Applicator Interface Option/Maintenance Kit

Installation Instructions

This kit includes the parts and documentation necessary to install the Applicator Interface
option/maintenance kit in the Xi4™ printers.

Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed below.

Table 1 • Parts List

 Ite Qt Part Number Description

m y1
Re P1007561 Xi4 5V Applicator Interface Option/Maintenance Kit
f
Re 1 P1011156 Xi4 24-28V Applicator Interface Option/Maintenance
f1 1 N/A Kit
Xi4 Applicator Interface
2 1 N/A Power Distribution Cable
3 1 N/A Communication Cable
4 2 HWQ0602 Cable Tie (sold in quantities of 20)
5 2 0 HW4396 Screw, M3 × 0.5 × 6 (sold in quantities of 25)
N/A = Not available as8a separate part (listed for identification purposes only).

Figure 1 • Kit Contents

1
2

3
4

© 2014 ZIH Corp. All product names and numbers are Zebra trademarks, and Zebra and the Zebra
logo are registered trademarks of ZIH Corp. All rights reserved. P1005575-002 Rev. A
5/1/14
2 Applicator Interface
Remove the Electronics Cover

Tools Required

Tools • You need these tools to complete this procedure:

 Phillips Screwdriver Set  Antistatic Wriststrap and Mat

 Wire Cutters

Remove the Electronics Cover

Note • Retain all parts removed during disassembly, unless otherwise directed.

1.
Caution • Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

Turn off (O) the printer, and then disconnect the AC power cord and all data cables.

2. See Figure 2. Remove the electronics cover by removing the three mounting screws
securing it.

Figure 2 • Remove the Electronics Cover

1 Electronics cover
2 Mounting screws (3)

P1005575-002 5/1/14
3. Lift up on the rear of the electronics cover, and then lift the electronics cover off the
printer.

4. Are you replacing an existing applicator interface board?

If… Then…
No a. See Figure 3. Remove and discard the option board slot cover by
removing and discarding the two mounting screws.
b. Go to Install the Applicator Interface Board on page 8.
Yes Continue with Remove the Old Applicator Interface Board on page 4.

Figure 3 • Remove the No Option Board Slot Cover

1 2

1 No option board slot cover

2 Option board slot
3 Mounting screws (2)
4 Applicator Interface
Remove the Old Applicator Interface Board

Remove the Old Applicator Interface Board

1. Are you working on a 110Xi4?

If… Then…
Yes a. See Figure 4. Disconnect the AC power input cable to the AC/DC
power supply and then open the white beaded cable tie and remove
the cables.
b. Cut the cable tie securing the applicator power cable to the AC/DC
power supply shield.
c. See Figure 5 on page 5. Remove the AC/DC power supply shield by
removing the two mounting screws and then lifting the shield out of
the printer.
d. See Figure 6 on page 5. Disconnect the applicator board cable from J6,
J7, or J8 on the AC/DC power supply.
e. See Figure 7 on page 6. Disconnect the applicator data cable from P31,
No a. P32, P33, or
See Figure P34page
8 on on the main logic the
6. Disconnect board (MLB).cable from the
applicator
output connector on the DC power supply, J5, J6, J7, J8, J9, or J10.
b. Open the white beaded cable tie and remove the applicator board
power cable.
c. See Figure 7 on page 6. Disconnect the applicator data cable from P31,
P32, P33, or P34 on the main logic board (MLB).

Figure 4 • Remove the AC Power Input Cable (110Xi4)

1
2

1 AC power input cable

2 White beaded cable tie
3 Cable tie
Figure 5 • Remove the AC/DC Power Supply Shield

1 AC/DC power supply shield

2 Mounting screws (2)

Figure 6 • Remove the Applicator Cables (110Xi4)

1
4
2
3

AC/DC power supply

J6, J7, and J8
3P31, P32, P33, and P34
4Main logic board (MLB)
 Figure 7 • Disconnect the Data Cable

P33P34
P31 P3
2
Figure 8 • Remove the Applicator Cables (140Xi4, 170Xi4, and 220Xi4)

1
5

4 2
3

DC power supply
J5 through J10
White beaded cable tie
4P31, P32, P33, and P34
5Main logic board (MLB)
2. Which model of applicator board are you removing?

If you removed a… Then…

5V See Figure 9. Remove the two mounting screws and then
slide the applicator board out of the printer.
24-28V Figure 10. Remove the two mounting screws and then slide
the applicator board out of the printer.

