0/kÂkÅ 3Åk¿ÅÌ ×bk ÂÌÎkÌ>kNÂ@Ì¥æz0lÔ @bÌ¥Êæ0ÔÌ,ÂÎkÂÅ Customer Order # 11991L Manufacturer Part # 11991LB Rev.
3URSULHWDU\ 6WDWHPHQW This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Corporation.
2AOlÍyÍ ÏlÏÆ ÏÃcØYÏ ³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³¦ Scope........................................................................................................................1 Model Designation...................................................................................................1 System Overview .....................................................................................................2 Communication Capabilities ...........................
Media Loading....................................................................................................... 15 Roll Media........................................................................................................ 15 Tear-Off Mode ................................................................................................. 17 Rewind Mode ................................................................................................... 17 Peel-Off Mode...............................
yØÃAÏÍAcÍ AOÃAÏ ³³³³³³³³³³³³³³³³³³³³³³³³³³³³Ñ Option Switches .....................................................................................................39 Bank 1 ...............................................................................................................40 Bank 2 ...............................................................................................................41 Configuration Mode........................................................................
cØÆÏlÏÆ ³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³{ Toggle Positioning................................................................................................. 59 Printhead Pressure Adjustment.............................................................................. 59 Black Mark Media Sensor Position Adjustment ................................................... 60 Transmissive Media Sensor Position Adjustment .................................................
®®lcà ³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³qÑ 230 VAC Power Cord ............................................................................................83 ASCII Code Chart..................................................................................................84 Adjusting Darkness for “In-Spec” Bar Codes........................................................85 Label Darkness Levels...................................................................................
Zebra S-Series User’s Guide viii
ÏÃcØYÏ 6FRSH This user’s guide contains descriptive information and operational instructions for the Zebra 105Se and the 160S thermal transfer demand printers. It contains information on how to set up and operate the printer as well as adjustment and maintenance procedures that can be performed by the operator. Information covering the use and operation of Zebra S-Series Printer options is also included.
6\VWHP 2YHUYLHZ The S-Series Printer, when connected to an appropriate ASCII data source, functions as a complete label, ticket, and tag printing system. Customersupplied asynchronous modems may be used to connect remote hosts to the S-Series Printer. Connection of the S-Series Printer to data sources using data codes other than ASCII requires the use of an appropriate protocol converter.
The standard printhead for the S-Series Printer has a print resolution of 8 dots/mm (203.2 dots/inch). Optional printheads are available for the 105Se for either 6 dots/mm (152 dots/inch) or 12 dots/mm (300 dots/inch) resolution. 0HGLD 7UDQVSRUW 0HFKDQLVP &DSDELOLWLHV The media transport mechanism of the S-Series Printer has been designed to accommodate various types of media, including die-cut labels, ticket and tag stock, continuous roll, and fanfold media.
0HGLD DQG 5LEERQ 5HTXLUHPHQWV Print quality not only depends on the Zebra S-Series Printer, but also on the print media. Factors such as reflectivity and contrast are important for bar code scanning applications. Factors such as paper abrasion and temperature requirements are important in maintaining the life of the printhead. We STRONGLY RECOMMEND the use of Zebra-brand media for continuous high quality printing.
8VH RI 6KLHOGHG &DEOH &$87,21 5HIHU WR ´,QWHUFRQQHFWLRQVµ RQ SDJH =HEUD SULQWHUV FRPSO\ ZLWK )&& ´5XOHV DQG 5HJXODWLRQVµ 3DUW 6XESDUW - IRU &ODVV $ (TXLSPHQW XVLQJ IXOO\ VKLHOGHG GDWD FDEOHV 8VH RI XQVKLHOGHG FDEOHV PD\ LQFUHDVH UDGLDWHG HPLVVLRQV DERYH WKH &ODVV $ OLPLWV DQG LV QRW UHFRPPHQGHG =HEUD SULQWHUV FRPSO\ ZLWK LQWHUQDWLRQDO UHJXODWLRQV JRYHUQLQJ UDGLDWHG HPLVVLRQV ZKHQ XVLQJ IXOO\ VKLHOGHG GDWD FDEOHV 8VH RI XQVKLHOGHG FDEOHV PD\ LQFUHDVH UDGLDWHG HPLVVLRQV DERYH WKH UHJXO
6 Zebra S-Series User’s Guide
ÆÏAAÏ 8QSDFNLQJ When unpacking the Zebra S-Series Printer, make sure you save all packing materials. Once the printer is out of the box, raise the printer’s media access door and remove the power cord. ,QVSHFWLRQ Inspect the printer for possible damage incurred during shipment. • Check all exterior surfaces for damage. • Raise the media access door and inspect compartment for damage to components.
