chapter 4 Troubleshooting and Diagnostics Zebra Xill Printer User s Guide 51 Operation Format 1 Simple Text and a Barcode Type this label format You ll get this printout XA E LH30 30 Ea FO20 10 AD FDZEBRA FS ZEBRA 1 2 3 FO20 60 B3N Y 20 N FDAAAOOI FS TABLET UU UU UU ULL UT I XZ Line 1 Indicates start of label format Line 2 Sets label home position in dots from the upper left hand corner of the label Line 3 Sets field origin selects font D defines field data as ZEBRA Line 4 Sets field origin selects bar code Code 39 sets barcode height at 20 dot rows defines field data for bar code as A AA001 Line 5 End of label format Format 2 Saving a Label Format As a Graphic Image Type this label format You ll get this printout XR LH30 30 Same as Format 1 but this format was also FO20 10 AD FDZEBRA FS saved in the printer s memory as a graphic FO20 60 B3N Y 20 N FDAA AO001 FS image named FORMAT2 AISFORMAT2 N E ZEBRA 7 XA l IN WI H II HI UU WU s roma ooo ESL OMEN Line 1 Indicates start of label format Line 2 Sets label home position
9. Slightly Dark Slightly dark 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 Slightly Light Slightly light labels are in some cases preferred to slightly dark for in spec bar codes Both normal and rotated bar codes will be in spec but small alphanumeric characters may not be complete Too Light Light labels are obvious Both normal and rotated bar codes have incom plete 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 Although it may not look as good as a slightly dark bar code it will be in spec In both normal and rotated styles small alphanumeric characters will look complete 114 Zebra Xill Printer User s Guide ROTATED BAR CODES zc m OC I gt wt Me ilk 5 31002 UI X6 3102x I enl 3022e TAI FLEN TAN AT E or til Ven SET WE H Louse WI IN er Oft 73e suey went fl MIM xCODE 39x sec INE LIE xCODE 39 SLIGHTLY DARK LLLI CODE 39 KA WI s3d09 HV8 TVINHON
10. ZPL II ZPL The printer will remain in the selected mode until it is changed by this front panel instruction or by using a ZPL ZPL I command The printer accepts label formats written in either ZPL or ZPL I This eliminates the need to rewrite any ZPL formats you already have Refer to the ZPL I Pro gramming Guide for more information on the differences between ZPL and ZPL I uoneaodQ Ft oprinz 1os 1ojuuq IK e1qoz Power Up and Head Close Parameters MEDIA POWER UP NEXT SAVE HEAD CLOSE NEXT SAVE Media Power Up H Press the right or left oval key to display other choices Default Feed Selections Feed Calibration Length and No Motion This parameter establishes the action of the media when the printer is turned on e Calibration recalibrates the media and ribbon sensors Feed feeds the label to the first web Length determines the length of the label No Motion media does not move Head Close H Press the right or left oval key to display other choices Default Feed Selections Feed Calibration Length No Motion Determines the action of the media after the printhead has been opened and then closed e Calibration recalibrates the media and ribbon sensors Feed feeds the label to the first web Length determines the length of the label No Motion media does not move uonedod oprinz s 1os IJUMA IK Jqoz Sv Label Positioning Parameters B NEXT SAVE B NEXT SAVE L
11. inch 7 50 mmx 6 00 mm 0 17 Char mm U L D U 3 c ep is U L D L D U 60 x 40 21x13 24 x 24 Default 15 x 12 5 R 0 103 x 0 093 10 71 Char inch 6 OCR A 2 63 mmx 2 38 mm 0 42 Char mm 0 118 x 0 118 8 48 Char inch SYMBOL 3 00 mm x 3 00 mm 0 33 Char mm U L D Scalable smooth font 0 SS Ce 88 Zebra Xill Printer User s Guide Specifications Table 8 Twelve Dots mm Printhead Dot Matrix Height U Uppercase B H F Width in dots L Lowercase Height x Width Character Density 0 030 x 0 020 50 00 Char inch 0 76 mm x 0 51 mm 1 97 Char mm 0 037 x 0 030 33 33 Char inch 0 93 mm x 0 76 mm 1 31 Char mm 0 060 x 0 040 25 00 Char inch 1 53 mm X 1 02 mm 0 98 Char mm 0 137 x 0 087 11 54 Char inch 3 47 mm x 2 20 mm 0 45 Char mm U LD 0 087 x 0 053 18 75 Char inch Ge 2 20 mm x 1 36 mm 0 74 Char mm U L D 0 200 x 0 160 6 25 Char inch is 5 08 mm x 4 07 mm 0 25 Char mm 0 100 x 0 093 10 71 Char inch OCRA 2 54 mm x 2 37 mm 0 42 Char mm 0 080 x 0 080 12 50 Char inch SYMBOL 2 03 mm x 2 03 mm 0 49 Char mm Scalable smooth font Zebra Xill Printer User s Guide 89 Specifications Standard Printer Font Examples FONT amp ABCDuxyz 12345 FONT B ABCDUXYZ 12345 FONT D ABCDwxyz 12345 FONT E OCR B ABCDwxyz 12345 FONT F ABCDwxyz 12345 FONT G Az4 FONT H lt OCR A UPPER CASE ONLY FONT 0
12. 8 x 203 P 224 4 50 mm 114 mm 4 50 x 114 mm i x 114mm Ticket tag notch length 0 079 0 079 0 079 0 079 Vertical 0 040 1mm 0 040 imm Lem 1 mm 0 040 1 mm EENEG oom popu tee uou eem pendicular to label tag edge Maximum f media width full media width full media width full media width EE iad Mark to mark leading edge registration tolerance 0 016 0 016 0 016 0 016 mark media Mark location Marks must be located within I mm of the edge of the media that will be closest to the printer s mainframe when loaded in the printer Mark densit gt 1 0 ODU Optical Den gt 1 0 ODU Optical Den gt 1 0 ODU Optical 1 0 ODU Optical Den SY sity Unit sity Unit Density Unit sity Unit Maximum density of the back of the media on which the black mark is printed 0 5 ODU 0 5 ODU 0 5 ODU 0 5 ODU SUOLI dg Specifications Power Line Cord Specifications The overall length must be less than 9 8 ft 3 0 meters t must be rated for at least 5 A 250 V The chassis ground earth MUST be connected to assure safety and reduce electromagnetic interference The ground connection is handled by the third wire earth in the power line cord See Figure 19 The AC power plug and IEC 320 connector must bear the certification mark of at least one of the known international safety organizations shown in Figure 20 IEC 320 rot d 3conpucroR CONNECTOR AC TOWER lt
13. 847 913 2578 Telefax Number 44 0 1494 536644 Zebra Training Programs At Zebra Technologies our training goal is to provide quality training pro grams that enhance the value of your Zebra printers We realize that two of the most important aspects of successful printer operation and maintenance are experience and training Now you can take advantage of our years of experience in operations applications maintenance and technical support and give yourself the advantage of comprehensive factory training All Zebra courses have been developed and enhanced to meet the specific needs of those who require in depth knowledge of Zebra printing systems Depending on your training requirements you can choose from individual training courses or packaged course groupings Training is conducted at Zebra s manufacturing and sales facility located in Vernon Hills Illinois a short drive from Chicago s O Hare International Airport The curriculum includes introductory courses covering bar codes thermal printing technology and selection of media and ribbons printer maintenance and operation courses and advanced programming and label designing courses All courses provide hands on experience Students receive professionally prepared training workbooks and maintenance manu als Zebra Xill Printer User s Guide 101 Support Services On site training and custom courses are available Class content can be cus tomized and schedules developed upon
14. Figure 29 Bar Code Examples Zebra Xill Printer User s Guide 115 116 Zebra Xill Printer User s Guide Glossary alphanumeric Indicating letters numer als and characters such as punctua tion marks backfeed Backfeed is when the printer pulls the media and ribbon if used backward into the printer so that the beginning of the label to be printed is properly positioned behind the print head bar code A code by which alphanumeric characters can be represented by a series of adjacent stripes of different widths Many different code schemes exist such as the universal product code UPC or Code 39 calibration of a printer A process in which the printer determines some basic information needed to print accurately with a particular media ribbon combination character set The set of all letters numerals punctuation marks and other characters that can be expressed by a particular barcode or font check digit A character added to a bar code symbol that indicates to the scanner that it has read the symbol correctly continuous media Media that has no web space between labels notch or gap to separate each label tag but rather the media is one long piece of material This media is typically cut into labels of similar length Zebra Xill Printer User s Guide 117 Glossary core diameter The inside diameter of the cardboard core at the center of a roll of media ribbon cutter A device that can cu
15. HAR gt CABLE NEUTRAL fre Sj YOUR COUNTRY FARVE N Figure 19 Power Line Cord 9 9 5 Q WO QD kns Ge Figure 20 International Safety Organizations Zebra Xill Printer User s Guide 87 Specifications Printer Fonts Standard Printer Fonts For more information on fonts refer to the ZPL II Programming Guide e Bit mapped fonts A B C D E F G H and GS are expandable up to 10 times height and width independent However fonts E and H OCR B and OCR A are not considered in spec when expanded The scalable smooth font CG Triumvirate Bold Condensed is expandable on a dot by dot basis height and width independent while maintaining smooth edges to a maximum of 1500 x 1500 dots BM Code Page 850 international characters are available in fonts A B C D E F G and through software control Table 7 Eight Dots mm Printhead Standard Dot Matrix Minimum Character Size Inter U Uppercase Fonts Height x PP charac L Lowercase Height x Width Character Density Width in dots ter Gap D Descenders 9x5 1 0 044 x 0 029 33 90 Char inc 1 13 mmx 0 75 mm 1 33 Char mm 11x7 2 0 054 x 0 044 22 60 Char inc 1 38 mmx 1 13 mm 0 89 Char mm 18 10 2 0 088 x 0 059 16 95 Char inc 2 25 mm x 1 50 mm 0 67 Char mm 0 138 x 0 098 10 17 Char inc OCR B 3 50 mmx 2 50 mm 0 40 Char mm 0 128 x 0 079 12 71 Char inc 3 25 mmx 2 00 mm 0 50 Char mm 0 295 x 0 236 4 24 Char
16. adjusting Printhead Shaft needs adjusting using the Wear Plate Incorrect printhead pressure or bal ance Printhead needs realigning with Call a service technician Platen Roller Ribbon Take Up tension needs adjusting to the minimum value Three point mount for Ribbon Sup ply Spindle needs adjusting Not applicable to the 220XiII printer Ribbon supply core slipping spin dle blades need adjusting Clean the printhead and or ribbon rollers See page 57 e See Toggle Adjustment on Toggle pressure needs adjustment page 61 Printhead angle needs adjusting using the Wear Plate adjustment Call a service technician procedure Dirty printhead or ribbon rollers Reduce toggle pressure See Tog Too much toggle pressure gle Adjustment on page 61 Zebra Xill Printer User s Guide Misregistration and mis print of 1 to 3 labels Truncated printing no printing or Feed key oper ates incorrectly while using non continuous media Label jam in rear area of printhead Missing characters or parts of characters on the front panel display screen Printed label feeds out and then backfeeds immediately to rest under the printhead Changes in configuration parameter settings did not take affect A label format was sent to the printer but not recog nized Troubleshooting and Diagnostics Table 6 Troubleshooting Continued Media was pulled when motor was Recalibrate the printer
17. back to the previous parameter PREVIOUS gt 9 Scrolls forward to the next parameter NEXT SAVE 9 Saves any changes you ve made in the Configuration and Calibration sequence gt gt Enters and exits the configuration mode SETUP EXIT These keys change the parameter values They are used in different ways depending on the parameter displayed Common uses are increase decrease a value answer yes or no indicate on or off scroll through several choices input the password Zebra Xill Printer User s Guide 27 Operation Front Panel Lights Table 2 describes the operation of the front panel lights Note If two operating conditions occur simultaneously one which causes a light to be on constantly and one which causes the same light to flash the light will flash Table 2 Front Panel Lights Power Printer is off or power not applied Take Label Normal operation gt Peel Off Mode Only Label is available Printing is paused until the label is removed Error Normal operation no printer errors X Printer error exists Check the display screen for more information Normal operation ribbon if used is properly loaded Printing is paused the front panel displays a warning message and the Pause light is on If the printer is in Direct Thermal mode Ribbon is loaded If the printer is in Thermal Transfer mode No ribbon is loaded Paper Out Normal operation media is proper
18. cated To contact Zebra Technical Support refer to Chapter 7 starting on page 93 Table 6 Troubleshooting Symptom All lights light but nothing appears on the front panel display and the printer locks up All lights are on but the dis Possibility of bad EPROMS firm Restart printer If symptom persists play screen is not ware installed in printer call a service technician Internal electronic failure Call a service technician Printer locks up when run Normally caused by some hard ning the Power On Self ware failure Display screen will Test describe the cause ERROR CONDITION For thermal transfer mode Ribbon Load ribbon correctly See Ribbon RIBBON OUT not loaded or incorrectly loaded Loading on page 19 Restart printer If symptom persists call a service technician Printer stops and Error light Ribbon Sensor not sensing ribbon Perform Media and Ribbon Sensor flashes that is loaded correctly Calibration on page 38 Zebra Xill Printer User s Guide 63 Troubleshooting and Diagnostics Table 6 Troubleshooting Continued Symptom WARNING RIBBON IN Error light flashes ERROR CONDITION PAPER OUT Printer stops and Error light flashes ERROR CONDITION HEAD OPEN Printer stops and Error light flashes WARNING HEAD TOO HOT Printer stops and Error light flashes WARNING HEAD COLD Error light flashes 64 For direct thermal mode Remove ribbon Ribbon
19. figuring the printer for a certain mode using the front panel display Tear Off Mode When the media is in the rest idle position the gap between labels is over the Tear Off Peel Off Plate The operator then tears off the label and a new label may be printed This mode of operation may also be used to print a large quantity of labels To do this send a format for printing a batch of labels to the printer The printing will continue until all labels have been printed Peel Off Mode Peel Off Option Required In this mode once the label is printed the media passes over the Tear Off Peel Off Plate at a sharp angle The backing material is peeled away from the label and winds around the Backing Rewind Spindle The media feeds forward until most of the label hangs loose from the backing The Label Available Sensor detects this label and pauses printing until the operator removes the label at which time the next label prints The Backing Rewind Spindle will hold the backing from a standard size media roll To remove the backing from the Rewind Spindle refer to page 14 Rewind Mode Rewind Option Required In this mode the media and backing are rewound onto a core as the labels are printed 24 Zebra Xill Printer User s Guide Operation When the media is in the rest idle position the start of the next label is directly under the printhead After the label is printed the media feeds for ward until the start of the next l
20. format was sent to the printer but not recog nized Data light flashes but no printing occurs A batch of labels was sent Several labels print then printer skips misplaces misses or distorts the print ing on the labels Table 6 Troubleshooting Continued Symptom Communications parameters are incorrect Prefix and delimiter characters set in printer do not match the ones used in the label format Buffer is overfilling Print a Communications Diagnostic label Check for Format or Overrun Errors Reset Communication Parameters see page 42 Set the characters in the printer to match the label format See Select ing Prefix and Delimiter Characters on page 42 If the problem continues check the ZPL I format for changed CC ACT and CD commands Check for proper flow control set ting Refer to Configuration and Calibration in Chapter 2 68 Zebra Xill Printer User s Guide Troubleshooting and Diagnostics Printer Diagnostics Power On Self Test A Power On Self Test POST is performed automatically each time the printer is turned on This test checks for proper initialization of various elec tronic circuits and establishes starting parameters as those stored in the printer s memory During this test sequence the front panel lights turn on and off to ensure proper operation See Power On Self Test Sequence on page 30 Additional Printer Self Tests Notes These self
21. in Figures 1 and 2 and wind it once or twice around either 1 the Rewind Spindle and reinstall the Hook or 2 a 3 core Zebra Xill Printer User s Guide 8 Getting Started Media loading is now complete See Adjusting the Transmissive Media Sensor Assembly Position on page 15 Rewind Mode for Printers With the Cutter Option p Remove the Media Rewind Plate from its storage location in front of the print mechanism inside the media compartment Invert the Rewind Plate so that the lip on the attached Hook Plate points down Insert the Hook Plate lip a short distance 12 into the lower opening in the Side Plate and slide the Rewind Plate in so that it stops against the printer s main frame Insert the two small tabs on the Rewind Plate into the corresponding slots in the Cutter Support Bracket The Rewind Plate should spring into the proper position Load the media as described in the instructions for Roll Media Loading on page 10 6 Remove the Hook from the Rewind Spindle Route the media as shown in Figures 1 and 2 and wind it once or twice around either 1 the Rewind Spindle and reinstall the Hook or 2 a 3 core Media loading is now complete See Adjusting the Transmissive Media Sensor Assembly Position on page 15 Zebra Xill Printer User s Guide 13 Getting Started Peel Off Mode Media Loading Rewind Option Required Figure 2 illustrates a printer with the Rewin
22. in the process and continue on to the next step B In Pause Mode press Cancel The printer skips the current label formatting process and goes on to the next label C Turn the printer power off to clear printer memory and start over Wrinkled ribbon See Wrinkled Ribbon in this table Printhead is dirty Clean the printhead See page 56 Print element is damaged Call a service technician Fine gray Hines on blank Wrinkled ribbon See Wrinkled Ribbon in this table labels at angles Long tracks of missing print on several labels Zebra Xill Printer User s Guide 65 Troubleshooting and Diagnostics Table 6 Troubleshooting Continued Symptom Wrinkled ribbon Light vertical lines approxi mately 0 005 wide running through all labels Light printing or no print ing on the left or right side of the label Short printed lines at 45 to label edge on left or right side of label 66 ted through macmnguncor See Ribbon Loading on page 19 Set darkness to the lowest setting Incorrect darkness setting possible for good print quality See Setting the Darkness on page 34 Set the pressure to the minimum needed See Adjustments on page 61 Media not feeding properly it is Make sure that the media is snug by walking from side to side adjusting the Media Guides Strip Plate needs adjusting Roller under Printhead needs realigning Ribbon Supply tension needs