Figure 9 • Remove and Install the 5V Applicator Board

1 Applicator board
2 Mounting screws (2)
8 Applicator Interface
Install the Applicator Interface Board

Figure 10 • Remove and Install the 24-28V Applicator Board

1 Applicator board
2 Mounting screws (2)

Install the Applicator Interface Board

1. Which model of applicator board did you remove?

If you have a… Then…

5V a. See Figure 9. Remove the applicator board from the
maintenance/option kit and then slide it into the mounting
hole in the rear panel.
b. Install the two mounting screws.
c. See Figure 11. Connect the applicator data cable to J4 on
the applicator board.
d. Connect the applicator power cable to J5 on the applicator
24-28V a. board.
See Figure 10. Remove the applicator board from the
maintenance/option kit and then slide it into the mounting
hole in the rear panel.
b. Install the two mounting screws.
c. See Figure 11. Connect the applicator data cable to J1 on
the applicator board.
d. Connect the applicator power cable to J3 on the applicator
board.
 Figure 11 • Connect the Applicator Data and Power Cables

5V Applicator 24-28V Applicator

Board J4 J3
Board

J1
J5

2. See Figure 7 on page 6. Connect the other end of the applicator data cable to P31, P32,
P33, or P34 on the main logic board (MLB).

3. Are you working on a 110Xi4?

If… Then…
No a. See Figure 8 on page 6. Connect the other end of the power cable to
either of connectors J5 through J10 on the DC power supply.
b. Insert the applicator power cable into the white beaded cable and then
close the cable tie.
Yes a. See Figure 6 on page 5. Connect the other end of the applicator power
cable to J6, J7, or J8 on the AC/DC power supply.
b. See Figure 5 on page 5. Reinstall the AC/DC power supply shield and
secure it with the two mounting screws removed previously. Ensure the
shield flaps are tucked in between the power supply and the aluminum
mounting plate and that the applicator power cable comes out through
the access hole in the top of the AC/DC power supply shield.
c. Connect the AC power input cable and then reinstall the white plastic
beaded cable tie with all cables that were removed and add the
applicator board power cable.
10 Applicator Interface
Applicator Port Pin-Outs

Applicator Port Pin-Outs

5V Board
See Figure 12 and Table 2 to identify the pins, signals, and functions for the 5V applicator
board port.

Figure 12 • 5V Applicator Board Pin-Outs

Isolated Power Non-isolated Power Supply
Supply (no jumpers (jumpers installed)
installed)

JP2 JP2

+5V +5V

JP1 I/O SIGNAL GROUND 1A JP1 I/O SIGNAL GROUND

1A
1 1
+5V +5V I/O ISOLATED +5V +5V I/O NON-ISOLATED
INPUT 2
2 START PRINT
START PRINT 3
3 FEED
FEED 4
4 PAUSE
PAUSE 5
5 REPRINT
+28V REPRINT +28V 6
6 +28V OUTPUT
+28V OUTPUT 7
2A 7 2A POWER GROUND
POWER GROUND 8
8 RIBBON LOW
RIBBON LOW 9
9 SERVICE REQUIRED
SERVICE REQUIRED 10
10 END PRINT
END PRINT 11
11 MEDIA OUT
MEDIA OUT 12
12 RIBBON OUT
RIBBON OUT 13
13 DATA READY
DATA READY 14
14 SPARE (Non-RFID)
SPARE (Non-RFID) 15
15 VOID (RFID)
VOID (RFID)

Table 2 • 5V Applicator Interface Connector Pin Configuration

P
Signal Name Signal Type Description
i
n
1 I/O I/O Using jumper JP2, this pin can be configured as
SIGNAL Signal isolated or non-isolated from the printer signal
GROUND Ground ground. See Figure 13 on page 13 for location of
(+5V Return) jumpers.
Customer must provide this external ground
if they want to run isolated mode.
2 +5V I/O Power Using jumper JP1, this pin can be configured as
(Fused at 1 A) isolated or non-isolated from the Applicator Interface
Circuit +5V Supply. See Figure 13 on page 13 for
Caution •
Replace the
location of jumper if you want to run isolated mode.
fuse only with Customer must provide this external 5V power
one of the same if they want to run isolated mode.
type and rating.
 Table 2 • 5V Applicator Interface Connector Pin Configuration (Continued)