6WRUDJH DQG 5HVKLSSLQJ If you are not placing the printer into operation immediately, repackage it using the original packing materials. The S-Series Printer may be stored under the following conditions: • Temperature: –40° to +158° F (–40° to +70° C) • Relative humidity: 20% to 85% non-condensing Should it become necessary to ship your printer, remove any ribbon and paper roll from the supply spools, otherwise damage to the printer could result.
Figure 1 $& 3RZHU )XVH 5HSODFHPHQW A user-replaceable AC power fuse is located just above the power ON/OFF switch (see Figure 1). For a 115 VAC installation, the replacement fuse is a 3AG Fast Blow style rated at 5 Amp/250VAC. For a 230 VAC installation, the fuse is the same style but rated at 3 Amp/250 VAC. Make sure the fuse you use is correct for the voltage source. Note: Before replacing the fuse, turn the AC power switch OFF and unplug the AC power cable. 1.
9$& 2SHUDWLRQ 1. Confirm that the voltage selector switch is set to 115 V. 2. Attach the supplied power cord to the AC power receptacle located on the rear of the printer. 3. Connect the opposite end of the power cord to a properly grounded source of 115 VAC (50 or 60 Hz) power rated for at least 5 Amps. 9$& 2SHUDWLRQ 1. Confirm that the voltage selector switch is set to 230 V. 2. Depending on how the printer was ordered, a power cord may or may not be provided for 230 VAC operation.
5LEERQ /RDGLQJ 6H Refer to Figure 4 throughout this procedure. Note: When placing the ribbon roll on the ribbon supply spindle, make sure that the core is pushed up against the stop on the ribbon supply spindle and that the ribbon is aligned squarely with its core. If this is not done, the ribbon may not cover the inside edge of the printhead, exposing print elements to potentially damaging contact with the media. Do not load ribbon if the printer is to be used in the direct thermal mode.
4. Important...To make ribbon loading and unloading easier, make a leader for your ribbon roll if it doesn’t already have one (refer to Figure 3). Tear off a strip of media (labels and backing) about 6" - 12" long from the roll. Peel off a label from this strip and remove the remaining labels. 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. Figure 3 5. Thread the leader and attached ribbon as shown in Figure 4.
Figure 4 Zebra S-Series User’s Guide 13
5LEERQ /RDGLQJ 6 Refer to Figure 4 throughout this procedure. Note: When placing the ribbon roll on the ribbon supply spindle, make sure that the core is pushed up against the stop on the ribbon supply spindle and that the ribbon is aligned squarely with its core. If this is not done, the ribbon may not cover the inside edge of the printhead, exposing print elements to potentially damaging contact with the media. Do not load ribbon if the printer is to be used in the direct thermal mode.
0HGLD /RDGLQJ To load media, move the printhead locking lever to the OPEN position. Refer to Figures 5, 6, 7, and 8. When the media is loaded, close the printhead by moving the lever on the upper printhead mechanism to the CLOSED position. Note: The first time you load media and whenever you subsequently change the media type, you must re-calibrate the printer. See “Calibration” on page 43 for details.
Figure 5 Figure 6 16 Zebra S-Series User’s Guide
7HDU 2II 0RGH Follow the instructions described in “Roll Media” on page 15. 5HZLQG 0RGH Note: Rewind option required. To initially configure the printer for this mode, follow these steps: 1. Remove the media rewind plate from its storage location in front of the printhead 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 (1/2") into the lower opening in the side plate. 4.
&XWWHU 0RGH Follow the instructions described in “Roll Media” on page 15 with the exception of step 6: first route the media through the cutter module (see Figures 5 and 6) and then close the printhead assembly by moving the lever located on the upper printhead assembly to the CLOSED position. )DQIROG 0HGLD To load fanfold media, place the fanfold media in the bottom or to the rear of the media compartment or fanfold supply bin (105Se only) and thread it through the printhead as shown in Figures 7 and 8.