23. not moving In Rewind or Peel Off mode printer was calibrated without media properly installed Label format is larger than available memory Load media correctly for rewind or peel off modes See Rewind Mode Media Loading on page 12 Reduce the size of the format or contact your sales representative for information on memory upgrades Snap Plate needs cleaning Call a service technician Display screen may be bad Printer set for Cutter mode with no Cutter installed Parameters are set incorrectly If problem continues there may be a problem with the Main Logic Board Communications parameters are incorrect Prefix and delimiter characters set in printer do not match the ones used in the label format Zebra Xill Printer User s Guide Run the Power On Self Test If problem persists call a service tech nician Set correct print mode See Select ing Print Mode on page 35 Enter the Configuration mode Set parameters correctly and save per manently Refer to Chapter 2 Call a service technician Print a Communications Diagnostic label Check for Format or Overrun Errors Reset Communication Parameters see page 42 Set the characters in the printer to match the label format See Select ing Prefix and Delimiter Characters on page 42 If the problem continues check the ZPL Il format for changed CC CT and CD commands 67 Troubleshooting and Diagnostics A label
24. protection feature send the ZPL ZPL Il command KPx where x can be any number 1 4 digits in length except Leaving the Program Mode 32 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 Zebra Xill Printer User s Guide Operation described below Pressing the left or right black oval key displays other choices and pressing the Next Save key selects the displayed choice PERMANENT permanently saves the changes Values are stored in the printer even when power is turned off TEMPORARY saves the changes until changed again or until power is turned off CANCEL cancels all changes since pressing the Setup Exit key except the Darkness and Tear Off settings if they were changed LOAD DEFAULTS loads factory defaults The factory defaults are shown on the following pages Note Loading factory defaults will require Calibration and resetting the Head Resistor value LOAD LAST SAVE loads values from the last Permanent Save Zebra Xill Printer User s Guide 33 Q2 LR opinz s 1os 1ojuuq 2X e1qoz Configuration and Calibration Sequence 2 Display Shows Action Explanation PRINTER READY Normal printer operation Setting Print Parameters gt gt DARKNESS SETUP EXIT Le TEAR OFF NEXT SAVE Adjusting Print Darkness Press the right oval key to increase darkness Press the left oval key to
25. request to address your organiza tion s specific needs For customized or on site courses tuition fees depend on course length and topics covered In addition to operation and maintenance courses Zebra offers two unique courses Bar Codes at Work and Labeling Bar Codes at Work is designed to improve the thermal printing and bar code knowledge base of many of our users and technicians Labeling provides the technician end user and programmer with the tools and techniques necessary to effectively produce labeling solutions Operation and Maintenance Courses 102 Each operation and maintenance course first introduces the student to vari ous bar code concepts and terminology Topics include direct thermal ther mal transfer printing continuous and non continuous media thin film thermal printheads and serial and parallel communication interfaces After completing this introductory material the student focuses on printer setup and configuration Each student sets up a printer exercises its self test diagnostics and performs the preventive maintenance procedures required to insure trouble free operation Mechanical and electrical operations are detailed through the disassembly and reassembly of the printer Printer options are installed and adjusted Critical checks and alignments important to the proper operation of the printer such as media and ribbon sensor sen sitivity spindle maintenance and adjustments printhead r
26. ribbon may drift Zebra Xill Printer User s Guide 61 Routine Care and Adjustment Printhead Pressure Adjustment This adjustment may be necessary if printing is too light on one side or if thick media is used Refer to Figure 14 1 Perform the Toggle Positioning procedure above If the problem is solved you may stop here otherwise continue with the rest of this pro cedure 2 Print some labels at Speed A such as by running the Pause test see page 71 3 While printing labels lower the Darkness setting until a gray level of printing is seen 4 Loosen the knurled upper locking nuts at the top of the toggle assem bly assemblies 5 Increase or decrease spring pressure using the knurled adjustment nuts on the shafts of the toggles until the left and right edges of printed area are equally dark Note Printhead life can be maximized by using the lowest pressure that produces the desired print quality 6 Increase Darkness to optimum level for the media being used 7 Retighten locking nuts Media Sensor Position Adjustment See Adjusting the Transmissive Media Sensor Assembly Position on page 15 62 Zebra Xill Printer User s Guide Chapter 4 Troubleshooting and Diagnostics This section contains troubleshooting charts used to localize and repair the printer when faults occur The procedures called out in the Action column may be performed by the operator or by a service technician when indi
27. speed D 6 per second 3 While the printer is paused pressing the Cancel key again alters the self test again Now each time the Pause key is pressed the printer prints 50 labels at speed A 4 While the printer is paused pressing the Cancel key again alters the self test a third time Now each time the Pause key is pressed the printer prints 50 labels at speed D 5 While the printer is paused pressing the Cancel key again alters the self test a fourth time Now each time the Pause key is pressed the printer prints 15 labels at 12 per second Zebra Xill Printer User s Guide 71 Troubleshooting and Diagnostics Note T2 Feed Key Self Test The Cancel Key Self Test should be performed prior to this self test Infor mation on the Configuration printout Cancel Key Self Test can be used with the results of this self test to determine the best Darkness setting for a specific media ribbon combination The Feed Key Self Test will print out at various Darkness settings above and below that of the Darkness value shown on the Configuration Label See Figure 17 Inspect these labels and determine which one has the best darkness setting for the application This value can be entered into the printer by setting the Darkness during the configuration procedure Refer to page 34 for more information The value printed on that label is added to plus or subtracted from minus the Darkness value specified on
28. tests produce sample printouts and provide specific information which helps determine the operating conditions for the printer Each self test is enabled by pressing a specific Front Panel key or combina tion of keys while turning the Power Switch on Keep the key depressed until the Data light turns off When the Power On Self Test is complete the selected self test starts automatically When performing self tests disconnect all data interface cables from the printer When canceling a self test prior to its actual completion always turn the printer power off and then back on to reset the printer When performing these self tests while in the Peel Off Mode you must remove the labels as they become available If your media is not wide enough or long enough unexpected and or undes ired results may occur Make sure that your print width is set correctly for the media you are using before you run any self tests otherwise the test may print out on the platen See page 36 for information on setting the print width Zebra Xill Printer User s Guide 69 70 Troubleshooting and Diagnostics Cancel Key Self Test Turn the printer off Press the Cancel Key and hold while turning the power on This self test prints a listing of the configuration parameters currently stored in the printer s memory See Figure 15 The configuration may be changed either temporarily for specific label for mats or ribbon and label stock or permane
29. 28 30 30 30 30 P irc d Aer dir A Ar di a 29 39 39 39 2D 39 39 39 39 DE 46 53 D BA FOO 50 AAN 18 5E 46 4F 30 2C 35 30 5E 41 41 4E 2C 31 38 2C TO FDCENTER STA 31 30 5E 46 44 43 45 4E 54 45 52 20 53 54 41 Figure 18 Communications Diagnostics Test Sample Printout Zebra Xill Printer User s Guide 73 74 Troubleshooting and Diagnostics Zebra Xill Printer User s Guide Chapter 5 Options Note Your printer may not have all of the options described in this chapter Call your sales representative for more information about these options Rewind Option Your Zebra Xill Series printer may be equipped with the optional Media Rewind capability required for Rewind and Peel Off modes of operation In Rewind Mode both labels and backing material rewind internally onto a 3 inch core A Rewind Bracket guides the media back to the Rewind Spin dle after printing In Peel off Mode only the backing rewinds onto the Rewind Spindle The Peel Tear Bar separates the label from the backing and the Label Available Sensor activates to allow the operator to remove a printed label before sub sequent labels print Select either the Rewind or Peel off Print Mode from the front panel display Zebra Xill Printer User s Guide 15 Cutter Options Your Zebra Xill printer may be equipped with a cutter used to cut the labels after they are printed The Cutter Option may be installed concurrently with other options including the Rewind
30. 3 Delimiter Character Setting 43 E Error light 28 Error Messages 63 Ethernet Interface 79 F Factory defaults 33 Fanfold Media Loading 10 11 Feed key 27 Feed Key and Pause Key Self Test 72 Feed Key Self Test 72 Fonts 78 Fonts Optional 92 Format Prefix Setting 43 Front Panel Display 2 26 Front Panel Keys 27 Front Panel Lights 28 Check Ribbon light 28 Data light 28 Error light 28 Paper Out light 28 Pause light 28 Power light 28 Take Label light 28 Fuse Replacement 59 Figure 60 Glossary 117 122 Index H Head Close Setting 44 Head Resistor Setting 46 Head Test Count Setting 46 Head Test Function 46 Host Handshake Setting 41 Host Port Setting 40 IBM Coax Interface 79 IBM Twinax Interface 79 Initial Printer Power Up 30 Input and Output Signals CCITT V 24 106 EIA RS 232 106 Standards Used 106 In Spec Bar Codes 113 K KMT Printhead 79 L Label Available Sensor 24 29 Label Positioning Parameters 45 Label Positioning Parameters Backfeed 45 Label Top Position 45 Left Position 45 Label Top Position Adjusting 45 Left Position Setting 45 List Bar Codes Setting 36 List Fonts Setting 36 List Formats Setting 37 List Images Setting 37 List Setup Setting 37 Listing Printer Information 36 Loading Media 7 Loading Ribbon See Ribbon Loading 19 Lower Media Sensor Adjustments 17 Figure 17 M Maintenance Kit 56 Maximum Length Setting 36 Media Loading Continuous Media 11 Fanfold 10 Fanfold Loading
31. 47 634 6700 44 0 1494 472872 information Customer Service Printers parts media and ribbon call your distributor or call Zebra Technical Support For questions relating to the Phone 847 913 2259 44 0 1494 472872 mechanical operation of Zebra equipment you already own call your distributor or contact Zebra Technical Fax 847 213 2378 FAAO 1424 580644 Support BBS 847 821 7113 BBS 847 821 7113 Zebra s Corporate Offices 847 634 6700 44 0 1494 472872 847 634 6700 44 0 1494 474222 Zebra Xill Printer User s Guide 93 Support Services Technical Support Sometime during the life of your Zebra Technologies Corporation equip ment you may find yourself in need of technical assistance We provide a fully trained technical support staff to answer any questions you may have If you need to contact our technical support staff for assistance please have both the model designation and serial number available so that we may help you more efficiently Zebra Technical Support Bulletin Board Service 847 821 7113 available 24 hours a day 7 days a week Zebra s trouble free immediate access technical support bulletin board ser vice allows you to identify and resolve the most common technical support issues immediately while on line It also provides information related to Zebra products and repair services This is a multi user BBS with ANSI or RIPscript support In order to view RIPscript graphic
32. 8 Printing Specifications Printing Specifications 90Xill 140Xill 170Xill 220Xill pum 0 0033 x 0 085x 0 0049 x 0 125x 00033x 0 085x 00049x 0 125x Dot size Width x Length 0 0039 0 100 mm 0 0049 a 0039 0 100mm 0 0049 Maximum print width 3 3 42 87mm mm 5 04 04 128mm mm 6 01 61 8 50 216mm mm ontinuous printing With 9 MB memory 6070 mm 8966 mm 3124 mm 5308 mm 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 suoneogrmodg Ribbon Specifications Ribbon width Zebra recommends using ribbon at least as wide as 0 79 40mm mm 4 33 i 110mm mm DS UT imum ribbon esie pz rinm a 3m Tz EEN oo CS oprinz s 1os IJUMA IK 0 1997 Media Specifications Media Specifications 90Xill 140Xill 170Xill 220Xill ini Om D t gew Maxi 5 59 14 TIT 182 88 2 Maximum label length with expanded memory and continuous media 3988 mm 106 3988 mm dees 0 076 mm 0 003 0 076 mm 0 003 0 076 mm 0 003 0 076 mm 0 012 0 305 mm 0 305 mm 10 012 0 305 mm 0 012 0 305 mm With standard hanger 3 3 76 mm 3 76mm p peus Max inter label gap 2 x label length for which you ve calibrated the printer 1 8 00 x 8 00 x 8 00 x 8 00 x Maximum internal fanfold media pack size label liner Lx W x H 3 54 x s x 90x 5 59 x ree x 142x TAT 203 f 182 8
33. Diagram 11 Zebra Xill Printer User s Guide Peel Off Mode 14 Media Power Up Setting 44 Media Sensor 29 Media Sensor Assembly Position Adjustment 15 Media Sensor Calibration 38 Media Sensor Profile Printing 38 Media Supply Spindle 77 Media Type Setting 35 N Network ID Setting 41 Next key 27 Null modem cable 108 Operating Modes Cutter mode 25 Peel Off Mode 24 Tear Off Mode 24 Operation and Maintenance Courses 103 Operator controls 25 Options Applicator Interface 77 Communication Interfaces 79 Cutter 76 Ethernet Interface 79 Fonts 78 92 IBM Coax Interface 79 IBM Twinax Interface 79 Internal Fanfold Media Supply Bin 76 KMT Printhead 79 Media Supply Fins 78 Media Supply Spindle 77 Memory SIMMs 76 On Line Verifier 77 PCMCIA Type I Memory Cards 78 Rewind Option 75 RS 485 Interface 80 Paper Out light 28 Parity Setting 40 Pause key 27 Pause Key Self Test 71 Pause light 28 PCMCIA Type I Memory Cards 78 Peel Off Mode 24 Peel Off Mode Media Loading 14 POST See Power On Self Test 30 Zebra Xill Printer User s Guide Index Power light 28 Power On Off Switch 25 Power On Self Test 30 Power Up and Head Close Parameters 44 Prefix and Delimiter Characters Selecting 42 Preventive Maintenance Kit 56 Previous key 27 Print Elements 57 Print Mode Setting 35 Print Parameters Setting Adjusting Print Darkness 34 Adjusting Tear Off Position 34 Maximum Length 36 Media Type 35 Print Method 35 Print Mode 35 Print Widt
34. EFT POSITION NEXT SAVE Backfeed Sequence H Press the right or left oval key to display other choices Default Default Default is defined as 90 Selections Default after before 10 20 30 40 50 60 70 80 This parameter establishes when and how much label backfeed occurs after a label is removed or cut in the Peel Off Cutter and Applicator modes It has no effect in Rewind or Tear Off Modes This parameter setting can be superseded by the JS instruction when received as part of a label format Refer to the ZPL I Programming Guide Note The difference between the value entered and 100 establishes how much backfeed occurs before the next label is printed For example a value of 40 means that 40 of the backfeed takes place after the label is removed or cut The remaining 60 takes place before the next label is printed A value of before means that all backfeed will take place before the next label is printed Adjusting Label Top Position Press the right oval key to increase the value press the left oval key to decrease the value The displayed value represents dots Default 0 Range 120 to 120 dot rows The Label Top Position adjusts the print position vertically on the label Positive numbers adjust the label top position further down the label away from the printhead negative numbers adjust the position up the label toward the printhead Adjusting Left Position Press the left oval key to move
35. Figure 5 on Zebra Xill Printer User s Guide 57 Routine Care and Adjustment page 17 Brush vacuum any accumulated paper lint and dust off of the sen sors Cleaning the Cutter Module For printers equipped with the optional cutter The Cutter Module requires periodic cleaning to remove paper dust and gummed label residue The procedure should be performed by the operator as needed to ensure proper cutter action If labels are not being cut properly or if the cutter jams with labels this is an indication that the cutter probably needs cleaning The cleaning frequency depends on your application and media type Clean the stationary cutter blade with cleaning solvent when it becomes gummed up with label adhesive and or paper debris If further cutter clean ing is necessary or if the cutter performs unsatisfactorily contact a service technician Lubrication CAUTION No lubricating agents of any kind should be used on this printer Some commercially available lubricants will damage the finish and the mechani cal parts if used 58 Zebra Xill Printer User s Guide Routine Care and Adjustment Fuse Replacement The Zebra Xill printer uses a metric style fuse 5 X 20 mm IEC rated at FSA 250V The end caps of the fuse must bear the certification mark of a known international safety organization See Figure 20 International Safety Organizations on page 87 The printer comes with two approved fuses one in the circuit an
36. Option The Cutter Option may be fac tory installed or it may be installed in the field by a qualified service techni cian The Cutter Option must be enabled by entering the Programming Mode and using the front panel display to select the Cutter Print Mode See Chapter 2 Operation for additional information The Cutter Catch Tray may be installed to collect labels tickets or tags after being cut Internal Fanfold Media Supply Bin Note Your Zebra Xill Series printer may be equipped with an optional internal Fanfold Media Supply Bin It is used to load fanfold media within the KO printer s media compartment and protects the media from environmental contaminants such as dust and dirt The Fanfold Media Supply Bin may be installed in the field by the operator The Fanfold Media Supply Bin may not be installed in Xill printers with the Rewind Option Fanfold media may be used on printers with the Rewind Option installed by using one of the external fanfold supply access slots at the bottom and rear of the printer Memory SIMMs 76 Memory SIMMs increase the graphics storage capacity of the printer increase the maximum print length and or increase through put by increas ing format while print abilities Contact your sales representative to pur chase compatible SIMMs in 1 2 4 and 8 MB sizes Zebra Xill Printer User s Guide Options Zebra On Line Verifier The Zebra On Line Verifier is an external device that provid