P
Signal Name Signal Type Description
i
n
3 START PRINT Input • Pulse Mode—The label printing process begins on
the HIGH to LOW transition of this signal if a
format is ready. De-assert this signal HIGH to
inhibit printing of a new label.
• Level Mode—Assert LOW to enable the printer
to print if a label format is ready. When de-
asserted HIGH, the printer completes the label
that is printing then stops and waits for this input
to be reasserted LOW.
4 FEED Input When the printer is idle or has been paused, assert this
input LOW to trigger repeated feeding of blank labels.
De-assert HIGH to stop feeding blank labels and
register to the top of the next label.
5 PAUSE Input To toggle the current Pause state, this input must
be asserted LOW for 200 milliseconds, or until the
SERVICE REQUIRED output (pin 10) changes
6 REPRINT Input state.
• If the Reprint feature is enabled, this input must
be asserted LOW to cause the printer to reprint
the last label.
• If the Reprint feature is disabled, this input is ignored.
7 +28V Power
(Fused at 200mA) Note • The Interface Power Supply. Supplies power
Caution to external sensors as required.
• Caution • Do not jumper the 28 volts from pin
Replace 7 to pin 2 on the 5V board. Damage to the
the fuse 5V board will occur.
only
with one of the
8 POWER GROUND Ground 28V ground if needed to power a device.
(+28V DC Return)
9 RIBBON LOW Output Asserted LOW if the Supplies Warning feature is
enabled and the amount of ribbon remaining on the
supply spindle is below the threshold level.
10 SERVICE Output Asserted LOW in the following circumstances:
REQUIR • the printhead is open
ED
• the ribbon or media is out
• the printer is paused
• an operational fault occurs
• a Resynch error occurs while the applicator
Resynch mode is set to Error mode
 Table 2 • 5V Applicator Interface Connector Pin Configuration (Continued)

P
Signal Name Signal Type Description
i
n
11 END PRINT Output • MODE 0—The applicator port is OFF.
• MODE 1—Asserted LOW only while the printer
is moving the label forward; otherwise de-
asserted HIGH.
• MODE 2—Asserted HIGH only while the printer is
moving the label forward; otherwise de-asserted
LOW.
• MODE 3—(Default) Asserted LOW for
20 milliseconds when a label is completed and
positioned. Not asserted during continuous
printing.
• MODE 4—Asserted HIGH for 20 milliseconds
12 MEDIA OUT Output when LOW
Asserted a label is there
while completed and positioned.
is no media Not
in the printer.
13 RIBBON OUT Output Asserted LOW while there is no ribbon in the printer.
14 DATA READY Output • Asserted LOW when sufficient data has been
received to begin printing the next label.
• De-asserted HIGH whenever printing stops after
the current label, due to either a pause condition
or the absence of a label format.
15 SPARE Output To be determined.
(No
n-
RFI
1 VOID Output • Asserted LOW when the RFID transponder over
5 the antenna is “voided.”
(RFI • De-asserted HIGH when the end print signal
D) is asserted.
Figure 13 • Isolated and Non-isolated Applicator Operation

Isolated Non-Isolated

Jumpers Removed
24.28V Applicator Board
See Figure 14 and Table 3 to identify the pins, signals, and functions for the 24-28V
applicator board port.

Figure 14 • 24-28V Applicator Board Pinouts

Isolated Power Supply Non-isolated Power Supply

I/O SIGNAL GROUND I/O SIGNAL GROUND

+24-28 I/O ISOLATED POWER +24-28 I/O ISOLATED POWER INPUT
INPUT START PRINT START PRINT
FEED FEED
PAUSE PAUSE
REPRINT REPRINT
+28V POWER OUTPUT +28V POWER OUTPUT

POWER GROUND POWER GROUND

RIBBON LOW RIBBON LOW

SERVICE REQUIRED SERVICE REQUIRED

END PRINT END PRINT

MEDIA OUT MEDIA OUT

RIBBON OUT RIBBON OUT

DATA READY DATA READY

SPARE (non-RFID) SPARE (non-RFID)
VOID (RFID) VOID (RFID)

Table 3 • 24-28V Applicator Interface Connector Pin Configuration

P
Signal Name Signal Type Description
i
n
1 I/O I/O No jumpers to configure.
SIGNAL Signal Customer must provide this external ground if
GROUND Ground they want to run isolated mode. (This ground
(+24-28V Return) can come from pin 8 when operating at 28V
non-
2 +24-28V I/O Power isolated mode
No jumpers to for all printers.)
configure.
(Fused at 2 A) Customer must provide this external power if
Replace the fuse they want to run isolated mode. (This power
only with one of can come from pin 7 when operating in 28V
the same type non-isolated
and rating. mode for all printers.)
3 START PRINT Input • Pulse Mode—The label printing process begins on
the HIGH to LOW transition of this signal if a
format is ready. De-assert this signal HIGH to
inhibit printing of a new label.
• Level Mode—Assert LOW to enable the printer
to print if a label format is ready. When de-
asserted HIGH, the printer completes the label
that is printing then stops and waits for this input
to be reasserted LOW.
 Table 3 • 24-28V Applicator Interface Connector Pin Configuration (Continued)