Figure 8 5HPRYLQJ 8VHG 5LEERQ 6H To remove used ribbon, refer to Figure 9 and follow the steps below. 1. Pull the hook out slightly, then rotate the hook back-and-forth several times as shown and remove it from the spindle. 2. Grasp the used ribbon and remove it from the ribbon take-up spindle. 3. Remove the empty core from the ribbon supply spindle. 4. Follow the ribbon loading procedure on page 11 to load the new ribbon.
5HPRYLQJ 8VHG 5LEERQ 6 Refer to Figure 10. 1. Turn the knob at the end of the ribbon take-up spindle (1) clockwise until it stops. This causes the ribbon release bars to pivot down (2), easing the spindle’s “grip” on the wound ribbon. 2. Slide the ribbon off of the ribbon take-up spindle. Once the used ribbon has been removed, ensure that the arrow on the knob aligns with the indented notch in the ribbon take-up spindle (see inset). 3. Remove the empty core from the ribbon supply spindle. 4.
,QLWLDO 3ULQWHU 3RZHU 8S After you finish loading the ribbon and media, continue reading through “Operation” beginning on page 23 and “Configuration and Calibration” beginning on page 39. Perform the following initial printer power-up steps as you come to them: 1. Power-On Self Test (POST) 2. Calibration Note: Subsequent power-ups do not necessarily require step 2 to be performed.
22 Zebra S-Series User’s Guide
%®lÃAÏ 2SHUDWLQJ
7UDQVPLVVLYH 6HQVLQJ 0RGH In transmissive sensing mode, a sensor detects a light shining through a web, notch, or hole in non-continuous media. In this way, the printer determines the position of the label/tag. %ODFN 0DUN 6HQVLQJ 0RGH In black mark sensing mode, a sensor detects the black marks that are printed on the back of the label liner for each label. The label length and top of label are determined by the location of the black mark.
3HHO 2II 0RGH When the media is in the rest (idle) position, the start of the label to be printed is slightly in front of the printhead. To print a label, the printer first backfeeds the media until the start of the label is directly under the printhead and then prints the entire label. In this mode, once the label is printed, the media passes over the tear-off/ peel-off bar at an extremely sharp angle.
)URQW 3DQHO .H\V 3$86( .H\ The PAUSE key stops and restarts the printing process. If the printer is idle (not printing) when the PAUSE key is pressed, no printing can occur. If the PAUSE key is pressed while printing is in progress, the printing stops once the current label is complete. Pressing the PAUSE key a second time resumes the printing process. )((' .H\ The FEED key forces the printer to feed one blank label.
02'( .H\ The MODE key puts the printer in configuration mode. In this mode, you can adjust the print darkness, media tear-off position, and label top position, or perform a calibration. See “Configuration and Calibration” beginning on page 39 for more information. )URQW 3DQHO /LJKWV Refer to Figure 11 for the location of the lights. Note: If an operating condition which causes a light to be ON constantly and one which causes the same light to flash occur simultaneously, the light flashes.
3RZHU 2Q 6HOI 7HVW A Power-On Self Test (POST) is performed each time the printer is turned ON. This test checks for proper initialization of various electronic circuits and establishes starting parameters as those stored in the printer’s memory. During this test sequence, the front panel lights turn ON and OFF to ensure proper operation. At the end of this self test, only the POWER light remains lit. If other lights are also lit, refer to “Troubleshooting” beginning on page 65.
Some of the printer self tests produce labels at varying print speeds. These speeds may be referred to as “inches per second,” “millimeters per second,” or by alphabetic letter designation (i.e., “A,” “B,” “C,” etc.). The following chart shows the relationships between the different speeds: Letter Designation English Metric A* B C 2"/sec. 3"/sec. 4"/sec. 5"/sec. 6"/sec. 51 mm/sec. 76 mm/sec. 102 mm/sec. 127 mm/sec. 152 mm/sec.
&$1&(/ .H\ 6HOI 7HVW This self test prints a single label which contains a listing of the printer’s current configuration parameters stored in configuration (EEPROM) memory. Press the CANCEL key while turning the AC power switch ON. See Figure 12 for a sample configuration printout. The configuration may be changed either temporarily (for specific label formats or ribbon and label stock), or permanently (by saving the new parameters in EEPROM Memory).
3$86( .H\ 6HOI 7HVW This self test is actually comprised of four individual test features, as described below. 1. The initial self test prints 15 labels at speed “A” then automatically PAUSES the printer. When the PAUSE key is pressed, an additional 15 labels print out. 2. While the printer is PAUSED, pressing the CANCEL key once alters the self test. When the PAUSE key is pressed, the printer prints 15 labels at speed “D” (“C” for the 300 dpi ). 3.