37. S232 RS422 485 RS485Multidrop Parallel Select the communications port that matches the one being used by the host computer Setting Baud H Press the right or left oval key to display other choices Default 9600 Selections 110 300 600 1200 2400 4800 9600 19200 28800 57600 The baud setting of the printer must match the baud setting of the host for accurate communications to take place Select the value that matches the one being used by the host Setting Data Bits H Press the right or left oval key to display other choices Default 7 Bits Selections 7 Bits 8 Bits The Data Bits of the printer must match the Data Bits of the host for accurate communications to take place Set the Data Bits to match the setting being used by the host Note Must be set to 8 data bits to use Code Page 850 or the Twinax or Coax interface options Setting Parity Press the right or left oval key to display other choices Default Even Selections Even Odd None The parity of the printer must match the parity of the host for accurate communications to take place Select the parity that matches the one being used by the host Setting Stop Bits H Press the right or left oval key to display other choices Default 1 Stop Bit Selections 1 Stop Bit 2 Stop Bits The stop bits of the printer must match the stop bits of the host for accurate communications to take place Select the stop bits that match the ones being used by the host uonedo
38. Scalable ABCDwxyz 12345 FONT GS 6 e Figure 21 Standard Printer Font Examples Optional Printer Fonts 90 There are many optional character fonts that can be purchased for your Xill printer in addition to those which are standard in the unit From time to time additions may be made to the list of available fonts Contact your sales representative for further information Only one additional font EPROM can be installed in the printer at a time This installation should be performed by a service technician Once installed this font can be used in addition to the standard fonts available in the printer Refer to your ZPL II Programming Guide or if using another software package to drive your printer to the instructions accompanying that package Optional fonts may also be stored on PCMCIA font cards Once an optional font is installed in the printer the Configuration Printout produced during the Cancel Key Self Test will indicate the font type as the Socket 1 ID Figure 23 illustrates the optional fonts and Figure 22 shows sample point sizes for the bitmap smooth fonts Zebra Xill Printer User s Guide Specifications ABCDEFGHIJKLMNO ABCDEFGHIJKLMNO 10pt ABCDEFGHIJKLMNO 12 pt ABCDEFGHIJKLMNO 14 pt ABCDEFGHIJKLMNO 18 pt ABCDEFGHIJKLM 24 pt ABCDEFGHIJ 30 pt ABCDEFG 36 pt ABCDEF Figure 22 Bitmap Smooth Fonts Point Size Examples Table 9 Optional Printer Fonts Currently Available Scala
39. Shield Signal Ground Reference Data Input B Data Output B Data Input A 4 Data Output A Figure 27 RS 422 RS 485 Interconnecting Cable RS 422 RS 485 Connector Rear Panel DB 25S J3 5 VDC Source Output B Output A Input B Input A Signal Ground Ref Frame Ground Figure 28 RS 422 RS 485 Connections Parallel Data Port A standard 36 pin parallel connector is available at the rear of the printer for connection to the data source When the printer is properly configured for Zebra Xill Printer User s Guide 109 parallel communications mode the standard RS 232 port will not function as an input port The parallel interface receives data from the data source but cannot send back printer status information over this port However if the Xill printer receives a Printer Status Request command over the paral lel interface it will send back this status over the RS 232 port Parallel Port Interconnections Table 12 shows the pin configuration and function of a standard computer to printer parallel cable Table 12 Parallel Connector Pinouts 36 Pin Description Connector The nStrobe printer input has internal 3 3 KQ pull up resistors to 5 V Ig 1 5 mA and is designed to receive a signal driven open collector Vo 0 8 V This pin is a signal from the host computer The nStrobe input is debounced on a LOW going edge to require an active wi
40. T EEPROM functionality test performed MEMORY CARD TEST Memory Card functionality test performed NOT INSTALLED will be added to display if no card is present Depending on how the label format was set up the printer will feed to the first web or label length calibrate ribbon and media sensors set label length and feed one or more labels or no media may be fed The ZPL II command that controls this is MF PRINTER READY Printer is ready for operation Configuration and Calibration After you have installed the media and ribbon and the POST Power On Self Test is complete the front panel display will show PRINTER READY You may now set printer parameters for your application using the front panel display and the five keys directly below it If it becomes necessary to restore the initial printer defaults see Feed Key and Pause Key Self Test on page 72 Note Unless otherwise noted all parameters are listed in the order they are dis played starting with DARKNESS Entering the Program Mode To enter the programming mode press the Setup Exit key Press either the Next Save key or Previous key to scroll to the parameter you wish to set Parameters in this section are shown in the order displayed when pressing the Next Save key Throughout this process press the Next Save key to continue to the next parameter or press the Previous key to go back to the previous parameter in the cycle Zebra Xill Printer
41. User s Guide 31 Changing Password Protected Parameters g CAUTION Note Note Operation An asterisk in the upper left hand corner of the display indicates that the value displayed is different than the currently stored value A Certain parameters are password protected by factory default 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 I instruction Once the password has been entered correctly it will not have to be entered again unless you leave and re enter the programming mode using the Setup Exit key You can disable the password protection feature so that it no longer prompts you for a password by setting the password to via the KP ZPL ZPL H command To re enable the password
42. a For proper printer operation a label length instruction must be included in the label format sent to the printer Zebra Xill Printer User s Guide 11 Getting Started Cutter Mode Media Loading Cutter Option Required Figures 2 and 3 illustrate a printer equipped with the Cutter Option To ensure proper media loading follow the directions for the Tear Off Mode with the exception that the media must also be routed through the Cutter Module as shown in Figures 2 and 3 Close the Printhead Open Lever The printer will automatically feed out and cut one label when the printer is powered on Turn to Adjusting the Trans missive Media Sensor Assembly Position on page 15 Rewind Mode Media Loading 12 Rewind Option Required Rewind Mode Configuration for Printers Without the Cutter Option 1 Remove the Media Rewind Plate from its storage location in front of the print mechanism inside the media compartment 2 Invert the Rewind Plate so that the lip on the attached Hook Plate points down 3 Insert the Hook Plate lip a short distance 12 into the lower opening in the Side Plate 4 Align the upper end of the Rewind Plate with the corresponding opening in the Side Plate and slide the Rewind Plate in so that it stops against the printer s main frame 5 Load the media as described in the instructions for Roll Media Loading on page 10 6 Remove the Spindle Hook from the Rewind Spindle 7 Route the media as shown
43. a Guide and the Media Supply Guide as far out from the printer frame as possible and flip down the Media Supply Guide Zebra Xill Printer User s Guide 9 Getting Started Roll Media Loading Place the media roll on the Media Supply Hanger and thread the media through the printhead assembly as shown in the Tear Off loading part of Figure 2 Flip up the Media Supply Guide and adjust the Media Supply Guide and the Media Guide against the outer edge of the media These guides must not cause pressure or excessive drag on the media Close the Printhead Open Lever and see Adjusting the Transmissive Media Sensor Assembly Position on page 15 TEAR OFF PEEL OFF REWIND Figure 2 Roll Media Loading Fanfold Media Loading Fanfold media from outside the printer feeds through either the bottom or rear access slot You may also use the Fanfold Supply Bin to hold media inside the printer housing 10 Zebra Xill Printer User s Guide Getting Started TEAR OFF CUTTER Figure 3 Fanfold Media Loading To load fanfold media thread the media through the Printhead Assembly as shown in Figure 3 Adjust the Media Guide against the outer edge of the media This guide must not cause pressure or excessive drag on the media Close the Printhead Open Lever and turn to Adjusting the Transmissive Media Sensor Assembly Position on page 15 Continuous Media Loading Continuous media mounts inside the printer in the same manner as roll medi
44. abel is under the printhead The media never backfeeds in this mode The completed labels are rewound onto a core for later use When the printer completes a batch of labels printing will stop Cutter Mode Cutter Option Required In this mode the printer prints the entire label and automatically cuts the label after it is printed The Cutter Catch Tray catches the completed labels Operator Controls This section discusses the functions of the various controls and indicators on the Xill printer The operator should become familiar with each of these functions Power Switch This switch is located on the back of the printer above the Power Cord and Fuse The Power Switch should be turned off before connecting or discon necting any cables Turning the switch on activates the printer and causes it to perform a Power On Self Test as it begins operation Turning the printer power on while holding down certain front panel keys will launch additional Printer Self Tests following the Power On Self Test External influences such as lightning storms or unwanted noise on the power or data cables may cause erratic printer behavior Turning the printer s power off and back on may re establish proper printer operation Zebra Xill Printer User s Guide 25 Front Panel Display 26 Operation The Front Panel Display communicates operational status and programming modes and parameters lt PREVIOUS CANCEL Fig
45. airs quickly Your equipment is returned to you according to your instructions Charges are based on the Flat Rate Unit Repairs and Flat Rate Module Repairs schedules Return shipping charges via the carrier of your choice UPS Ground within the United States if not specified will be added to your final invoice Five working days are normally required for repair and return processing Optional expedited service is available for a nominal additional fee which assures that your repaired and tested module or unit is shipped back to you within 48 hours of receipt excluding weekends and holidays Zebra Xill Printer User s Guide 99 Support Services User Self Maintenance If qualified technicians are part of your organization then this may be the option that best fits your needs Zebra provides a variety of helpful services if you choose to perform your own maintenance Making sure you have the proper spare parts is just one of the ways we can help Product specific parts and maintenance documentation is available and repair parts can be expedited at your request Training seminars are offered regularly to assist your technicians with equipment repairs Two of the most important aspects of successful product repair are experience and training Take advantage of our years of experi ence and give your technicians the advantage of comprehensive factory training Training is conducted at Zebra s Corporate facility located a short dr
46. ation Zebra warrants the enclosed diskette to be free of defects in material and workmanship for a period of 60 days from the date of purchase In the event of notification within the warranty period of defects in material and workmanship Zebra will replace the defective diskette or documentation Zebra specifically disclaims all other warranties expressed or implied including but not limited to implied warranties of merchantability and fitness for a particular purpose INNO EVENT WILL ZEBRA TECHNOLOGIES BE LIABLE FOR LOST PROFITS LOST DATA OR ANY OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES CAUSED BY ABUSE OR MISAPPLICATION OF THE SOFTWARE OR BY ITS USE IN VIOLATION OF THE U S COPYRIGHT LAW OR INTERNATIONAL TREATY Zebra Xill Printer User s Guide Contents Warranty MOMAN NEE iii T Printer Watranty ioo eec ER RE RREA iii 2 Supplies WAtfanly z eoe Eee need EE isse EEEE EEEE EES iii 3 Warranty Exclusions and Condrttons iii Zebra Software License Agreement iv Ee EE xi List of Tables cirin UD HE EORR Er OE EQUI RU xii Intpogdneton E 1 Print Mechanism Capabilities eese 2 Media Transport Mechanism Capabilities A Front Panel Display A 2 System Requitemients i oto E tr EI HET DECEDERE EROS es 3 Media and Ribbon Requirements esses eene eee 3 Brani UNS ENNER 4 Reporting Dam AO ssiniscsiorss etssnssseseseeniesssss
47. bel formats and images as well as any temporarily saved parameter settings stored in the printer s internal memory will be lost When power is turned back on you will need to reload these items To clean the printhead refer to Figure 11 and follow these steps 1 Open the Media Compartment Door Zebra Xill Printer User s Guide Routine Care and Adjustment PRINTHEAD BLACK MARK gf SENSOR SS PLATEN PEEL TEAR AVAILABLE ROLLER BAR SENSORS Figure 11 Cleaning Diagram 2 Open the Printhead by moving the Printhead Open Lever to the open position as shown in Figure 11 3 Remove the media and ribbon if present 4 Moisten an applicator tip with Zebra Technologies Corporation recom mended solvent and wipe along the print elements from end to end The print elements are the brown strip just behind the chrome strip on the printhead Allow a few seconds for the solvent to evaporate 5 Rotate the platen roller and clean thoroughly with solvent and an appli cator 6 Brush vacuum any accumulated paper lint and dust away from the roll ers 7 Reload ribbon and or media close and latch the printhead close the Front Panel and the Media Compartment Door and continue printing Cleaning the Sensors The Media Ribbon and Label Available Sensors should be cleaned on a regular basis to ensure proper operation of the printer To locate the position of these sensors refer to Figure 11 Figure 4 on page 16 and
48. ble Smooth Fonts each is Bitmap Fonts supplied only in supplied as a complete set of Normal Bold Type sizes 6 8 10 12 14 Bold Italic and Bold Italic styles 18 and 24 pt Cs SS Zebra Xill Printer User s Guide 91 Specifications Table 9 Optional Printer Fonts Currently Available Scalable Smooth Fonts each is Bitmap Fonts supplied only in supplied as a complete set of Normal Bold Type sizes 6 8 10 12 14 Bold Italic and Bold Italic styles 18 and 24 pt LL 86 runi Condes C mam 7 Optional Printer Font Examples CG Palacio Standard 0123 Bold 0123 Italic 0123 Bold Italic 0123 CG Times Standard 0123 Bold 0123 Italic 0123 Bold Italic 0123 CG Triumvirate Standard 0123 Bold 0123 talic 0123 Bold Italic 0123 CG Triumvirate Condensed Bold 0123 CG Futura Standard 0123 Bold 0123 Italic 0123 Bold Italic 0123 Greek Standard 0123 Bold 0123 Italic 0123 Bold Italic 0123 Univers Standard 0123 Bold 0123 Italic 0123 Bold Italic 0123 Figure 23 Select Examples of Optional Fonts 92 Zebra Xill Printer User s Guide Chapter 7 Support Services How to Reach Us Which department do you need Zebra Technologies Zebra Technologies Corporation USA Europe Limited UK Internet web site Provides current information about i http www zebra com Zebra its products and its services Inquiry Department For literature and distributor 8
49. ch as reflectivity and contrast are important for bar code scanning applications Factors such as paper abra sion and temperature requirements are important to maintaining the life of the printhead We STRONGLY RECOMMEND the use of Zebra Technologies Corpora tion brand supplies for continuous high quality printing A wide range of paper polypropylene polyester and vinyl stock has been specifically engi neered to enhance the printing capabilities of the Zebra Xill Series printer and to ensure against premature printhead wear Continuous roll form paper fanfold media or cardstock with optional per forations and registration holes may be used The life of the printhead may be reduced by the abrasion of exposed paper fibers when using perforated media Zebra Xill Printer User s Guide 3 Getting Started Ribbons used in the Zebra Xill printer MUST be as wide as or wider than the media used Zebra brand ribbons provide an extremely smooth backing surface which protects the printhead from abrasion by the media If the rib bon is narrower than the media areas of the printhead will be unprotected and will be subject to premature wear Since print quality is affected by media and ribbon printing speeds and printer operating modes it is very important to run tests for your applica tions This is especially true if you re operating in Peel Off mode where these variables combine with label size backing content die cut depth and even hum
50. crease the value Default Range The default and range of acceptable values varries depending on your printer s configuration Values are adjustable in 1 0 inch 25 4 mm increments Maximum Length is used in conjunction with the Calibration procedure The value of this setting determines the maximum label length that will be used during the media portion of the calibration process Only a few labels are required to set media sensors Always set the value that is closest to but not lower than the length of the label you are using For example if the length of the label is 14 5 inches set the parameter for 15 0 inches 381 mm List Fonts Press the right oval key to print a label listing all of the available fonts This selection is used to print a label that lists all of the fonts currently available in the printer including standard printer fonts plus any optional fonts Fonts may be stored in RAM in Font EPROMSs or on Font Cards List Bar Codes Press the right oval key to print a label listing all of the available bar codes This selection is used to print a label that lists all of the bar codes currently available in the printer uonedod oprinz s 1os 1ojuuq IK eqoz Le NEXT SAVE NEXT SAVE NEXT SAVE gt NEXT SAVE LIST IMAGES LIST FORMATS LIST SETUP INITIALIZE CARD List Images Press the right oval key to print a label listing all of the available images This selection is used to print a label t