P
Signal Name Signal Type Description
i
n
4 FEED Input When the printer is idle or has been paused, assert this
input LOW to trigger repeated feeding of blank labels.
De-assert HIGH to stop feeding blank labels and
register to the top of the next label.
5 PAUSE Input To toggle the current Pause state, this input must
be asserted LOW for 200 milliseconds, or until the
SERVICE REQUIRED output (pin 10) changes
6 REPRINT Input state.
• If the Reprint feature is enabled, this input must
be asserted LOW to cause the printer to reprint
the last label.
• If the Reprint feature is disabled, this input is ignored.
7 +28V Power The printers internal power supply. Supplies power
(Fused at 500mA) to external sensors as required.
Caution Note • If operating with 28V signals only, pin
• 7 may be used to supply power to pin 2,
Replace creating a 28V non-isolated mode of
the fuse operation.
only
with one of the
8 POWER GROUND Ground The internal power Ground.
(+28V DC Return) Note • If pin 7 is used to supply power to pin
2, use this pin to ground pin 1, creating 28V
non-isolated mode of operation.
9 RIBBON LOW Output Asserts LOW if the Supplies Warning feature is
enabled and the amount of remaining ribbon
remaining on the supply spindle is below the
threshold level.
10 SERVICE Output Asserted LOW in the following circumstances:
REQUIR • the printhead is open
ED
• the ribbon or media is out
• the printer is paused
• an operational fault occurs
• a Resynch error occurs while the applicator
Resynch mode is set to Error mode
 Table 3 • 24-28V Applicator Interface Connector Pin Configuration (Continued)

P
Signal Name Signal Type Description
i
n
11 END PRINT Output • MODE 0—The applicator port is OFF.
• MODE 1—Asserted LOW only while the printer
is moving the label forward; otherwise de-
asserted HIGH.
• MODE 2—Asserted HIGH only while the printer is
moving the label forward; otherwise de-asserted
LOW.
• MODE 3—(Default) Asserted LOW for 20
milliseconds when a label is completed and
positioned. Not asserted during continuous
printing.
• MODE 4—Asserted HIGH for 20 milliseconds
12 MEDIA OUT Output when LOW
Asserted a label is there
while completed and positioned.
is no media Not
in the printer.
13 RIBBON OUT Output Asserted LOW while there is no ribbon in the printer.
14 DATA READY Output • Asserted LOW when sufficient data has been
received to begin printing the next label.
• Deasserted HIGH whenever printing stops after
the current label, due to either a pause condition
or the absence of a label format.
15 SPARE Output To be determined.
(No
n-
RFI
1 VOID Output • Asserted LOW when the RFID transponder over
5 the antenna is “voided.”
(RFI • De-asserted HIGH when the end print signal
D) is asserted.
 Applicator Interface 17
Input/Output Specifications

Input/Output Specifications

Figure 15 • Typical Input Circuit

Opto V_I/O
Isolator
LED

R
Input

Table 4 • Input User Specifications

Applicator Resistor at Maximum Current Minimum

Board V_I/O Current
24-28V 4.7K Ohm 6mA at 28V 2mA

5V 220 Ohm 18mA at 5V 2mA

Figure 16 • Typical Output Circuit

Opto V_I/O
Isolator
Photo-transistor Present on 24-28V
Applicator
Interface Board
Only

10K Ohm

Output

I/O Signal Ground

Table 5 • Output User Specifications

Output Current
a. Limited by 10K ohm pull-up resistor.
Ioh
b. Not actively driven high.
18 Applicator Interface
Reinstall the Electronics Cover
a. 7mA maximum.
Iol
b. Not intended to sink high current loads.
Reinstall the Electronics Cover
1. See Figure 2 on page 2. Reinstall the electronics cover by aligning the cover so that it
slips over the main frame.

2. Reinstall the mounting screws to secure the electronics cover.

3. Reconnect the AC power cord and all data cables.

4. Turn on (l) the printer.

 Applicator Interface 19
Reinstall the Electronics Cover
Printed in
China on
chlorine-free
recycled paper. P1005575-002