Zebra® Xi4™ User Guide
© 2009 ZIH Corp. The copyrights in this manual and the software and/or firmware in the printer described therein are owned by ZIH Corp. Unauthorized reproduction of this manual or the software and/or firmware in the printer may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability. This product may contain ZPL®, ZPL II®, and ZebraLink™ programs; Element Energy Equalizer® Circuit; E3®; and Monotype Imaging fonts.
Declaration of Conformity Declaration of Conformity We have determined that the Zebra printers identified as the Xi4™ Series 110Xi4™, 140Xi4™, 170Xi4™, 220Xi4™ manufactured by: Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills, Illinois 60061-3109 U.S.A.
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 in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications.
Contents Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Compliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents 5 • Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . .
Contents Print Specifications by Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Xi4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140Xi4, 170Xi4, and 220Xi4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Document This section provides you with contact information, document structure and organization, and additional reference documents. Contents Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Document Who Should Use This Document Who Should Use This Document This User Guide is intended for use by any person who needs to perform routine maintenance, upgrade, or troubleshoot problems with the printer. How This Document Is Organized The User Guide is set up as follows: P1009874-001 Section Description Introduction on page 15 This section provides a high-level overview of the printer and its components.
About This Document Contacts Contacts Technical Support via the Internet is available 24 hours per day, 365 days per year. Web Site: www.zebra.com E-mail Back Technical Library: E-mail address: emb@zebra.com Subject line: Emaillist Self Service Knowledge Base: www.zebra.com/knowledgebase Online Case Registration: www.zebra.
About This Document Document Conventions Document Conventions The following conventions are used throughout this document to convey certain information. Alternate Color (online only) Cross-references contain hot links to other sections in this guide. If you are viewing this guide online in .pdf format, you can click the cross-reference (blue text) to jump directly to its location. LCD Display Examples Text from a printer’s Liquid Crystal Display (LCD) appears in Bubbledot ICG font.
About This Document Document Conventions Illustration Callouts Callouts are used when an illustration contains information that needs to be labeled and described. A table that contains the labels and descriptions follows the graphic. Figure 1 provides an example.
About This Document Document Conventions Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ______________
1 Introduction This section provides a high-level overview of the printer and its components. Contents External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction External View External View Figure 2 shows the components inside the media compartment of your printer. Depending on printer model and the installed options, your printer may look slightly different. Familiarize yourself with these components before continuing with the printer setup procedure.
Introduction Control Panel Control Panel All controls and indicators for the printer are located on the control panel (Figure 3). • The control panel Liquid Crystal Display (LCD) shows the operating status and printer parameters. • The control panel buttons are used to control the printer operations and to set parameters. • The control panel lights (LEDs) show the printer’s operating status or indicate which control panel buttons are active.
Introduction Control Panel 5 LCD The control panel LCD functions differently in different printer modes. • In Operating mode, the LCD displays the printer’s status, sometimes in conjunction with a control panel light. • In Pause mode, the printer stops printing temporarily. • In Setup mode, you can use the control panel LCD to view or modify printer parameters (see Standard Control Panel Parameters on page 99).
2 Printer Setup This section provides the tasks that you must complete and the issues that you must consider before you load and configure your printer. Contents Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Setup Before You Begin Before You Begin Review this checklist, and resolve any issues before you set up or use your printer. Unpack and Inspect the Printer Have you unpacked the printer and inspected it for damage? If you have not, see Unpack and Inspect the Printer on page 21. Select a Site Have you selected an appropriate location for the printer? If you have not, see Select a Site for the Printer on page 22.
Printer Setup Handling the Printer Handling the Printer This section describes how to handle your printer. Unpack and Inspect the Printer When you receive the printer, immediately unpack it and inspect for shipping damage. • Save all packing materials. • Check all exterior surfaces for damage. • Raise the media door, and inspect the media compartment for damage to components. If you discover shipping damage upon inspection: • Immediately notify the shipping company and file a damage report.
Printer Setup Select a Site for the Printer Select a Site for the Printer Consider the following when selecting an appropriate location for your printer. Select a Surface Select a solid, level surface of sufficient size and strength to accommodate the printer and other equipment (such as a computer), if necessary. The choices include a table, countertop, desk, or cart. For the printer’s weight and dimensions, see General Specifications on page 164.
Printer Setup Select a Data Communication Interface Select a Data Communication Interface Table 3 provides basic information about data communication interfaces that you can use to connect your printer to a computer. You may send label formats to the printer through any data communication interface that is available. Select an interface that is supported by both your printer and your computer or your Local Area Network (LAN).
Printer Setup Select a Data Communication Interface Data Cables and Wireless Cards You must supply all data cables or wireless cards for your application. Data Cables Ethernet cables do not require shielding, but all other data cables must be fully shielded and fitted with metal or metallized connector shells. Unshielded data cables may increase radiated emissions above the regulated limits. To minimize electrical noise pickup in the cable: • Keep data cables as short as possible.