51. cts the printhead from damage ribbon wrinkle A wrinkling of the rib bon caused by improper alignment of the strip plate and or printhead pres sure This wrinkle can be seen just above the strip plate Ribbon wrinkle can cause voids in the printing and or it can cause the spent ribbon to rewind unevenly Correct this condi tion by performing adjustment proce dures Zebra Xill Printer User s Guide roll media Media that comes supplied rolled up on a core usually card board Contrast this with fanfold media which comes folded in a rect angular stack supplies A general term for ribbon and media tag A type of media having no adhesive backing but featuring a hole or notch by which the tag can be hung on something Usually tags are made of cardboard or other durable material take label sensor See label available sensor thermal direct printing See direct ther mal printing thermal transfer printing A printing method in which the printhead heats an ink or resin coated ribbon against the media causing the ink resin to transfer onto the media By selec tively heating the ribbon an image can be formed on the media See also ribbon void A space where printing should have occurred but due to some error condition it did not occur A void can cause a bar code symbol to be read incorrectly or to not be read at all 119 Glossary 120 Zebra Xill Printer User s Guide Index Numerics
52. d oprinz s 1os IJUMA IK eJqoz Iv HOST HANDSHAKE NEXT SAVE B NEXT SAVE NETWORK ID NEXT SAVE Setting Host Handshake H Press the right or left oval key to display other choices Default XON XOFF Selections XON XOFF DTR DSR The handshake protocol of the printer must match the handshake protocol of the host for communi cations to take place Select the handshake protocol that matches the one being used by the host Setting Protocol H Press the right or left oval key to display other choices Default None Selections None Zebra ACK NACK Protocol is a type of error checking system Depending on the selection an indicator may be sent from the printer to the host signifying that data has been received Select the Protocol that is requested by the host Further details on Protocol can be found in the ZPL Programming Guide available from Zebra Technologies Corporation Note Zebra is the same as ACK NACK except that with Zebra the response messages are sequenced Note If Zebra is selected printer must use DTR DSR host handshake protocol Setting Network ID H Press the left oval key to move to the next digit position press the right oval key to increase the value of the digit Default 000 Range 000 999 Network ID is used to assign a unique number to a printer used in a network This gives the host the means to address a specific printer If the printer is used in a network you must select a Network ID numb
53. d Option To insure proper media loading see Figure 2 and follow the procedure below Remove the Rewind Plate if one is present and store it on the two mount ing screws on the inside of the front panel Align the notch in the bracket so the Label Available Sensor shown in Figure 14 on page 61 can detect a peeled label Load media as shown in Figure 1 or 2 Remove the Hook from the Rewind Spindle Remove the labels from about one yard one meter of the media backing and then wind the backing around the Rewind Spindle and reinstall the hook Make sure that the media backing is against the Backing Guide Plate See Adjusting the Transmissive Media Sensor Assembly Position on page 15 Removing the Label Backing Material 14 Rewind Option Required Since the Backing Rewind Spindle holds the backing from a standard size media roll we recommend that you perform this procedure whenever you change the media To remove the backing material from the Backing Rewind Spindle follow these steps you don t need to turn the printer power off for this procedure 1 Unwind about one yard one meter of backing from the Backing Rewind Spindle and cut it off at the spindle Pull out the Spindle Hook and slide the backing material off of the spin dle and discard Wind the media around the Rewind Spindle once or twice and reinstall the Spindle Hook Continue winding to remove any slack in the media Zebra X
54. d one in the spare fuse holder 1 Turn the printer power off and unplug the power cord from the back of the printer See Figure 12 2 Using a small blade screwdriver or similar tool remove the Fuse Holder from the printer 3 Remove the faulty fuse and install a new fuse of the correct type Refer to Figure 13 The fuse that goes into the printer first is the one that is in circuit If you use the spare fuse be sure to order a replacement fuse fuses can be ordered from your Zebra distributor 4 Snap the Fuse Holder back into position 5 Reconnect the power cord If the new fuse fails right away the printer has an internal component fail ure and must be repaired Zebra Xill Printer User s Guide 59 60 Routine Care and Adjustment FUSE HOLDER MODULE SMALL BLADE SCREWDRIVER Figure 13 Fuse Replacement Step 2 Zebra Xill Printer User s Guide Routine Care and Adjustment Adjustments Ae S EE ws AVAILABLE SENSORS ADJUSTING NUTS Figure 14 Toggle Adjustment Toggle Positioning Both toggles should be positioned so that they provide even pressure on the media The toggles are positioned by sliding them to the desired location On media too narrow to accommodate both toggles position one toggle over the center of the media and decrease the pressure on the unused toggle Note Make sure that the toggle pressure is even across the width of the media otherwise the media and or
55. decrease darkness Default 10 Range 0 to 30 Darkness settings are dependent upon a variety of factors including ribbon type media and the condition of the printhead You may adjust the darkness for consistent high quality printing If printing is too light or if there are voids in printed areas you should increase the darkness If printing is too dark or if there is spreading or bleeding of printed areas you should decrease the darkness The Feed Key Self Test on page 72 can also be used to determine the best darkness setting Since the Darkness setting takes effect immediately you can see the results on labels that are currently printing CAUTION Set the Darkness to the lowest setting that provides good print quality Darkness set too high may cause ink smearing and or it may burn through the ribbon Adjusting the Tear Off Position Press the right oval key to increase the value press the left oval key to decrease the value Each depression of the key adjusts the Tear Off position by four dot rows Default 0 Range 64 to 64 This parameter establishes the position of the media over the tear bar after printing The label and backing can be torn off or cut between labels uonedod oprinz s 1os IJUMA IK eJqoz SE NEXT SAVE gt NEXT SAVE gt NEXT SAVE NEXT SAVE PRINT MODE MEDIA TYPE SENSOR TYPE PRINT METHOD Selecting Print Mode Press the right or left oval key to display other cho
56. does it occur on all labels e What is the printer s serial number Zebra Technical Support is available Monday through Friday Call us directly at Zebra USA 847 913 2259 7 15 a m to 5 30 p m CST Zebra UK 44 0 1494 472872 9 00 a m to 5 30 p m GMT Technical Support via Mail or Fax If you prefer to seek assistance in writing please mail or fax a completed service form page 96 to the address or fax number shown on the form Enclose any sample printouts that might illustrate the problem This is nec essary to avoid delays Zebra Xill Printer User s Guide 95 Support Services Zebra Technologies Corporation Service Form Zebra Technologies Corporation Zebra Technologies Europe Limited 333 Corporate Woods Parkway Zebra House The Valley Centre Vernon Hills Illinois 60061 3109 Gordon Road High Wycombe Buckinghamshire HP13 6EQ England Phone Number 847 913 2259 Phone Number 44 0 1494 472872 Telefax Number 847 913 2578 Telefax Number 44 0 1494 536644 Complete this form before requesting technical assistance Serial Be specific include ALL letters and numbers Contact Person Company Address State ZIP Phone _ eee Hours available for return call Hardware interface type Unit interfaced with Description of problem 96 Zebra Xill Printer User s Guide Support Services Product Service and Support Programs At Zebra Technologies our service and support goal is to keep your prin
57. downtime Zebra Xill Printer User s Guide 97 Support Services Extended Factory Service Agreement The Extended Factory Service Agreement covers all parts and labor required to assure optimum performance with the exception of printheads All Zebra equipment returned for service under this agreement undergoes a complete preventive maintenance check up at no additional charge Return shipping charges via UPS Ground from Zebra are also covered Five working days are normally required for repair and return processing Optional Expedited Service is also available for a nominal fee Customer Shipping Option If you can realize cost savings by utilizing your own carriers for round trip shipment of your Zebra equipment Zebra offers the Customer Shipping Option giving you complete control over the method and price of transporting your equipment Third Party Support and Maintenance 98 Zebra Solution Center and National Sales and Service Center Support Our ZSC and NSSC business partners offer Zebra approved third party maintenance programs Both on site and depot repair programs may be available depending upon the organization Contact our Technical Support staff for more information on the ZSC for your region Wang Customer Services Division Zebra Technologies Authorized National Service Supplier provides on site maintenance of the complete line of Zebra printers Wang and Zebra work together to provide the TotalCare Service P
58. dth greater than 0 5 ms before data is latched Data inputs have TTL input characteristics with internal 3 3 kQ pullups and represent 1 TTL unit load or less The Data inputs are positive logic with a HIGH voltage level corre sponding to a logic 1 Pin 2 through Pin 9 DO through D7 respectively The nAck output is an active LOW pulse used to indicate termination nAck is a driven open collector with a 3 3 kQ internal pull up The output sinks 7 mA to a VOL 0 4 V 10 The Busy output is active HIGH whenever the printer cannot accept data due to any normal or abnormal condition including buffer overflow head open over temperature and media error conditions Busy is a driven open collector with a 3 3 kQ internal pull up The output sinks 7 mA to a VOL 0 4 V The PError signal is active HIGH whenever the printer is out of media or ribbon The Select signal function is determined by an additional configuration option which becomes active when the port is present In the default condition Select is active HIGH whenever the 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 110 Zebra Xill Printer User s Guide em 2 9 a zo e D NEC 1930 3135 2 Cabling Requirements Note Note Data cables must be fully shielded and fitted with metal or metalized con nector shells Shielded cables and connect
59. e Labels are rewound internally e Applicator mode Labels are peeled from the liner and presented for use by an external applicator device Zebra Xill Printer User s Guide 81 Specifications Options BM Twinax Interface BM Coax Interface ZebraNet Ethernet Interface 10Base T and 10Base 2 e RS 485 Interface e Font cards Font EPROMs Memory SIMMs Memory cards Cutter Rewind Cutter Rewind Cutter Tray Applicator Verifier Media supply spindle Fanfold supply bin KMT printhead not applicable to the 220Xill printer Zebra Programming Language ZPL I Downloadable graphics scalable and bitmap fonts and formats Object copying between memory areas RAM and memory card Code Page 850 character set Adjustable print cache Data compression Automatic virtual input buffer man agement Automatic memory allocation Format inversion Mirror image printing Four position field rotation 0 90 180 270 82 Slew command Programmable quantity with print pause Communicates in printable ASCII characters Error checking protocol Controlled via mainframe mini com puter PC portable data terminal Serialized fields n spec OCR A and OCR B UPC EAN User programmable password Status message to host upon request Zebra Xill Printer User s Guide Specifications Bar Codes Code 11 Code 39 Supports ratios of 2 1 up to
60. e 4 The POST prompts are in English unless an error occurs in which case the display cycles through all available languages repeatedly However you may change the display language for all other prompts Refer to Selecting the Display Language on page 49 Note If the printer fails any of these tests the word FAILED will be added to the display If this occurs refer to the Troubleshooting section starting on page 63 If loading the printer with media and ribbon for the first time or changing the type of media perform the Calibration on page 38 Table 4 Power On Self Test Sequence This sequence occurs each time the printer is powered up 1 Allindicator lights turn on simultaneously Then through the following steps they turn off in sequence starting at the bottom 2 Three different sets of characters will be displayed to verify that the dis play screen is working properly SRAM TEST SRAM functionality test performed Optional ROM functionality test performed The words NOT OPTION RON TEST INSTALLED will be added to display if no optional ROM is used PRINTHEAD TEST Printhead is checked for proper operation 6 PROCESSOR TEST Processor functionality test performed E CUBED TEST E Cubed functionality test performed 30 Zebra Xill Printer User s Guide Operation Table 4 Power On Self Test Sequence Continued This sequence occurs each time the printer is powered up 8 EEPROM TES
61. e exited the Configuration and Calibration Sequence and you are now ready for normal printer operation uoneaodQ Operation RIBBON fee MEDIA MEDIA MEDIA MEDIA MEDIA Figure 10 Media and Ribbon Sensor Profile Sample Printout 50 Zebra Xill Printer User s Guide Operation Sample ZPL I Label Formats ZPL II is Zebra Technologies Corporation s Zebra Programming Language II label design language ZPL II lets you create a wide variety of labels from the simple to the very complex including text bar codes and graphics This section contains three sample label formats for you to begin experi menting with It is not intended as an introduction to ZPL II To learn about ZPL II send in the request card at the beginning of this book for a free copy of the ZPL II Programming Guide For each format do the following 1 Setup the printer and turn the power on 2 Use a text editing program ex Windows Write or DOS Editor and type in the label format exactly as shown in the sample label format below 3 Save the file in a directory for future use Use the extension zpl 4 Copy the file to the Zebra Xill printer Note Typically computers running DOS use the COPY command to send a file to the Zebra printer For example if your file name is format1 zpl then type COPY FORMAT 1 ZPL XXXX where XXXX is the port to which your Zebra printer is connected for example COM1 or LPTI 5
62. ed environmental and electrical conditions Printer Power Up Follow the instructions in this section to connect this printer to a source of electrical power and a data source Voltage Selection The Xill printer auto adjusts for 90 264 VAC electrical power No further adjustment is required Power Cord WARNING For personnel and equipment safety always use a three prong plug with a ground earth connection Make sure that the Power On Off Switch located at the back of the printer is in the off position before connecting the power cable to an electrical out let Depending on how your printer was ordered a power cord may or may not be included If one is not included or if the one included is not suitable for your requirements refer to Power Line Cord Specifications on page 87 The power cord connector must be plugged into the mating connector on the rear of the printer 6 Zebra Xill Printer User s Guide Getting Started Communications CAUTION The Xill printer has been designed with flexible communication capabilities that allow the printer to be interfaced to a variety of controlling devices A single DB25 connector includes all signals necessary for interfacing the printer to RS 232 RS 422 or RS 485 serial data communication devices at data rates from 110 to 57 600 baud Baud rate parity data length number of stop bits and handshaking protocol are programmable via the front panel display and keypad
63. ed by a limited warranty of six 6 months from the date of original shipment by ZEBRA Technologies To qualify for this warranty the printer must be returned to the factory or other authorized service center Although the user is not required to purchase ZEBRA brand supplies media and or ribbons to the extent it is determined that the use of other supplies media and or ribbons shall have caused any defect in the thermal printhead for which a warranty claim is made the user shall be responsible for ZEBRA Technologies customary charges for labor and materials to repair such defect To the extent that it is determined that failure to follow the preventive maintenance schedule and procedures listed in the User s Guide shall have caused any defect in the thermal printhead for which a warranty claim is made this limited warranty shall be void ZEBRA TECHNOLOGIES SOLE OBLIGATION UNDER THIS WARRANTY SHALL BE TO FURNISH PARTS AND LABOR FOR THE REPAIR OR REPLACEMENT OF PRODUCTS FOUND TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP DURING THE WARRANTY PERIOD As a condition of this warranty the user must a obtain a ZEBRA Return Authorization for the printer or subassembly s b ship the printer or subassembly s transportation prepaid to the authorized service location and c include with the Product or subassembly s a written description of the claimed defect Unless ZEBRA Technologies authorizes return of the entire Product the user shall return
64. ed diameter fins There is a wide range of optional character fonts that can be purchased for your Xill printer in addition to those fonts which are standard in the unit Fonts may be purchased on EPROMS or on PCMCIA cards depending on your needs Refer to Optional Printer Fonts on page 90 for information about optional fonts From time to time additions may be made to the list of available fonts Contact your sales representative for further information PCMCIA Type I Memory Cards 78 These memory cards work with the Xill printer s standard memory card interface With these cards users can store complete label formats images graphics and fonts for easy transfer to the printer s memory Storing data on PCMCIA cards minimizes download time and maximizes throughput Contact your sales representative to purchase compatible cards Zebra Xill Printer User s Guide Options KMT Printhead The KMT printhead used on all older printers is available for use with the Xill printers for customers who want to maintain full compatibility with their existing printers Communication Interfaces IBM Twinax Interface This interface emulates IBM System 3 X and AS 400 5224 5225 5256 and 4214 printers This option comes with an auto terminating 1 ft Y con nector cable IBM Coax Interface This interface emulates an IBM System 3287 printer used in the IBM 3270 environment This option comes with a BNC connector to inte