)((' .H\ 6HOI 7HVW Note: The CANCEL Key Self Test should be performed before this self test. Information on the configuration printout (see Figure 12 on page 30) 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 prints out at various darkness settings above and below that of the darkness value shown on the configuration label.
)((' .H\ DQG 3$86( .H\ 6HOI 7HVW Pressing these two keys at the same time, while turning the power ON, temporarily resets the printer configuration to the factory default values. These values remain active until power is turned OFF. Whenever the printer is reset to factory defaults, a media calibration procedure must be performed immediately. See page 43 for details. 02'( .H\ 6HOI 7HVW This test places the printer in the communications diagnostics mode.
)((' .H\ DQG &$1&(/ .H\ 6HOI 7HVW This test prints seven pre-programmed label formats at different speeds. The printer automatically pauses after each format.
6DPSOH =3/ ,, /DEHO )RUPDWV ZPL II® (Zebra Programming Language II) is Zebra Technologies Corporation’s 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 experimenting with. It is not intended as an introduction to ZPL II.
)RUPDW 6LPSOH 7H[W DQG D %DUFRGH Line # 1 2 3 4 5 Type this label format: ^XA ^LH30,30 ^FO20,10^AD^FDZEBRA^FS ^FO20,60^B3N,Y,20,N^FDAAA001^FS ^XZ You’ll get this printout: 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”.
)RUPDW 8VLQJ D 6HULDOL]HG 'DWD )LHOG Line # 1 2 3 4 5 6 7 Type this label format: ^XA ^LH30,30 ^FO20,10^AD^FDZEBRA^FS ^FO20,60^B3,,40,,^FDAAA001^FS ^FO20,180^AF^SNSERIAL NUMBER 00000000111,1,Y^FS You’ll get this printout: ^PQ10 ^XZ Ten labels should print. The first and last are shown here. Line #1-3: These commands were described in Format 1. Line #4: Defines field data for bar code as “AAA001”. Line #5: Defines serialized field, starting value of 111, increment by 1, insert leading zeros.
38 Zebra S-Series User’s Guide
yØÃAÏÍAcÍ AOÃAÏ 2SWLRQ 6ZLWFKHV These switches are located at the rear of the printer above the Signal Interface Cable Connection. See Figure 16. In the tables on the following page, an “R” means the switch is OFF (positioned to the right), while an “L” means the switch is ON (positioned to the left). All switches are in the OFF position when the printer is shipped from the factory.
%DQN Note: For Serial Interface Printers only. The S-Series Printer, with the RS-232 Serial Interface, uses eight miniature switches located on the rear of the printer above the signal interface cable connector. The ON/OFF positions of these switches establish some of the printer configuration parameters. Bank 1 switches must be properly positioned to establish serial data communications with the host computer. Thereafter, the position of these switches should not be changed.
%DQN These switches can manually override any ZPL II commands that affect print mode, media mode, and media type. They can also override settings established during the calibration procedure. Reasons why you might want to use these override switches are: • Troubleshooting. By using these switches, you know beyond a doubt what operating mode your printer is in.
&RQILJXUDWLRQ 0RGH The configuration mode allows you to fine-tune the internal printer configuration settings for your application.
&DOLEUDWLRQ Note: Perform the calibration procedure when media and ribbon are first installed and each time a different type of media or ribbon is installed. During this procedure, the printer automatically determines the media type, label length, media and ribbon sensor settings, and printing method. Media type is determined by sensing either continuous or non-continuous media as blank labels move through the printer. If non-continuous media is sensed, label length is also calibrated.
$GMXVWLQJ WKH 3ULQW 'DUNQHVV This procedure sets the darkness of the printing on the label. Use the lowest setting that provides the necessary print quality. 1. Press the MODE key. PAUSE and DARKEN lights turn ON. 2. Press UP or DOWN to adjust the current setting. 3. Press the MODE key three times. The MODE lights flash ON and OFF to indicate that the settings have been saved in memory. 4. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF.
ÏlÃYlYÏÆ 6\VWHP &RPSRQHQWV Figure 18 6\VWHP &RQVLGHUDWLRQV &RPPXQLFDWLRQV &RGH The Zebra S-Series Printer sends and receives American Standard Code for Information Interchange (ASCII). This code consists of 128 characters (256 for Code Page 850) including upper and lower case letters, punctuation marks, and various control codes.