Printer Setup Select a Data Communication Interface Table 4 • Connecting the Printer to a Computer or Network 2/23/09 Interface Connection and Configuration RS-232 Serial The baud rate, number of data and stop bits, the parity, and the XON/XOFF or DTR control must match those of the host computer. See Standard Control Panel Parameters on page 99 to view or change these parameters. IEEE 1284 Bidirectional Parallel No additional configuration is necessary.
Printer Setup Select a Data Communication Interface Table 4 • Connecting the Printer to a Computer or Network (Continued) Interface Connection and Configuration USB No additional configuration is necessary. Caution • Be careful not to plug the USB cable into the wired Ethernet print server connector on the printer because doing so will damage the connector.
Printer Setup Connect the Printer to a Power Source Connect the Printer to a Power Source The AC power cord must have a three-prong female connector on one end that plugs into the mating AC power connector at the rear of the printer. If a power cable was not included with your printer, refer to Power Cord Specifications on page 28. Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation.
Printer Setup Connect the Printer to a Power Source Power Cord Specifications Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation. This cord must use an IEC 320 female connector and the appropriate region-specific, three-conductor grounded plug configuration. Depending on how your printer was ordered, a power cord may or may not be included.
Printer Setup Types of Media Types of Media Important • Your printer can use various types of media: • Standard media—Most standard media uses an adhesive backing that sticks individual labels or a continuous length of labels to a liner. • Tag stock—Tags are usually made from a heavy paper. Tag stock does not have adhesive or a liner, and it is typically perforated between tags.
Printer Setup Types of Media Table 5 • Roll and Fanfold Media Media Type Non-Continuous Roll Media How It Looks Description Roll media is wound on a 3-in. (76-mm) core. Individual labels are separated by one or more of the following methods: • Web media separates labels by gaps, holes, or notches. • Black mark media uses pre-printed black marks on the back side of the media to indicate label separations.
Printer Setup Ribbon Overview Ribbon Overview Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is transferred to the media during the thermal transfer process. The media determines whether you need to use ribbon and how wide the ribbon must be. When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is narrower than the media, areas of the printhead are unprotected and subject to premature wear.
Printer Setup Ribbon Overview Adhesive Test If you have labels available, perform the adhesive test to determine which side of a ribbon is coated. This method works well for ribbon that is already installed. To perform an adhesive test, complete these steps: 1. Peel a label from its liner. 2. Press a corner of the sticky side of the label to the outer surface of the roll of ribbon. 3. Peel the label off of the ribbon. 4. Observe the results.
3 Operations This section provides the procedures for loading and calibrating the printer. Note • Complete the tasks and resolve the issues in Printer Setup on page 19 before operating the printer. Contents Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mode Descriptions and Printer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operations Print Modes and Printer Options Print Modes and Printer Options The printer can use different print modes and options for label removal (Table 6). Use a print mode that matches the media being used and the printer options available. For more information on the types of media, see Types of Media on page 29. To select a print mode, see Select Print Mode on page 101.
Operations Print Modes and Printer Options Media Paths Table 7 shows the media paths for print mode and printer option combinations using roll media. Fanfold media uses the same print modes and printer options as roll media. RFID printers can use all of these printer options and have the same media paths.
Operations Print Modes and Printer Options Table 7 • Media Paths for Print Modes with Various Printer Options (Continued) Print Mode Printer Option Cutter Cutter Rewind Rewind (without Cutter option) Rewind Rewind (with Cutter option) Media Path Red solid lines = media, Blue dotted lines = backing only P1009874-001 Xi4 User Guide 2/23/09
Operations Prepare the Media for Loading Prepare the Media for Loading You can use roll media or fanfold media in your printer. Roll media hangs on and is loaded from the media supply hanger. Fanfold media is stored away from or in the bottom of the printer and can drape across the media supply hanger. Roll Media To place roll media on the media supply hanger, complete these steps: 1. Raise the media door. 2. Remove and discard any tags or labels that are dirty or that are held by adhesives or tape.
Operations Prepare the Media for Loading 3. Insert the media into the printer. 110Xi4 Other Xi4 Models a. Pull out the media supply guide as far as it goes. a. Slide out and flip down the media supply guide. b. Place the roll of media on the media supply hanger. Push the roll as far back as it will go. b. Place the roll of media on the media supply hanger. Push the roll back as far as it will go. c. Slide in the media supply guide until it touches the edge of the roll. c.
Operations Prepare the Media for Loading Fanfold Media You can store fanfold media behind the printer (rear feed) or under the printer (bottom feed). Using the media supply hanger is optional. To load fanfold media, complete these steps: 1. Raise the media door. 2. Thread the fanfold media through the rear access slot (1) or the bottom access slot (2). If using... Then use this access slot...
Operations Prepare the Media for Loading 3. Do you wish to use the media supply hanger? If… Then… No Continue with the media loading procedure for the desired print mode. Yes a. Slide out and flip down the media supply guide. b. Drape the media over the media supply hanger. 4. Flip up the media supply guide, and then slide it in until it touches the edge of the media.
Operations Load Media in Tear-Off Mode Load Media in Tear-Off Mode Follow these instructions to operate the printer in Tear-Off mode. Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead. You are not required to turn off the printer power when working near an open printhead, but Zebra recommends it as a precaution.