65. eives from the media and ribbon sensors based on the specific media and ribbon combination you are using On the sensor profile this essentially corresponds to moving the graph up or down to optimize the readings for your application When RELOAD ALL is displayed 1 Open the Printhead and pull the media forward until a label is positioned under the Media Sensor 2 Move the ribbon back to its proper position 3 Close the Printhead uonedodQ Now that the scale has changed the printer performs a calibration equivalent to pressing the Calibrate key During this process the printer checks the readings for the media and ribbon based on the new scale you ve established determines the label length and determines whether you are in thermal direct or thermal transfer print mode The process is now complete To see the new readings on the new scale print a Sensor Profile above Or WPMD s 1os 1ojuuq IK 0 1997 Setting Communication Parameters Communication parameters must be set correctly for the printer to communicate with the host These parameters make sure that the printer and host are speaking the same language All communications parameters are password protected NEXT SAVE NEXT SAVE NEXT SAVE NEXT SAVE NEXT SAVE gt gt gt HOST PORT BAUD SET DATA BITS PARITY STOP BITS Setting Host Port Press the right or left oval key to display other choices Default Main RS232 Selections Main R
66. eplacement and print quality alignments are discussed and performed by the students Trou bleshooting techniques and common faults are described and reviewed through hands on exercises To assist in troubleshooting communications related problems an introduction to the Zebra Programming Language ZPL and ZPL II9 is provided Students review the general structure of ZPL interface computers to the Zebra printers and follow a series of exer cises which lead them through the steps necessary to create and print labels Zebra printer courses may be taken separately or bundled together to cover printer families The following table shows the course offerings currently available Zebra Xill Printer User s Guide Support Services Table 10 Zebra Printer Operation and Maintenance Courses 90Xi 140Xi 170Xi 90Xill 140Xill 170Xill 220Xill 90Xi 140Xi Z140 Z142 Z143 Z91 Bar Codes at Work This one day course presents an introduction to bar coding This course covers bar code terminology specifications and applications associated with selected often used bar codes In order to gain a better understanding of labeling problems and solutions the selection and matching of media and ribbons are discussed After identifying the media and ribbon required to meet the labeling solution Zebra printer specifications and capabilities are compared and the applicable Zebra printer set up is configured to produce the required labels Pr
67. er uonedodQ cv WPMD s Jos IJUMA 2X e1qoz COMMUNICATIONS NEXT SAVE Setting Communications Mode o Press the right or left oval key to display other choices Default Normal Mode Selections Normal Mode Diagnostics The Communication Diagnostics Mode is a troubleshooting tool for checking the interconnection between the printer and the host When Diagnostics is selected all data sent from the host to the printer will be printed as straight ASCII hex characters The printer prints all characters received including control codes like CR Carriage Return A sample printout is shown in Figure 18 on page 73 Notes on diagnostic printouts An FE indicates a framing error An OE indicates an overrun error An PE indicates a parity error An NE indicates noise For any errors check that your communication parameters are correct Set the print width equal to or less than the label width used for the test See page 36 for more information Selecting Prefix and Delimiter Characters Prefix and delimiter characters are 2 digit hex values used within the ZPL ZPL Il formats sent to the printer The printer uses the last prefix and delimiter characters sent to it whether from a ZPL Il instruction or from the front panel Note To change the values refer to the ASCII code chart on page 112 for character choices DO NOT use the same hex value for the Con trol Format and Delimiter character The printer needs to see di
68. er to the documentation provided with that option Setting the Applicator Port H Press the right or left oval key to display other choices Default Off Selections Off Mode 1 Mode 2 Mode 3 Mode 4 Determines the action of the verifier port Off The applicator port is off Mode 1 Asserts the END PRINT signal low while the printer is moving the label forward e Mode 2 Asserts the END PRINT signal high while the printer is moving the label forward Mode 3 Asserts the END PRINT signal low for 20 milliseconds when a label has been com pleted and positioned Not asserted during continuous printing modes Mode 4 Asserts the END PRINT signal high for 20 milliseconds when a label has been com pleted and positioned Not asserted during continuous printing modes uonedodQ 8v PMD s JOS 1ojuuq 2X e1qoz MEDIA LED RIBBON LED MARK LED LCD ADJUST These parameters are automatically set during the calibration procedure They should only be changed by a qualified service technician Refer to the maintenance manual for more information on these parameters Press the Next Save key repeatedly to skip these parameters LCD Display Adjustment H Press the left oval key to decrease the value reduce brightness press the right oval key to increase the value increase brightness Range 00 to 19 This parameter allows you to adjust the brightness of your display to accommodate your working environment Adjust th
69. es the means to automatically scan and analyze certain bar code symbols as they are printed If the verifier detects a problem with the bar code it will automatically pause the printer The operator must then correct the problem and take the printer out of pause mode before printing will resume Several operational modes are available ranging from simple freescan to one where specific symbology and data is required Applicator Interface The Applicator Interface is an ideal method of integrating Xill printers into custom applications This interface allows printer control from a personal computer or Programmable Logic Controller PLC via one cable attached to a connector located at the rear of the printer This provides the capability of placing the Xill printers on a production line in a loose loop print and apply configuration or other applications where the printer must be con trolled by a machine Media Supply Spindle The optional Media Supply Spindle replaces the standard hanger This is useful for applications that require the printer to be mounted in a non hori zontal position where the standard media hanger prohibits consistent media flow Zebra Xill Printer User s Guide 71 Options Optional Media Supply Fins Fonts Optional Media Supply Fins are available to convert the standard 3 inch 76 mm core diameter to a 1 77 inch 45 mm core for smaller core media rolls Simply remove the current fins and install the reduc
70. etin Board Service 94 Toggle Positioning 61 Troubleshooting Error Messages 63 Upper Media Sensor Figure 16 W Warranty Information iii Z Zebra On Line Verifier 77 Zebra Training Programs 101 ZPL Mode Setting 43 Zebra Xill Printer User s Guide Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills Illinois 60061 3109 Telephone 847 634 6700 Facsimile 847 913 8766 http www zebra com Zebra Technologies Europe Limited Zebra House The Valley Centre Gordon Road High Wycombe Buckinghamshire HP13 6EQ UK Telephone 44 0 1494 472872 Facsimile 44 0 1494 450103 Customer Order 48460L Manufacturer Part 48460LB Zebra Technologies Corporation
71. f reservations are canceled in writ ing at least fifteen 15 days prior to the start of the course Please note that when course enrollment is less than four attendees we reserve the right to cancel the course Zebra Xill Printer User s Guide Appendix Printer Interface Technical Information System Considerations Communications Code The Xill printer sends and receives American Standard Code for Informa tion Interchange ASCII This code consists of 128 characters 256 for Code Page 850 including uppercase and lowercase letters characters punctuation marks and various control codes Interfaces The method of interfacing the Zebra Xill Series printer to a data source depends on the communication options installed in the printer The standard interfaces are an RS 232 RS 422 RS 485 serial data port and a bi direc tional parallel port The IBM Twinax or IBM Coax option is available for those applications which require them Zebra Xill Printer User s Guide 105 Data Specifications When communicating via an asynchronous serial data port RS 232 RS 422 RS 485 the baud rate number of data and stop bits parity and hand shaking are user selectable Parity only applies to data transmitted by the Xill printer since the parity of received data is ignored When communicating via the parallel port the previously mentioned parameters are not considered Refer to Chapter 2 starting on page 23 to configure the communicatio
72. fferent characters to function properly CONTROL PREFIX NEXT SAVE Control Prefix Character a Press the left oval key to move to the next digit position press the right oval key to increase the value of the digit Default 7E tilde displayed as a black square Range 00 FF Exclude the values indicated on the ASCII code chart on page 112 The printer looks for this 2 digit hex character to indicate the start of a ZPL ZPL Il control instruc tion uonedod oprinz 1os IJUMA IK eJqoz tr NEXT SAVE NEXT SAVE FORMAT PREFIX DELIMITER CHAR Selecting ZPL Mode NEXT SAVE ZPL MODE Format Prefix Character o Press the left oval key to move to the next digit position press the right oval key to increase the value of the digit Default SE caret Range 00 FF Exclude the values indicated on the ASCII Code Chart in the Appendix The printer looks for this 2 digit hex character to indicate the start of a ZPL ZPL Il format instruc tion Delimiter Character H Press the left oval key to move to the next digit position press the right oval key to increase the value of the digit Default 2C comma Range 00 FF The Delimiter character is a 2 digit hex value used as a parameter place marker in ZPL ZPL II for mat instructions Refer to the ZPL I Programming Guide for more information Selecting ZPL Mode H Press the right or left oval key to display other choices Default ZPL II Selections
73. h 36 Print Width Setting 36 Printer Connections Parallel Cable 110 RS 232 interconnect cable 108 RS 422 RS 485 Interconnect Cable 109 RS 422 RS 485 Internal Connections 109 Printer Information Listing Bar Codes 36 Fonts 36 Formats 37 Images 37 Setup 37 Printer Op Maint courses table 103 Printer Self Tests Introduction to 69 Printer Status Sensors 29 Label Available Sensor 29 Media Sensor 29 Ribbon Sensor 29 Printhead Pressure Adjustment 62 Printhead Replacement Setting the Head Resistor Value 46 Printhead Test 46 Printhead Cleaning 56 Program Mode entering 31 Program Mode leaving 32 Protocol Setting 41 R Removing the Label Backing Material 14 Removing Used Ribbon 21 Diagram 21 Ribbon Loading 19 Diagram 18 123 Ribbon Sensor 29 Ribbon Sensor Calibration 38 Roll Media Loading Diagram 10 RS 232 Connections Figure 107 RS 232 RS 422 RS 485 Pinouts 106 RS 422 RS 485 Connections 109 RS 422 RS 485 Interconnection Cable 109 RS 422 RS 485 Internal Connections 109 RS 485 Interface 80 Self Tests Cancel Key 70 Communications Diagnostics 72 Feed Key 72 Feed Key and Pause Key 72 Pause Key 71 Sensor Profile Printing See Media Sensor Profile 38 Serial Data Port 106 Setup Exit key 27 Standard Printer Font Examples 90 Stop Bits Setting 40 124 Index Support Services 93 Take Label light 28 Tear Off Mode 24 Tear Off Position Setting 34 Tear Off Peel Off Plate 24 Technical Support 94 Technical Support Bull
74. hat lists all of the images currently stored in the printer s RAM optional EPROM or on an optional memory card List Formats Press the right oval key to print a label listing all available formats This selection is used to print a label that lists all of the formats currently stored in the printer s RAM optional EPROM or on an optional memory card List Setup Press the right oval key to print a label listing the current printer configuration This selection is used to print a label that lists the current printer configuration information Same as Cancel Key Self Test Initialize Memory Card b CAUTION Initializing will erase all previously stored information from the memory card Press the right oval key to select yes and proceed to the verification menu If your printer is set to require a password you will now be prompted to enter the password This selection initializes the memory card ARE YOU SURE Press the right oval key to initialize the card Press the left oval key to cancel the request and return to INITIALIZE CARD uonedodQ 8t opinz s Jos 1ojuuq IK e1qoz Media and Ribbon Sensor Calibration Note Before you begin this procedure make sure that the Maximum Length is set to a value equal to or greater than the length of the labels you are using If the Maximum Length is set to a lower value the calibration process will assume that continuous media is in the printer See page 36 for more information
75. he Upper Media Sensor Position Note If you own a 140Xill or 170Xill printer and need to move the sensor to the outside half of the maximum media width or from the outside half to the inside half contact a service technician to perform this procedure because it will require additional steps which are beyong the scope of this user s guide To adjust the upper media sensor follow these steps Remove ribbon if it is installed 2 Locate the Upper Media Sensor Refer to Figure 4 The Upper Media Sensor is directly below the adjustment screw head 3 Loosen the Upper Media Sensor Adjustment screw Phillips head 16 Zebra Xill Printer User s Guide Getting Started 4 Slide the upper sensor along the slot to the desired position When using label stock that has a gap between labels die cut labelstock position the media sensor anywhere along the gap EXCEPT where the rounded corners of the label are detected When using tagstock position the upper sensor directly over the hole or notch 5 Tighten the screw MEDIA SENSOR Figure 5 Lower Media Sensor Adjustment Lower Media Sensor Adjustment Refer to Figure 5 throughout this procedure 1 Locate the Lower Media Sensor assembly a spring clip holding a circuit board near the bottom rear of the printhead assembly 2 Position the sensor by sliding it in its slot so that the two brass colored infrared emitters are centered under the upper sensor 3 If you are moving
76. he Zebra printer To connect the printer to other DTE devices with DB 25 connectors such as the serial port of a PC an RS 232 null modem crossover cable should be used Zebra Xill Printer User s Guide 107 DB 9S DB 25P Connector Connector to P C to Xi Printer o ON OD OF Q n5 Figure 25 9 Pin to 25 Pin Interconnecting Cable When the printer is connected via its RS 232 interface to Data Communica tion Equipment DCE such as a modem use a standard RS 232 straight through interface cable Figure 26 illustrates the connections required for this cable g O m g m FRAME GROUND FG TRANSMIT DATA TD RECEIVE DATA RD REQUEST TO SEND RTS CLEAR TO SEND CTS DATA SET READY DSR SIGNAL GROUND SG CARRIER DETECT CD DATA TERMINAL READY DTR BONOUBWNA 1 2 3 4 5 6 7 8 20 Figure 26 25 Pin to 25 Pin Interconnecting Cable RS 422 RS 485 Interconnections The Zebra Xill printer may be connected to a host by either an RS 422 or an RS 485 interface The DB 25 connector on the rear of the printer uses spe cific pins for this purpose Figure 27 illustrates the required cable wiring for 108 Zebra Xill Printer User s Guide interconnecting to the printer s DB 25 connector Figure 28 illustrates the internal connections of the Xill printer s RS 422 or RS 485 connector Interconnecting Cable from Host to RS 422 RS 485 Port Male DB 25 To Printer
77. ices Default Tear Off Selections Tear Off Peel Off Cutter Rewind Applicator Print mode settings tell the printer the method of media delivery that you wish to use Be sure to select a print mode that your hardware configuration supports since some selections displayed are for optional printer features Setting Media Type Press the right or left oval key to display other choices Default Continuous Selections Continuous Non continuous This parameter tells the printer the type of media you are using Selecting continuous media requires that you include a label length instruction in your label format LLxxxx if you are using ZPL or ZPL II When you select non continuous media the printer feeds media to calculate label length the dis tance between two detections of the inter label gap webbing or alignment notch or hole Setting the Sensor Type Press the right or left oval key to display other choices Default Web Selections Web Mark This parameter tells the printer whether you are using media with a web gap space between labels notch or hole to indicate the separations between labels or if you are using media with a black mark printed on the back If your media does not have black marks on the back leave your printer at the default Web Selecting Print Method Press the right oval key for the next value press the left oval key for the previous value Default Thermal Transfer Selections Thermal Transfer Direct Ther
78. idity to affect printer operation Unpacking Save the carton and all packing materials in case shipping is ever required Inspect the printer for possible damage incurred during shipment Check all exterior surfaces Raise the media access door and inspect the media compartment Reporting Damage If you discover shipping damage upon inspection mmediately notify the shipping company of the damage Retain all packaging material for shipping company inspection File a damage report with the shipping company and notify your local distributor and Zebra Technologies Corporation of the damage Zebra Technologies Corporation is not responsible for any damage incurred during shipment of the equipment and will not repair this damage under warranty Immediate notification of damage to the shipping company or its insuring agency will generally result in ensuring any damage claim validity and ultimate monetary compensation 4 Zebra Xill Printer User s Guide Getting Started Storage and Reshipping If you are not placing the Xill printer into operation immediately repackage it using the original packing materials The Xill printer may be stored under the following conditions Temperature 4 to 140 F 20 to 60 C Relative humidity 5 to 85 non condensing To ship the Zebra Kl Series printer carefully pack it in a suitable container to avoid damage during transit Whenever possible use the original con tainer fro