,QWHUIDFHV The method of interfacing the Zebra S-Series Printer to a data source depends on the communication options installed in the printer. Depending on how the printer was ordered, the interface is either an RS-232 serial data port or a parallel port. 'DWD 6SHFLILFDWLRQV When communicating via the serial data port (RS-232), the baud rate, number of data bits, and the parity are user-selectable (see Table 1 on page 40 for acceptable setting combinations).
+DUGZDUH &RQWURO 6LJQDO 'HVFULSWLRQV Request To Send (RTS) is a control signal from the S-Series Printer to the host computer. RTS is always in the ACTIVE condition (positive voltage) whenever the printer is powered ON. Data Set Ready (DSR) is a control signal from the host computer to the printer. When DSR is in the ACTIVE condition (positive voltage), the printer can transmit status to the host. When RTS is in the INACTIVE condition (negative voltage), the printer does not transmit any data.
,QWHUFRQQHFW WR '7( 'HYLFHV The printer is configured as Data Terminal Equipment (DTE). To connect the printer to other DTE devices (such as the serial port of a PC), use an RS-232 Null Modem (crossover) cable. Figure 19 illustrates the connections required for this cable. Figure 19 ,QWHUFRQQHFW WR '&( 'HYLFHV When the printer is connected via its RS-232 interface to Data Communication Equipment (DCE) such as a modem, use a standard RS-232 (straight-through) interface cable.
3DUDOOHO &DEOLQJ 5HTXLUHPHQWV The required cable must have a standard 36-pin parallel connector on one end, which is plugged into the mating connector located at the upper rear of the printer. The parallel interface cable is connected using bail clips, instead of screws, in a similar position to that of the serial data cable. The other end of the parallel interface cable connects to an appropriate point at the host computer.
6LJQDO 'HVFULSWLRQV The following chart provides a description of each of the pins in the parallel connector. A standard parallel data cable provides the required interconnection between the computer and the printer. Parallel Connector Pin Assignments Pin No. 1 2-9 10 11 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.
-ÃlÞlÏÞlÍ"AÏlAYl 2YHUYLHZ This section contains preventive maintenance information for the Zebra S-Series Printer. These procedures may be performed by the operator. &OHDQLQJ ([WHULRU 6XUIDFHV The exterior surfaces of the printer may be cleaned as required by using 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 sparingly.
3ULQWKHDG DQG 3ODWHQ 5ROOHU Inconsistent print quality, such as voids in the bar code or graphics, may indicate a dirty printhead. For optimum performance, Zebra recommends performing the cleaning procedure on the following page after every roll of ribbon (perform this procedure after every roll of media for direct thermal printing). Note: Label Available Sensors are shown for location purposes only. They are not standard on all printers.
It is not necessary to turn printer power OFF prior to cleaning. If power is turned OFF, all label formats, images, and parameter settings stored in the printer’s formatting RAM are lost. Permanent parameter settings stored in EEPROM are retained. When power is turned back ON, it may be necessary to reload some items. To clean the printhead and platen roller, open the media compartment door, refer to Figure 21, and perform the following steps: 1.
Extend the Life of Your Printhead With Save-A-Printhead Cleaning Film Challenge The printhead is the most critical component in your printer, and possibly the most delicate. It is a consumable item just like the brakes on your car, which eventually wears over time. However, with ongoing careful attention and maintenance, you can extend the life of the printhead! Below are photographs of three printheads. The first printhead is brand new.
Avoid the Contributing Factors to Premature Printhead Failure Abrasion- Over time, the movement of media/ribbon across the printhead wears through the protective ceramic coating, exposing and eventually damaging the print elements (dots). In order to avoid abrasion: • Clean your printhead frequently and use well-lubricated thermal transfer ribbons with backcoatings optimized to reduce friction. • Minimize printhead pressure and burn temperature settings by optimizing the balance between the two.
How to Use Save-a-Printhead Cleaning Film 1. Remove power from the printer. 2. Open the printhead, remove media and ribbon from the print mechanism. 3. Clean the printhead per the recommended Preventive Maintenance procedures. 4. Position the Save-a-Printhead film in the print path, placing the glossy side down away from the printhead (matte side up). 5. Close and latch the printhead. 6. Slowly pull the full length of the film through the print mechanism. 7.