Operations Load Media in Tear-Off Mode 5. Slide the outer media guide (1) all the way out. 1 6. If your printer includes a media dancer assembly (1), thread the media under the media dancer assembly roller. For all printers, thread the media under the media guide roller (2) and then the upper media sensor (3). Important • Make sure that you thread the media under these components. If you thread the media over the them, the media obstructs the ribbon sensor and causes a false RIBBON OUT error.
Operations Load Media in Tear-Off Mode 7. Push the media forward until it passes under the printhead assembly (1), under the snap plate (2), and then over the platen roller (3). 1 2 3 8. Align the media with the inner media guide (1). Slide in the outer media guide (2) until it just touches the edge of the media.
Operations Load Media in Tear-Off Mode 9. Tighten the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 10. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) clockwise until it locks into place.
Operations Load Media in Peel-Off Mode Load Media in Peel-Off Mode Peel-Off mode (Figure 7) advances one label at a time. The printer does not print another label until the first label is removed. The TAKE LABEL light flashes until the label is removed. The backing is wound on the rewind spindle, but the rewind plate is not used.
Operations Load Media in Peel-Off Mode Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead. You are not required to turn off the printer power when working near an open printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose all temporary settings, such as label formats, and you must reload them before you resume printing.
Operations Load Media in Peel-Off Mode 4. Open the printhead assembly by rotating the printhead-open lever (1) counter-clockwise. 1 5. Loosen the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 6. Slide the outer media guide (1) all the way out.
Operations Load Media in Peel-Off Mode 7. If your printer includes a media dancer assembly (1), thread the media under the media dancer assembly roller. For all printers, thread the media under the media guide roller (2) and then the upper media sensor (3). Important • Make sure that you thread the media under these components. If you thread the media over the them, the media obstructs the ribbon sensor and causes a false RIBBON OUT error. 3 2 1 8.
Operations Load Media in Peel-Off Mode 9. Extend approximately 36 in. (920 mm) of media out of the printer. Remove and discard the labels from this exposed media. 10. Remove the hook from the rewind spindle. 11. If you are using a core, slide it onto the rewind spindle until it is flush against the guide plate. Note • A core is not required. 12. Wind the media liner counterclockwise around the rewind spindle. a. 2/23/09 Reinstall the hook.
Operations Load Media in Peel-Off Mode 2 1 b. Rotate the spindle counterclockwise several turns to wind the media liner over the hook and remove any slack. 13. Align the media with the inner media guide (1). Slide in the outer media guide (2) until it just touches the edge of the media.
Operations Load Media in Peel-Off Mode 14. Tighten the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 15. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) clockwise until it locks into place. 2 1 The backing winds on the rewind spindle or core. 16. For instructions for removing the backing from the rewind spindle, see Remove Media Liner from the Rewind or Peel Spindle on page 64.
Operations Load Media in Cutter Mode Load Media in Cutter Mode A cutter is a rotating knife with a self-sharpening blade that is attached to the front of the printer. The cutter is used to cut individual labels as they are printed. Figure 8 shows the printer loaded with labels in Cutter mode.
Operations Load Media in Cutter Mode 3. Open the printhead assembly by rotating the printhead-open lever (1) counter-clockwise. 1 4. Loosen the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 5. Slide the outer media guide (1) all the way out.
Operations Load Media in Cutter Mode 6. If your printer includes a media dancer assembly (1), thread the media under the media dancer assembly roller. For all printers, thread the media under the media guide roller (2) and then the upper media sensor (3). Important • Make sure that you thread the media under these components. If you thread the media over the them, the media obstructs the ribbon sensor and causes a false RIBBON OUT error. 3 2 1 7. Caution • The cutter blade is sharp.
Operations Load Media in Cutter Mode 8. Align the media with the inner media guide (1). Slide in the outer media guide (2) until it just touches the edge of the media. 1 2 9. Tighten the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1).
Operations Load Media in Cutter Mode 10. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) clockwise until it locks into place.
Operations Load Media in Rewind Mode Load Media in Rewind Mode Rewind mode (Figure 9) allows the media to be wound on a core after printing. This section shows how to load media for Rewind mode in printers that do not have a Cutter option.
Operations Load Media in Rewind Mode Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead. You are not required to turn off the printer power when working near an open printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose all temporary settings, such as label formats, and you must reload them before you resume printing.
Operations Load Media in Rewind Mode 7. Insert media into the printer. See Prepare the Media for Loading on page 37 for instructions. 8. Open the printhead assembly by rotating the printhead-open lever (1) counter-clockwise. 1 9. Loosen the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 10. Slide the outer media guide (1) all the way out.
Operations Load Media in Rewind Mode 11. If your printer includes a media dancer assembly (1), thread the media under the media dancer assembly roller. For all printers, thread the media under the media guide roller (2) and then the upper media sensor (3). Important • Make sure that you thread the media under these components. If you thread the media over the them, the media obstructs the ribbon sensor and causes a false RIBBON OUT error. 3 2 1 12.