79. ill Printer User s Guide Getting Started Adjusting the Transmissive Media Sensor Assembly Position Note Note When the Xill printer is powered on it performs a self test and configures its operating characteristics Some of these characteristics are determined by the position of the Transmissive Media Sensor See Figure 4 on page 16 The factory set position is sufficient for most types of media However if media sensor adjustments are needed follow the procedures below The Reflective Black Mark Media Sensor position is not adjustable it is positioned to accommodate all black mark media that meets the specifica tions listed in Media Specifications on page 86 If you are using continuous media no gap notch or hole between labels or black mark media position the transmissive sensor over the media so that the printer can detect an out of paper condition The factory set position should be sufficient for this purpose The Transmissive Media Sensor Assembly consists of two sections The media passes between a light source and a light sensor The light source is positioned below the media while the light sensor is positioned above the media This adjustment aligns the position of the light sensor with the notch or edge of the label Zebra Xill Printer User s Guide 15 Getting Started UPPER MEDIA SENSOR ADJUSTMENT 4 0 AR mu Figure 4 Upper Media Sensor Adjustment Adjusting t
80. in dots from the upper left hand corner of the label Line 3 Sets field origin selects font D defines field data as ZEBRA Line 4 Sets field origin selects bar code Code 39 sets barcode height at 20 dot rows defines field data for bar code as AAAO01 Line 5 Saves the format in the printer s memory as a graphic image named FORMA T2 the N indi cates do not print after saving Line 46 7 See Format 1 Line 8 Load and print the graphic image saved as FORMAT2 Line 9 See Format 1 52 Zebra Xill Printer User s Guide Operation Format 3 Using a Serialized Data Field Type this label format You ll get this printout A XA ZEBRA 2 LH3030 NNK N SAAB 12 POEM eee S SERIAL NUMBER 000000001 11 E DEER E FO20 180 AF SNSERIAL NUMBER 00000000111 1 Y FS Em ARGO 1 SERIAL NUMBER 88090000120 Line 1 3 See Format 1 Line 4 Defines field data for bar code as AAAOOL Line 5 Defines serialized field starting value of 111 increment by 1 insert leading zeros Line 6 Sets print quantity to 10 Line 7 See Format 1 Zebra Xill Printer User s Guide 53 54 Operation Zebra Xill Printer User s Guide rees Routine Care and Adjustment Cleaning Table 5 Cleaning Schedule Platen Roller Transmissive Media Air bl Direct Thermal Print Mode After every Sensor E roll of media or 500 ft of fanfold media Reflective Black Mark So
81. inter set up includes the loading and unloading of supplies operator preventive maintenance and the overview of communi cation interfaces and protocols The methods necessary to create the label ing solution include an overview of the following label creation tools e ZPL and ZPL I Z Tools Utility Software e Zebra s driver for the Windows operating system Labeling This program begins with a brief review of basic ZPL and ZPL II Since each of our printer operation and maintenance courses includes an overview of ZPL and ZPL II we recommend that students attend one of these courses Zebra Xill Printer User s Guide 103 104 Support Services prior to participating in this advanced program After reviewing basics this course looks at advanced ZPL techniques that increase throughput and enhance graphics capabilities The students use Z Tools software to apply images and TrueType fonts to labels Using Zebra s driver for the Win dows operating system and Zebra s BAR ONE SCAN ONE WEDGE ONE M and TRACK ONE software labels are created and printed and bar code data is accumulated and tracked in the TRACK ONE relational database To register for Zebra training call our Technical Training staff at 847 634 6700 ext 2384 To confirm your enrollment a 100 00 USD deposit or purchase order must be received at least thirty 30 days prior to the scheduled course com mencement Deposits will be refunded i
82. ions The above warranties are in lieu of all other warranties expressed or implied oral or written statutory or otherwise including any implied warranty of merchant ability or fitness for a particular purpose ZEBRA Technologies shall not be responsible for the specific application to which any Products are applied including but not limited to compatibility with other equipment Zebra Xill Printer User s Guide All statements technical information and recommendations relating to ZEBRA Products are based upon tests believed to be reliable but do not constitute a guarantee or warranty ZEBRA TECHNOLOGIES SHALL NOT UNDER ANY CIRCUMSTANCES WHATSOEVER BE LIABLE TO BUYER OR ANY OTHER PARTY FOR LOST PROFITS DIMINUTION OF GOOD WILL OR ANY OTHER SPECIAL OR CONSEQUENTIAL DAM AGES WHATSOEVER WITH RESPECT TO ANY CLAIM HEREUNDER IN ADDITION ZEBRA TECHNOLOGIES LIABILITY FOR WARRANTY CLAIMS SHALL NOT IN ANY EVENT EXCEED THE INVOICE PRICE OF THE PRODUCT CLAIMED DEFECTIVE NOR SHALL ZEBRA TECHNOLOGIES BE LIABLE FOR DELAYS IN REPLACEMENT OR REPAIR OF PROD UCTS No salesperson representative or agent of ZEBRA Technologies is authorized to make any guarantee warranty or representation in addi tion to the foregoing warranty NO WAIVER ALTERATION ADDITION OR MODIFICATION OF THE FOREGOING WARRANTIES SHALL BE VALID UNLESS MADE IN WRITING AND SIGNED BY AN EXECUTIVE OFFICER OF ZEBRA TECHNOLOGIES Zebra Software License Agreement The enclo
83. is if your display is difficult to read uonedod oprinz s 1os 1ojuuq IK eJqoz 6v NEXT SAVE LANGUAGE Selecting the Display Language Press the right or left oval key to display other choices Default English Choices English Spanish French German Italian This parameter allows you to change the language used on the front panel display You have now completed the entire Configuration and Calibration sequence You may do one of the following two things NEXT SAVE pelles SETUP EXIT NEXT SAVE DARKNESS SAVE SETTINGS PRINTER READY You are now back at the first parameter in the configuration sequence Save Settings Press the right or left oval key to display other choices Default Permanent Choices Permanent Temporary Cancel Load Defaults Load Last Save This display appears when you attempt to exit the configuration mode Permanent Permanently saves the changes even when printer power is turned off Temporary Saves the changes until changed again or until power is turned off Cancel Cancels all changes since you entered the configuration mode except for Darkness and Tear Off Position if they were changed Load Defaults Loads factory defaults Note Loading factory defaults will require Calibration and resetting the Head Resistor value Load Last Save Loads the values from the last permanent save Press the Next Save key to activate the displayed choice You hav
84. is loaded Load ribbon and recalibrate printer ribbon and recalibrate Load ribbon and recalibrate printer For thermal transfer mode Make sure that the snap plate is in place and clean No media loaded or incorrectly Load media correctly Rewind loaded Mode Media Loading on page 12 Misadjusted medi sensor Check position and sensitivity of media sensors Printer set for non continuous media but continuous media was loaded Printhead is not fully closed Close printhead completely R Set the head resistor value to match Printhead Resistor value not set cor recti the head resistance value printed on y the printhead See page 46 Printhead Open sensor not working Call a service technician Allow printer to cool Printing resumes automatically when the printhead element cools to operating temperature Printhead is dirty Clean the printhead See page 56 Set the head resistor value to match Printhead Resistor value not set cor recti the head resistance value printed on y the printhead See page 46 Load proper media or reset printer for current media type Printhead is overheated Printing continues while printhead heats up If error remains environ Printhead is not hot enough ment may be too cold for proper printing Relocate printer to warmer area A Set the head resistor value to match Printhead Resistor value not set cor recti the head resistance value printed on
85. ive away from Chicago s O Hare International airport A full range of subjects are offered from basic indoctrination through maintenance and adjustments to advanced programming techniques On site training and custom classes are available Class content can be customized and schedules developed upon request to address the specific needs of your organization Costs are dependent upon class length and material covered International Service and Support 100 In addition to our factory service and support programs your support and maintenance needs are provided through a network of authorized Zebra dis tributors and resellers in over 50 countries throughout the world These organizations offer a variety of service and support programs allowing you to select the service option that best meets your needs For more informa tion on the service suppliers in your country contact our Technical Support Staff Don t let a maintenance problem interrupt your label production Zebra Xill Printer User s Guide Support Services For more information about Zebra Technologies service and support pro grams contact our Technical Support staff at Zebra Technologies Corporation Zebra Technologies Europe Limited 333 Corporate Woods Parkway Zebra House The Valley Centre Vernon Hills Illinois 60061 3109 Gordon Road High Wycombe Buckinghamshire HP13 6EQ England Phone Number 847 913 2259 Phone Number 44 0 1494 472872 Telefax Number
86. l times as shown and then remove it from the spindle 3 Grasp the used ribbon and remove it from the Ribbon Take Up Spindle 4 Remove the empty core from the Ribbon Supply Spindle 5 Follow the Ribbon Loading procedure on page 19 to load the new rib bon Zebra Xill Printer User s Guide 21 22 Getting Started Zebra Xill Printer User s Guide Chapter 2 Operation Operating Your Zebra Xill Series Printer Now that your printer is ready for operation how does it work The Zebra Xill Series printer is designed to receive instructions from a host computer such as an IBM compatible PC To create a label you will either need to write a format in ZPL II which is a programming language for creating label formats or you will need to use a software program designed to for mat labels for the Zebra Xill Series printer If you are using label design software refer to the instructions provided with your software package to determine how to do this If you are using or plan to use ZPL II programming language to format your labels make sure you have a copy of the ZPL II Programming Guide Refer to the mail fax in card at the front of this book to obtain a copy For some sample ZPL II label formats refer to page 51 Zebra Xill Printer User s Guide 23 Operation Printer Operating Modes The Xill printer can be configured for one of several different operating modes by sending the proper commands from the host computer or by con
87. lons s E 85 Media Specifications 5 5o are DEOR ied eben ee 86 Power Line Cord Specifications e occ n ENEE te tree tr rine repens 87 Printet FOts 52 eet ee ee D UR ON sade is cols etes Lodge D des a rv eta 88 Standard Printer Fonts dere Dee 88 Standard Printer Font Examples 90 Optional Printer Fonts eerte tente te etna deiode 90 Optional Printer Font Examples 92 93 PLOW TO Reach Us non e reb Eer Egeter 93 Technical Suppott sitom uS PER EP i POI ION RERO 94 Zebra Technical Support Bulletin Board Service 94 Technical Support Service via Telephone seeeseeerreeerrrrerreee 94 Technical Support via Mail or Fax sse 95 Product Service and Support Programmis essere 97 Select the Program that Fits Your Business HI Extended Factory Service Agreement wss sseoss sosrsrosnsnssnnorsa 98 Third Party Support and Maintenance sess 98 Zebra Solution Center and National Sales and Service Center Support 98 Wang Customer Services Division 98 Zebra Factoty SELVICES siioni eret ibit pee iE demie er Sede 99 User Self Maintenance erc ter ERES 100 International Service and Support lU Zebra Trains Programs oe ote Reeg 101 Operation and Maintenance Courses 102 Bar Codes at Worksin re inore a e Eei 103 Labeling EEN 109 Printer Inte
88. lows is a simple yet effective method for adjusting the darkness to print in spec bar codes 1 Load media and ribbon if used calibrate the printer and select the proper print method 2 To print a label for evaluation use the following procedure A With power off press and hold the Feed key B Turn the printer power on then release the Feed key The printer will begin printing test labels 3 Print a label then press 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 are printed in a vertical format 4 Compare the test label printed to the bar codes in Figure 29 If the test label appears too dark or too light increase or decrease the darkness set ting accordingly 5 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 press the Pause key then press the Cancel key 7 Save the new settings permanently if desired Too Dark Dark 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 Zebra Xill Printer User s Guide 113
89. lvent Thermal Transfer Print Mode After every Media Sensor EVER roll of ribbon CAUTION Use only the cleaning agents indicated Zebra Technologies Corporation will not be responsible for any other fluids being used on this printer Zebra Xill Printer User s Guide 55 Routine Care and Adjustment Table 5 on page 55 provides a brief cleaning schedule Specific cleaning procedures are provided below A Preventive Maintenance Kit part 01429 is available from Zebra Kit items are also sold separately by the part numbers shown Preventive Maintenance Kit Solvent Alcohol 4 oz bottle part 01426 Applicators bag of 100 part 01427 Cleaning the Exterior The exterior surfaces of the Zebra KL Series printer may be cleaned with a lint free cloth Do not use harsh or abrasive cleaning agents or solvents If necessary a mild detergent solution or desktop cleaner may be used spar ingly Cleaning the Interior Remove any accumulated dirt and lint from the interior of the printer using a soft bristle brush and or vacuum cleaner Inspect this area after every four rolls of media Cleaning the Printhead and Platen Roller Note 56 Inconsistent print quality such as voids in the bar code or graphics may indicate a dirty printhead For best results perform the following cleaning procedure after every roll of ribbon You do not need to turn the printer off before cleaning the printhead If power is turned off all la
90. ly loaded No media is under the media sensor Printing is paused the display shows an error message and the Pause light is on SH Normal operation Pause Printer has stopped all printing operations Either the Pause key was pressed a On pause command was included in the label format the on line verifier detected II an error or a printer error was detected Refer to the display screen for more information Normal operation no data being received or processed Printer is receiving data from the host computer Flashing slows when the lashing printer cannot accept more data but returns to normal once data is again being received Data Data processing or printing is taking place No data is being received Flashi Oo 28 Zebra Xill Printer User s Guide Operation Printer Status Sensors Zebra Xill Series printer contains several status sensors These sensors alert the operator to various conditions by either stopping the printing or turning on a light Sensors are described in Table 3 Table 3 Printer Status Sensors Sensors whatitmonitons Howitworksg Sune Geen EECH If the printhead is open the Error light flashes Position Sensor printhead lever If the printhead is too cold the front panel dis play indicates this condition and printing contin Checks the temperature of the print ues while the printhead warms up If the head printhead is too hot printing stops while the printhead cools to standa
91. m the factory A shipping container can be purchased from Zebra Technologies Corporation if the original one is lost or destroyed If you use a different container package the printer carefully to avoid damage Zebra will not be responsible for shipping damage incurred due to improper pack aging CAUTION When packaging the printer in a rigid container use shock mounts or shock absorbing packing material A rigid container will allow shock on the out side to be transmitted undamped to the printer which may cause damage Also before packing remove all ribbon and media from the supply and take up rewind spindles to prevent damage to the printer Site Requirements CAUTION To insure that the printer has proper ventilation and cooling do not place any padding or cushioning material under the unit because this restricts air flow The Zebra Kl Series printer may be installed on any solid level surface of sufficient size and strength to accommodate the physical dimensions and weight of the unit The area enclosure in which the printer will operate must meet the environmental conditions specified Electrical power must be available and in close proximity to the printer Zebra Xill Printer User s Guide 5 Getting Started Since the Zebra Xill Series printer was designed and is fabricated as an industrial type unit it will function satisfactorily in areas such as ware houses factory floors and office environments that conform to specifi
92. mal The print method parameter tells the printer the method of printing you wish to use direct thermal no ribbon or thermal transfer using thermal transfer media and ribbon Note Selecting direct thermal when using thermal transfer media and ribbon creates a warning condition but printing will continue uonedodQ 9 opinz s Jos IJUMA IK e1qoz PRINT WIDTH NEXT SAVE MAXIMUM LENGTH NEXT SAVE Listing Printer Information LIST FONTS NEXT SAVE LIST BAR CODES NEXT SAVE Setting Print Width Press the right oval key to increase the value press the left oval key to decrease the value To change the unit of measurement press the left oval key until the unit of mea surement is active then press the right oval key to toggle to a different unit of measure inches mm or dots Default Range The default and range of acceptable values varries depending on what printer you have Refer to Printing Specifications on page 85 for further information about the ranges avail able for your model Select a print width that is closest to your media but AT LEAST as wide Print width tells the printer the width of the media you are using Setting width too narrow may result in unprinted por tions of your label format Setting width too wide wastes formatting memory and may cause print ing off the right side of the label Setting Maximum Length Press the left oval key to decrease the value press the right oval key to in