0HGLD 5LEERQ DQG /DEHO $YDLODEOH 6HQVRUV These 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 21 on page 52, Figure 24 on page 61, and Figure 25 on page 62. &XWWHU 0RGXOH Periodically, the cutter module should be cleaned to remove paper dust and label residue. Cleaning the cutter module ensures that labels are cut properly and not jam in the cutter mechanism. Refer to Figure 22.
/XEULFDWLRQ &$87,21 6RPH FRPPHUFLDOO\ DYDLODEOH OXEULFDQWV ZLOO GDPDJH WKH SULQWHU LI XVHG Lubrication of the S-Series Printer should be performed by a qualified service technician according to the directions provided in Volume 1 of the Maintenance Manual.
cØÆÏlÏÆ 7RJJOH 3RVLWLRQLQJ Note: The 105Se printer has one toggle; the 160S printer has two toggles. The toggle(s) should be positioned to provide even pressure on the media. Toggles are positioned by sliding them left or right to the desired location. On the 105Se, the single toggle should normally be positioned over the center of the media.
Figure 23 %ODFN 0DUN 0HGLD 6HQVRU 3RVLWLRQ $GMXVWPHQW This sensor position requires no adjustment or calibration by the user. 7UDQVPLVVLYH 0HGLD 6HQVRU 3RVLWLRQ $GMXVWPHQW The transmissive media sensor senses either the “web” between labels or a hole or notch in the media to determine the length of the label or ticket. The factory-set position should be sufficient for any width label using media with a web.
8SSHU 7UDQVPLVVLYH 0HGLD 6HQVRU 3RVLWLRQ $GMXVWPHQW To adjust the upper media sensor, refer to Figure 24 and follow these steps. 1. Remove the ribbon and locate the upper media sensor. 2. Loosen the Phillips head screw. 3. Slide the upper sensor along the slot to the desired position. When using media that has a web between labels, position the media sensor anywhere along the web (if you have labels with rounded corners, do not position the sensor where the rounded corners of the label might be detected).
/RZHU 7UDQVPLVVLYH 0HGLD 6HQVRU 3RVLWLRQ $GMXVWPHQW To adjust the lower media sensor, follow these steps: 1. Locate the lower media sensor assembly (a spring clip holding a small printed circuit board) under the rear idler roller. 2. Position the sensor so that the two brass-colored infrared emitters are under the upper sensor by sliding it in its slot. 3. Gently pull wires out of the printer frame as required. (Wires should have a little slack.
0HGLD DQG 5LEERQ 6HQVRU 6HQVLWLYLW\ $GMXVWPHQW Note: This adjustment is initially set by Zebra Technologies Corporation during final printer calibration. Under normal circumstances, further adjustments should not be necessary. The exception to this might be the use of media with extremely thick or thin backing, which could require re-adjustment of the sensor sensitivity.
8. Open the printhead. 9. Pull the media out of the printer until a label is positioned under the printhead. Move the ribbon back to its normal position. Note: Be sure that the label is positioned between the upper and lower media sensors. 10. Close the printhead. 11. Press the MODE key to print a media and sensor profile and save the new values (see Figure 26). 12. Perform the media calibration procedure on page 43.
2ÃØOlÆÏ 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 indicated. SYMPTOM DIAGNOSIS No AC power applied to the printer. All indicator lights never light. Faulty AC power fuse. ACTION Ensure that the AC power cable is connected to a working voltage source. Refer to page 9 for fuse replacement procedures. Call a service technician.
SYMPTOM Printer stops. PAUSE light and PAPER/RIBBON light both ON. DIAGNOSIS ACTION Media incorrectly loaded or not loaded. Misadjusted media sensor. Media not calibrated. Load media correctly. See “Media Loading” on page 15. Check position and sensitivity of media sensor and/or calibrate media. See “Media and Ribbon Sensor Sensitivity Adjustment” on page 63 and “Calibration” on page 43. Load ribbon correctly. See page 11 for the 105Se and page 14 for the 160S. Call a service technician.
SYMPTOM DIAGNOSIS ACTION Possible media sensor or calibration problem. Adjust media sensor position (see page 63) or calibrate media (see page 43). Call a service technician if Loss of printing registration on necessary. labels. Printer set for non-continuous Set printer for correct media. media, but continuous media See See “Media Loading” on loaded. page 15. Improperly adjusted media Refer to “Media Loading” on (For Peel-Off Mode) edge guides. page 15.
