Tip & How-To about Zebra 110Xi III Plus Thermal Printer

How to locate and align the media sensors on Zebra Xi series and Z105 series printers

One of the most common problems with Zebra Xi, XiII, XiIII, Xi4, and 105S,105Se, 105SL series of printers is sensing or proper advancement of the labels. The printer has two sensors, top and bottom, that must be properly aligned with each other.
The label passes between the sensors. The idea is that the label blocks the light between the two sensors and the gap between each label does not block the light. So the labels advance based on light, no light, light, no light etc... When you press the calibrate button, the printer is checking for this alternating condition. The printer also uses this principle to know when there are no more labels. Once the condition stays at “light” for a certain distance, the printer will show “out of labels”.
Here’s what is important to understand: These two sensors can be moved left and right across the width of the printer. They move independently of each other and this is what usually causes problems with the labels not advancing properly. See my video at the link below and it will walk you through step-by-step on how to properly align the two sensors.
**Note that the red light you see in the “throat” of the printer when you raise the printhead is not the sensor being discussed here. That red light is a “reflective” or “mark” sensor and is used for labels that have no vertical gaps and have a black mark printed on the backside of the liner.

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