93. may be subject to civil liability All trademarks are the property of their respective owners Centronics is a registered trademark of Genicom Corporation Compugraphic is aregistered trademark and CG Triumvirate CG Triumvirate Condensed CG Palacio and CG Times are all Trademarks of AGFA Corpo ration Futura is a trademark of Fundicion Tipografica Neufville S A TrueType is a registered trademark of Apple Computer Inc Univers is a registered trademark of Linotype AG and or its subsidiaries IBM is a registered trademark and Windows is a trademark of IBM Cor poration BAR ONE SCAN ONE Stripe TRACK ONE WEDGE ONE Zebra ZPL and ZPL II are registered trademarks and Total Care is a trademark of Zebra Technologies Corporation Copyright Zebra Technologies Corporation All rights reserved Zebra Xill Printer User s Guide Warranty Information 1 Printer Warranty ZEBRA printers excluding thermal printheads which are warranted separately below are warranted against defects in material or work manship for six 6 months from the date of original shipment by ZEBRA Technologies Corporation This warranty does not cover normal wear and tear and shall be null and void if the equipment is modified improperly installed or used damaged by accident or neglect or in the event any parts are improperly installed or replaced by the user Since printhead wear is part of normal operations the original printhead and replacement printheads are cover
94. n parameters for the Xill printer The values selected must be the same as those used by the host equipment connected to the Xill printer RS 232 RS 422 RS 485 Serial Data Port The connections for these standard interfaces are made through the DB25S connector on the rear panel For all RS 232 input and output signals the Xill printer follows both the Electronics Industries Association s ELA RS 232 specifications and the Consultative Committee for International Telegraph and Telephone CCITT V 24 standard signal level specifications Table 11 RS 232 RS 422 RS 485 Pinouts BEER N Ote Pins 5 8 10 12 15 17 18 21 25 are not used and are unterminated 106 Zebra Xill Printer User s Guide RS 232 Interconnections The Zebra Xill printer is configured as Data Terminal Equipment DTE Figure 24 illustrates the internal connections of the printer s RS 232 con nector RS 232 Connector DTE Rear Panel DB 25S J3 Frame Ground TXD Transmit Data Output RXD Receive Data Input RTS Request To Send Output DSR Data Set Ready Input Signal Ground 5 VDC Source DTR Data Terminal Ready Output Figure 24 RS 232 Connections Figure 25 illustrates the connections required to interconnect the Xill printer with the standard 9 pin serial port connector on a PC Note If using a 9 pin to 25 pin adapter plug attached to the computer use a null modem cable between the adapter plug and t
95. ntinuous Media Since continuous media does not contain label start end indicators you must tell the printer via software how long each label is If you are using ZPL or ZPL I include a Label Length ALL instruction in each label for mat you send to the printer refer to your ZPL I Programming Guide If you are using other software to communicate with your printer refer to the instructions provided with that software Black Mark Media This type of media has black marks printed on the back that indicate the start end of each label The Reflective Media Sensor detects these marks which allows the printer to differentiate between labels It is generally used with a cutter to separate the labels because there is no gap between the labels to allow them to be peeled off To load media refer to Figures 1 through 3 and follow the loading proce dure for your application This section details the media loading instructions for the printer For descriptions of the operating modes refer to Chapter 2 starting on page 23 Zebra Xill Printer User s Guide Getting Started Tear Off Mode Media Loading DANCER ROLLER ASSEMBLY PLATEN ROLLER TEAR OFF PEEL OFF REWIND BAR SPINDLE OPTION SPINDLE HOOK K ONLY ON SELECT MODELS Figure 1 Media Loading Figure illustrates the method of loading media First move the Printhead Open Lever counterclockwise to the open position and raise the printhead Second slide the Medi
96. ntly by saving the new parame ters in memory Saving new parameters occurs whenever a Calibration procedure is performed Refer to Chapter 2 for further information about the Configuration procedure PRINTER CONFIGURATION DARKNESS TEAR OFF PRINT MODE MEDIA TYPE SENSOR TYPE PRINT METHOD PRINT WIDTH LABEL LENGTH MAXIMUM LENGTH HOST PORT BAUD DATA BITS PARITY STOP HOST HANDSHAKE PROTOCOL NETHORK ID COMMUNICATIONS CONTROL PREFIX FORMAT PREFIX DELIMITER CHAR ZPL MODE MEDIA POMER UP FIRMWARE IN THIS PRINTER IS COPYRIGHTED Figure 15 Cancel Key Self Test Sample Printout Zebra Xill Printer User s Guide Troubleshooting and Diagnostics Pause Key Self Test 1234567890123456789012345678901234567890123456789012345678901234567 Figure 16 Pause Key Self Test Sample Printout This self test can be used to provide the test labels required when making adjustments to the printer s mechanical assemblies See the sample printout in Figure 16 Turn the printer off Press the Pause key and hold while turning the power on 1 The initial self test prints 15 labels at speed A 2 4 per second then automatically pauses the printer Each time the Pause key is pressed an additional 15 labels print 2 While the printer is paused pressing the Cancel key alters the self test Now each time the Pause key is pressed the printer prints 15 labels at
97. only the subassembly s Products returned shall be packaged in the original packing and shipping container or comparable container In the event equipment is not so packaged or if shipping damage is evident it will not be accepted for service under warranty Surface transporta tion charges for the return of the printer to the customer shall be paid by ZEBRA Technologies within the 48 contiguous states and the Dis trict of Columbia Customer shall pay shipping costs customs clearance and other related charges outside the designated area If ZEBRA Technologies determines that the Product returned to it for warranty service or replacement is not defective as herein defined BUYER shall pay all costs of handling and transportation 2 Supplies Warranty ZEBRA supplies are warranted to be free from defects in materials or workmanship for a period of either the stated material shelf life or 6 months from date of shipment whichever occurs first provided that the BUYER has complied with ZEBRA Technologies guidelines on storage handling and usage of the labeling supplies in ZEBRA printers ZEBRA Technologies does not warrant the performance of ZEBRA labeling supplies on non ZEBRA printers Any supplies product shown to the satisfaction of ZEBRA Technologies within the time provided to be so defective shall be replaced without charge or ZEBRA Technologies may issue a credit in such an amount as it deems reasonable 3 Warranty Exclusions and Condit
98. ors are required to prevent radia tion and reception of electrical noise To minimize electrical noise pickup in the cable Keep data cables as short as possible Do not bundle the data cables tightly with the power cords Do nottie the data cables to power wire conduits Zebra printers comply with FCC Rules and Regulations Part 15 Subpart J for Class A Equipment using fully shielded 6 foot data cables Use of longer cables or unshielded cables may increase radiated emissions above the Class A limits RS 422 and RS 485 applications should use twisted shielded pairs as rec ommended in the Appendix of the TIA EIA 485 Specification Zebra Xill Printer User s Guide 111 ASCII Code Chart See Table 13 Shaded values are NOT recommended to be used for Com mand Prefix Format Prefix or Delimiter characters Table 13 ASCII Code Chart E 3 o Ei E als S Q x V Hex Character v ler re r d Zebra Xill Printer User s Guide 112 Adjusting Darkness for In Spec Bar Codes All direct thermal and thermal transfer materials do not use the same dark ness setting The best way to check for the proper darkness is to use a bar code verifier that actually measures bars spaces and will calculate the PCS Print Contrast Signal ratio Without the assistance of a verifier your eyes and or the scanner to be used in the system are the best way to select the optimum darkness setting What fol
99. ort Mechanism Capabilities The media transport mechanism of the Xill printer has been designed to accommodate various types of media including die cut labels ticket and tag stock continuous roll media fanfold media and black mark media Media may be rewound internally onto standard three inch cores if the Rewind Option is installed The Rewind Option also allows backing mate rial to be rewound internally so that the printer can operate in Peel Off mode Front Panel Display The Xill printer features a two line by 16 character per line liquid crystal display screen Operational status programming modes and parameters and other messages are displayed here This display features adjustable backlighting for added visibility 2 Zebra Xill Printer User s Guide Getting Started System Requirements In addition to the Xill printer you will need the following items to form a complete label preparation system e Label ticket or tagstock A device such as a computer for data entry and output of label formats e A data communication cable to connect the controlling device to the KO printer Remote installations may require additional cables and commu nication devices such as modems and or protocol converters Thermal transfer ribbon if printing in Thermal Transfer mode Media and Ribbon Requirements Print quality not only depends on the Zebra Xill Series printer but also on the printer s media and ribbon Factors su
100. ory to match the resistance value of the printhead It will not need to be changed unless 1 The printhead is replaced 2 The printer is set to the factory defaults The factory default value is usually lower than the actual resistance value CAUTION DO NOT set the value higher than that shown on the printhead Setting a higher value may damage the printhead Before replacing a printhead look on the bottom of the printhead element for the label that shows the resistance value ohm value uonedod WPMD s 1os 1ojuuq IK Jqoz LV NEXT SAVE NEXT SAVE VERIFIER PORT APPLICATOR PORT Setting the Verifier Port H Press the right or left oval key to display other choices Default Off Selections Off 1 VER RPRNT 2 VER THRUPUT The Auxiliary Port is used to determine how the printer will react to the Zebra On Line Verifier There are currently three operating conditions for this port Off tThe Verifier Port is off 1 VER RPRNT ERR Label reprinted if verifier detects an error If a bar code is near the upper edge of the label the label will be fed out far enough to be verified and then backfed to allow the next label to be printed and verified 2 VER THRUPUT Allows greatest throughput but may not indicate a verification error imme diately upon detection May print from 1 to 3 labels before an error is recognized and printing stops For more information on the operation of the optional verifier ref
101. pindle and that the ribbon is aligned squarely with its core If this is not done the ribbon may not cover the printhead entirely on the inside thereby exposing print elements to potentially damaging contact with the media 3 Open the Printhead by moving the Printhead Open Lever counterclock wise to the open position 4 Optional To make ribbon loading and unloading easier make a leader for your ribbon roll if it doesn t already have one Tear off a strip of media labels and backing about 6 to 12 inches long from the roll Peel off a label from this strip Apply half of this label to the end of the strip and the other half to the end of the ribbon This acts as a ribbon leader RIBBON LABEL STRIP OF MEDIA 6 12 INCHES LONG 5 Thread the ribbon with leader if used as shown without creasing or wrinkling it 6 Remove the hook from the Ribbon Take Up Spindle 7 Place the ribbon leader under the long leg of the hook and wind the rib bon onto the Ribbon Take Up Spindle for several turns in a counter clockwise direction 8 Close the Printhead by moving the lever clockwise to the closed posi tion Zebra Xill Printer User s Guide Getting Started Ribbon Removal RIBBON TAKE UP SPINDLE 2 HOOK 3 Figure 8 Removing Used Ribbon 1 Break the ribbon as close to the Ribbon Take Up Spindle as possible 2 Refer to Figure 8 Pull the hook out slightly rotate the hook back and forth severa
102. rd operating tempera ture Checks for proper media loading The Paper Out light will turn on if you run out of Transmissive If non continuous media is used media This condition will also occur if you are Printhead Temperature Sensor Media Sensor this sensor detects the label length using non continuous media and the media does for individual labels not move because it is jammed Reflective Detects the presence of black marks If it detects a black mark the printer knows that Media Sensor on the back of black mark media itis at the beginning of a label Monitors the presence of ribbon If you run out of ribbon the Check Ribbon light Sensor turns on Once a label prints it will pass between the two Label parts of this sensor and cause the printer to Available Peer on Mode TERRES seet pause The Take Label light turns on When the a label is available W Sensor label is removed printing resumes and the light turns off Zebra Xill Printer User s Guide 29 Operation Initial Printer Power Up Each time you turn the printer on it automatically performs a self test called the Power On Self Test POST Turn the printer on now by pressing the Power Switch at the rear of the printer The Front Panel Power On indicator will light up The other front panel indicator lights and the Liquid Crystal Display LCD monitor the progress of the Power On Self Test POST The self test sequence is shown in Tabl
103. reprinted areas on the media or experiences difficulty in determin ing web location If the sensitivity of the Media and or Ribbon Sensors MUST be adjusted use the Media and Ribbon Sensor Sensitivity procedure below NEXT SAVE uonedod PMO s 1os IJUMA IK eJqoz 6 NEXT SAVE MEDIA AND RIBBON CALIBRATE Media and Ribbon Sensor Sensitivity Press Next Save to skip this procedure and continue with Setting Host Port below Press the right oval key to start the calibration procedure This procedure is used to adjust the sensitivity of the Media and Ribbon Sensors Note The procedure must be followed exactly as presented All steps must be performed even if only one of the sensors requires adjustment 2 Display Shows Action Explanation LOAD BACKING REMOVE RIBBON CALIBRATING PLEASE WAIT RELOAD ALL MEDIA AND RIBBON CALIBRATE Press the left oval key to cancel the operation or do the following Open the Printhead Remove as many labels as needed to load a section of blank backing material under the media sensor just behind the printhead See Figure 4 Upper Media Sensor Adjust ment on page 16 to locate the sensor Press the left oval key to cancel the operation or do the following 1 Remove the ribbon sliding it as far to the right as possible will have the same effect as removing it 2 Close the Printhead The printer automatically adjusts the scale gain of the signals it rec
104. rface Technical Informatl tt s sssssssssssss sesessasssss ssrssnesssssnsossenissnss 105 System Considerations cete tenente etienne 105 viii Zebra Xill Printer User s Guide Cc Communications Code eese 105 Interfaces cse eter eee LOD Data Specifications ENEE 106 RS 232 RS 422 RS 485 Serial Data Port essssess 106 RS 232 Interconnections s sssssesesrsersorerir arean 107 RS 422 RS 485 Interconnections 108 Parallel Data Port 109 Parallel Port Interconnections 0snsenoesenese0000ee 110 Cabling Requirements eoo eR Hr er TEE ENERE 111 AS CIP COde Chait EE 112 Adjusting Darkness for In Spec Bar Codes sss 113 Too Dark pos EET 113 DS HON Daik EE 114 Shiehtly Lighters desorssonroetr 114 yore 114 EE 114 17 Zebra Xill Printer User s Guide Zebra Xill Printer User s Guide List of Figures 1 Media Loading 9 2 Roll Media Loading 10 3 Fanfold Media Loading 11 4 Upper Media Sensor Adjustment 16 5 Lower Media Sensor Adjustment 17 6 Ribbon Loading Diagram for the 90Xill and 140Xill Printers 18 7 Ribbon Loading Diagram for the 170Xill and 220Xil Printers 19 8 Removing Used Ribbon 21 9 Front Panel 26 10 Media and Ribbon Sensor Profile Sample Printout 50 11 Cleaning Diagram 57 12 Fuse Replacement Step 1 60 13 Fuse Replacement S
105. rface to your host mainframe s controller ZebraNet Ethernet Interface The ZebraNet Micro Print Server MPS provides ethernet connectivity for your Zebra printer The ZebraNet MPS is a multiprotocol print server It provides shared network access to a Zebra printer for a variety of network protocols and operating systems The MPS1 T provides a twisted pair 10Base T connector for network connections and a parallel Centronics port to which network nodes can spool print jobs The MPS1 2 provides a thinwire 10Base 2 connector and a parallel port for the same purposes Both servers can queue multiple pending jobs and service those jobs in the order in which they are received from the hosts Zebra Xill Printer User s Guide 79 Options RS 485 Interface The RS 485 interface provides a simple and cost effective way to connect a PC and multiple printers together to create an instant network This simple cabling system connects directly to a personal computer s serial port and allows multiple hook ups perfect for anyone who wants to connect several printers to a single host 80 Zebra Xill Printer User s Guide Chapter 6 Specifications Note Your printer may not have all of the options described in this chapter Media Handling Tear off mode Labels are produced in strips e Peel off mode Labels are dispensed and peeled from the liner as needed Cutter mode Labels are printed and individually cut Rewind mod
106. rference at his own expense In order to insure compliance this printer must be used with a Shielded Power Cord and Shielded Communication Cables The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies Corporation could void the user s authority to operate the equipment Canadian DOC Compliance Statement This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in the radio interference regulations of the Canadian Department of Communications CE Compliance If the accompanying printer displays the CE mark it also meets EMC directive 89 336 EEC with ammendments effective at the time of manufacture Liability Disclaimer Zebra Technologies Corporation takes steps to assure that its published Engineering specifications and Manuals are correct however errors do occur Zebra Technologies Corporation has been advised of the possibility of such damages Because some states do not allow the exclusion or limitation of liability for consequential or incidental damages the above limitation may not apply to you Copyrights This copyrighted manual and the label printer described herein are owned by Zebra Technologies Corporation All rights are reserved Unauthorized reproduction of this manual or the software in the label printer may result in imprisonment of up to one year and fines of up to 10 000 17 U S C 506 Copyright violators
107. rogram for our customers TotalCare is a comprehensive package of support services designed specifi cally for the Zebra line of printer products Zebra Xill Printer User s Guide Support Services Your business requires the Zebra printer to be ready when you are To help you Wang offers a complete maintenance program at your location You may choose from a variety of remedial support services Each includes toll free access to Wang s National Response Center Installation Relocation Services and Preventive Maintenance Procedures Those of you who do not contract for Wang TotalCare Service can still obtain service from Wang On site maintenance is available from Wang to non contracted customers on an as available basis Labor is billed at the normal hourly Wang labor rates and any parts that may need replacement are billed at list price Contact a member of our Technical Support staff for more information on Wang service options Zebra Factory Services The potential savings and peace of mind provided by prepaid service agree ments may not fit your business needs If you require a pay as you go ser vice program Zebra s Flat Rate Factory Service is the way to get quality repair work if the need arises It s simply a matter of contacting a member of our Technical Support staff with your service request We quote repair prices and issue a Return Mate rial Authorization RMA You ship us your equipment and we perform the rep
108. s download the free graphical user interface which provides point and click capabilities This service is available 24 hours a day 7 days a week With your PC or terminal connected to a modem simply dial 847 821 7113 and answer the sign on questions Prior to dialing set your system to 8 data bits no parity and 1 stop bit We automatically accommodate modem speeds up to 28 800 baud We recommend that you set a screen log in your communication package so that you can record the information accessed on your PC for off line review We support virtually all standard communications packages Technical Support Service via Telephone 94 Before you call Misunderstanding instructions or omitting a step are the most common sources of error Please reread the manual and use the table of contents and appendix for help Be prepared To possibly avoid the excess time and expense of a long Zebra Xill Printer User s Guide Support Services distance phone call please complete the service form page 96 in its entirety Only with ALL of the information requested can we give you accu rate and fast assistance Also you should be able to answer the following questions when you call Does the printer perform all self test functions properly Does the printer work properly with some equipment but not with other equipment e Are the cables the same Were the configuration settings changed sthe problem limited to one label or
109. sed software and documentation are protected by the United States copyright law and international treaty and therefore you must treat them like a book with the exception that you may make copies to protect yourself against loss of the original Your right to use the enclosed software and documentation as described below is non exclusive and non transferable Zebra retains owner ship in the software and documentation and all other right title and interest The enclosed software and documentation may be used by any number of people and may be freely moved from one computer to another as long as there is no possibility of their being used by more than one person on more than one computer at the same time Machine readable files representing graphics or fonts which you have created independently may be converted to ZPL format files using the enclosed software and such files may be used copied onto diskettes or font cards given away or sold without paying license fees to Zebra Pictorial or graphic images and machine readable files representing them may be protected by United States copyright law and interna tional treaty provisions which prohibits you from transcribing or scanning such images or using copying or converting such files without permission of the copyright owner You may not use this software in violation of U S copyright law or international treaty By using this software you agree to be bound by these terms Zebra Technologies Corpor
110. sinisst nssserirsogenrssribennsrsr 4 Storage and ReshippinB e eorr ee Een HO RS ERES 5 Site Requirements estre itp Up nep p reb seas e cipe ie te due RE dp dere E Printer Powet Up E 6 Voltage Selection onere teen tenta 6 Power Cord eoo nee etri 6 Communications desi eth eet e E EE ER e ee av NESSER 7 Loading E EE H Introduction to Media Loading esee 7 Non Continuous Media eee 8 Continuous Media ee erect rere 8 Black Mark Media H Tear Off Mode Media Loading eee 9 Roll Media Loading teet 10 Fanfold Media Loading sss 10 Continuous Media Loading eee eee 11 Cutter Mode Media Loading eee 12 Rewind Mode Media Loadung eee 12 Rewind Mode Configuration for Printers Without the Cutter Option eite tente ttes 12 Zebra Xill Printer User s Guide Rewind Mode for Printers With the Cutter Option 13 Peel Off Mode Media Loading ssisseswsssvsssvsr sv stsvsssnsrssvsnssnnsrs 14 Removing the Label Backing Material eee 14 Adjusting the Transmissive Media Sensor Assembly Position 15 Adjusting the Upper Media Sensor Position ss 16 Lower Media Sensor Adjustment s sesisssrcsssvesensrsesssssess rveressnss 17 Ribbon oO AGUS E 19 Ribbon Remoyalz2i Zeene 21 23 Operating Your Zebra St Series Printer secesii sissies
111. t each label tag immediately after it is printed diagnostics Information about what printer functions are not working This information is used for trouble shooting problems direct thermal printing Printing in which direct thermal media is used No ribbon is used Instead the media is coated with a substance which reacts to heat generated by the print head to produce an image fanfold media Media that comes folded in a rectangular stack rather than on a roll font A complete set of alphanumeric characters in one style of type Ex Times Univers ips inches per second See print speed label An adhesive backed piece of paper plastic or other material on which information is printed label available sensor For printers equipped with the Peel Off Option this sensor detects a printed label waiting to be taken or picked by the operator While it detects this label 118 the printer will not print additional labels Once the label has been taken printing resumes Also called take label sensor label backing label liner The material on which labels are affixed during manufacture and which is discarded or recycled by the end users Label backing or liner has a non stick sur face which allows the label to be eas ily removed by the end user and placed in the desired location media Material onto which data is printed by the printer Types of media include tagstock continuous fan
112. tep 2 60 14 Toggle Adjustment 61 15 Cancel Key Self Test Sample Printout 70 16 Pause Key Self Test Sample Printout 71 17 Feed Key Test Sample Printout 73 18 Communications Diagnostics Test Sample Printout 73 19 Power Line Cord 87 20 International Safety Organizations 87 21 Standard Printer Font Examples 90 22 Bitmap Smooth Fonts Point Size Examples 91 23 Select Examples of Optional Fonts 92 24 RS 232 Connections 107 25 9 Pin to 25 Pin Interconnecting Cable 108 26 25 Pin to 25 Pin Interconnecting Cable 108 27 RS 422 RS 485 Interconnecting Cable 109 28 RS 422 RS 485 Connections 109 29 Bar Code Examples 115 Zebra Xill Printer User s Guide List of Tables 1 Front Panel Keys 27 2 Front Panel Lights 28 3 Printer Status Sensors 29 4 Power On Self Test Sequence 30 5 Cleaning Schedule 55 6 Troubleshooting 63 7 Eight Dots mm Printhead 88 8 Twelve Dots mm Printhead 89 9 Optional Printer Fonts Currently Available 91 10 Zebra Printer Operation and Maintenance Courses 103 11 RS 232 RS 422 RS 485 Pinouts 106 12 Parallel Connector Pinouts 110 13 ASCII Code Chart 112 xii Zebra Xill Printer User s Guide Chapter 1 Getting Started Congratulations You have just purchased a high quality thermal demand printer manufactured by the industry leader in quality service and value Zebra Technologies Corporation For over 25 years Zebra has provided customers with the highest caliber of products and support This man
113. ter performing optimally Zebra Technical and Repair Services provide a broad range of service options If you are in need of technical assistance or repair services our technical support staff stands ready with answers to any ques tions you may have No matter how simple or complex your situation Zebra s Hotline Support is only a phone call away Call 847 913 2259 Select the Program that Fits Your Business If your Zebra equipment requires maintenance you can select the service option that best fits your needs Zebra offers several choices for customers located both within and outside of the United States Service options avail able within the United States include Extended Factory Service Agreement Customer Shipping Option Third Party Support and Maintenance Zebra Solution Center Sup port National Sales and Service Center Support Zebra Authorized National On site Service by Wang Customer Services Division Zebra Factory Services Flat Rate Factory Service User Self Maintenance Operator and Maintenance Training Programs No matter which program you choose you ll find the Zebra response con sistently fast and reliable Buying a maintenance agreement places a blanket of protection around your Zebra equipment It provides the peace of mind of knowing that your units are insured against unexpected and potentially costly repairs You have the assurance that service will be available when you need it minimizing your
114. the Configuration Label The resulting numeric value 0 to 30 is the best darkness value for that specific media ribbon combination Feed Key and Pause Key Self Test Pressing these two keys at the same time while turning the Power on tem porarily resets the Printer Configuration to the factory default values These values will be active only until power is turned off unless you save them permanently in memory Communications Diagnostics Test This test is controlled from the front panel display Refer to page 42 A typ ical printout from this test is shown in Figure 18 Turn the power off to exit this self test This label will be inverted when printed Additional Printer Diagnostics Additional diagnostic tests are available for the Zebra Xill printer however they are beyond the scope of this user s guide Refer to the maintenance manual part 48452L for information about these additional tests Zebra Xill Printer User s Guide Troubleshooting and Diagnostics Relative Darkness Print Speed 2 in sec SiscprzIs Segen subdouw Tf ru8jepaqe gt Ei s S m n 9 x c A a z 6 I P 2 E E c ES x x N Si 23456759 ABCDEFGHIJKLMNOPQRSTUVYWXYZ abcde Imnopqrstuvwxyz Figure 17 Feed Key Test Sample Printout FS FO394 25 AA 5E 46 53 5E 46 4F 33 39 34 2C 32 35 5E 41 41 N 18 10 FDCOOO0 4E 2C 31 38 2C 31 30 5E 46 44
115. the sensor away from the printer s main frame Gently pull wires out of the printer frame as required Wires should have a little slack Call a service technician if there is not enough slack Zebra Xill Printer User s Guide 17 Getting Started in the wires to adjust the sensor to the desired position If you are mov ing the sensor toward the printer s main frame and a large loop of wire develops call a service technician to properly adjust the wires RIBBON RIBBON TAKE UP SUPPLY ey cee PLATEN ROLLER UPPER ROLLER Figure 6 Ribbon Loading Diagram for the 90Xill and 140XiII Printers 18 Zebra Xill Printer User s Guide Getting Started RIBBON RIBBON TAKE UP SUPPLY 7 Se RIBBON 4 DOUBLE ROLLER PLATEN ROLLER UPPER ROLLER Figure 7 Ribbon Loading Diagram for the 170XiI and 220XilI Printers Ribbon Loading To load ribbon refer to Figures 6 and 7 and follow the procedure below Note Use ribbon that is at least as wide as the media The smooth backing of the ribbon protects the printhead from wear and premature failure due to exces sive abrasion For Direct Thermal Print Mode ribbon is not used and should not be loaded in the printer 1 Align the segments of the Ribbon Supply Spindle Zebra Xill Printer User s Guide 19 Getting Started Note 20 2 Place the ribbon roll on the Ribbon Supply Spindle Make sure that the core is pushed up against the stop on the ribbon supply s
116. tment 62 Media Sensor Position Adjustment 62 63 Printer DiaSMostics E 69 Power On Selt E OD Additional Printer Self Tests 69 Cancel Key Self Test 70 Pause Key Self EE 71 Feed Key Self Test 4 5 orm nies 72 Feed Key and Pause Key Self Test 72 Communications Diagnostics Test 72 Additional Printer Diagnostics s ssssssersreesrrerna 72 s Danae ME said 75 E E 76 Internal Fanfold Media Supply Bin see 76 Memory SIMMS ctor beni e p aet Oe tudo mi teet eee 76 Zebra On Line MERTES TI Applicator Interface esee eerte reden enne rere ae ea tend VE cR o e eo dE dh TI Media Supply Spindle e e Optional Media Supply Ems 78 Le e M PEE 78 PCMCIA Ty pel Memory Catds nee eee veter ees 78 KMT Brintliedd BEE 79 Communication Interfaces eese enne tenerent enne 79 IBM Twinax Interface eene ertet rct t endo neee ddoe 79 IBM Coax Interface ire rrr Pi Eed NEEN 79 ZebraNet Ethernet Interface sissit easirsasinenerises iaie 79 RS 485 Interface etre eH ER eR ee 80 Zebra Xill Printer User s Guide vii Chapter 6 Specifications 81 Media EL EE 81 E Le E ER Zebra Programming Language ZPE mn 82 bre n H U 83 General REI EES ERAI ELO A UNIONE 84 Printing Specifications geed EENS 85 Ribbon SpeciHc at
117. to the next position press the right oval key to change between and and to increase the value of the digit The displayed value represents dots Default 0000 Range 9999 to 9999 Note For a negative value enter the value before changing to the minus sign This parameter establishes how far from the left edge of a label the format will begin to print by adjusting horizontal positioning on the label Positive numbers adjust the printing to the left by the number of dots selected negative numbers shift printing to the right uonedodQ 9y WPMD s 1os 1ojuuq IK 8 1997 NEXT SAVE gt NEXT SAVE HEAD TEST COUNT HEAD RESISTOR Setting the Head Test Count H Press the left oval key to move to the next digit position press the right oval key to change the value of the digit Default 0000 Disables the test Range 0000 to 9999 The printer periodically performs a test of the printhead functionality called a Printhead Test or Head Test This parameter establishes how many labels are printed between these internal tests Setting the Head Resistor Value Press the left oval key to move to the next digit position press the right oval key to increase the value of the digit CAUTION This parameter should only be changed by qualified personnel Initial Value Factory set to match the printhead shipped with your printer varries Default Value 0500 Range 0500 1175 This value has been pre set at the fact
118. ual provides all of the information you will need to operate your printer on a daily basis To create label formats refer to the ZPL II Pro gramming Guide part 46469L if you did not order one with your printer it is available by sending in the card at the front of this manual There is also a maintenance manual for this printer The maintenance man ual part 48452L contains the information you may need in order to maintain your printer Introduction The Xill printer when connected to a host computer functions as a com plete system for printing labels tickets and tags The printer receives instructions from the host computer Microprocessors continuously monitor Zebra Xill Printer User s Guide 1 Getting Started these signals along with the inputs received from the control panel and vari ous sensors The microprocessors interpret this information and control the Xill printer s mechanics printhead communications command interpreta tion label formatting media control and mechanical drive Print Mechanism Capabilities The Xill print mechanism has been designed to print information on labels tickets and tags It uses a square or rectangular dot thermal printhead that heats a ribbon as it passes beneath the print elements melting its ink onto the media direct thermal print mode involves using heat sensitive media instead of an inked ribbon Print speeds may be selected via software con trol Media Transp
119. ure 9 Front Panel eo ov SE NEXT SAVE SETUP EXIT I O POWER CO TAKE LABEL f ERROR Q9 CHECK RIBBON OM PAPER OUT C PAUSE e FEED DATA CALIBRATE Zebra Xill Printer User s Guide Operation Front Panel Keys Table 1 Front Panel Keys Starts and stops the printing process If the printer is not printing no printing can occur Printing printing stops once the current label is complete Press to remove error messages from the display Note Pause Mode can also be activated via ZPL II PP PP Forces the printer to feed one blank label each time the key is pressed Printer not printing one blank label feeds immediately Printing one blank label feeds after the current batch of labels is complete Note Equivalent to the Slew to Home Position PH PH ZPL I instruction When in the Pause mode this key will cancel print jobs Print job in queue press once for each print job to be deleted Press and hold for several seconds to cancel all print jobs in the printer s memory The Data light will turn off When in Pause mode this key will calibrate the printer for Media length CALIBRATE Media type continuous or non continuous Print mode direct thermal or thermal transfer Note The keys below are used only when configuring the printer Specific uses of these keys are explained in the Configuration and Calibration section starting on page 31 4 Scrolls
120. y the printhead See page 46 Zebra Xill Printer User s Guide ERROR CONDITION HEAD ELEMENT BAD Experiencing print quality problems WARNING CUTTER JAMMED OUT OF MEMORY XXXXXXXXXXXXXX Printer stops and PAUSE light is on XXXXXXXXXXXXXX can be any of the following messages e Creating bitmap e Storing bitmap Building format Storing format Storing graphic Storing font Troubleshooting and Diagnostics Table 6 Troubleshooting Continued Printhead element is bad or going bad Printhead Resistor value not set cor rectly Cutter blade in media path Not enough memory to perform the function shown on the second line of the error message 0000000000000 To correct the situation call a ser vice technician to replace the print head To override this error message place JTO and JO in your ZPL I format Set the head resistor value to match the head resistance value printed on the printhead See page 46 Turn the power off Remove the media reload the media and turn the power on If the error condition still exists call a service technician You may do any of the following A B or C A For errors related to storing things With PAUSE on use the HM ZPL II command to display the amount of free memory Then Redesign graphic format to fit avail able memory or remove items from memory to create more space OR Press the Pause key to skip the step

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