SYMPTOM DIAGNOSIS ACTION Wrinkled ribbon. See “Wrinkled ribbon.” on Long tracks of missing print on page 68 under SYMPTOM. several labels. Print element damaged. Call a service technician. Glue material from back of Refer to "Cleaning" beginning labels causing media on page 51 and perform In Peel-Off Mode, skewed or movement problems. maintenance and cleaning of stuck labels. the printer. Media and backing not See “Media Loading” on properly aligned in printer. page 15.
SYMPTOM DIAGNOSIS Parameters are set or saved incorrectly. Changes in parameter settings did not take effect. ACTION Reload the factory defaults. See “Calibration” on page 43 and calibrate the printer. Then, cycle the power ON/OFF switch. Call a service technician. If problem continues, there may be a problem on the main logic board. Communications parameters See “MODE Key Self Test” on or DIP switches are set page 33. Check for format or incorrectly. overrun errors.
SYMPTOM DIAGNOSIS Cutter is dirty. Labels are jamming in cutter, or labels are being cut more than once. Label length is too short. Media jammed in cutter. For printers with the cutter option installed: printing stops. PAPER/RIBBON, PAUSE, and CANCEL LEDs on. 70 Connecting cable not connected to cutter module. Cutter module is dirty. End of the media is not positioned correctly on top of the platen. ACTION Follow cutter module cleaning procedure on page 57. Increase label length.
0®lYyYAÏÆ 3ULQWHU 6SHFLILFDWLRQV 3ULQWLQJ &RQVLGHUDWLRQV Specification Resolution (thermal transfer or direct thermal) Dot size Maximum print width Maximum print length 105Se 160S 203 dots per inch (8 dots per mm) Optional 152 dots per inch (6 dots per mm) Optional 300 dots per inch (12 dots per mm) 203 dots per inch (8 dots per mm) 0.00492" (0.125 mm) 0.00656" (0.167 mm) 0.0033" x 0.0039" (0.084 x 0.100 mm) 0.00492" (0.125 mm) 4.09" (104 mm) 4.09" (104 mm) 4.09" (104 mm) 6.
0HGLD +DQGOLQJ • Tear-Off Mode: Produced in strips. • Peel-Off Mode: Requires Peel-Off option or Media Rewind option. Labels are dispensed and peeled from the liner, and the liner is rewound internally. • Rewind Mode: Requires Media Rewind option. A full roll of printed labels is rewound internally. • Cutter Mode: Requires Cutter Module option. Media cut after printing; under software control. 0HGLD Media Specifications Total media width 105Se 4.5" 114.3 mm 7.2" 182.9 mm Minimum 0.75" 19.05 mm 2.
5LEERQ 105Se Ribbon Width Zebra recommends using ribbon Maximum at least as wide as the media Minimum you are using to protect the printhead from wear. 160S 4.33" 110 mm 6.89" 175 mm 0.94" 24 mm 2.0" 51 mm 300 m Standard lengths 2:1 media to ribbon roll ratio 984 ft. 300 m 984 ft. 3:1 media to ribbon roll ratio 1476 ft. 450 m 1476 ft. 450 m Roll size Inner diameter of core 1.0" 25.4 mm 1.0" 25.4 mm Outside diameter of full roll of ribbon 3.2" 81 mm 3.
6WDQGDUG )RQWV The scalable smooth font (CG Triumvirate™ Bold Condensed) is expandable on a dot-by-dot basis, height- and width-independent, while maintaining smooth edges. Maximum size depends on available memory. Fonts A, B, C, D, E, F, G, and H are expandable up to 10 times, height- and width-independent; however, fonts E and H (OCR-A and OCR-B) are not considered in-spec when expanded. IBM Code Page 850 international character sets are standard in fonts A, B, C, D, E, F, G, and through software control.
Font Matrices for 6 dots/mm Printhead Font Matrix (in dots) Type Character Size Inches Millimeters Height Width Intercharacter gap A 9 5 1 U-L-D 0.059 0.039 25.40 1.50 1.00 1.00 B 11 7 2 U 0.072 0.059 16.93 1.83 1.50 0.67 C,D 18 10 2 U-L-D 0.118 0.079 12.70 3.00 2.00 0.50 E 21 10 3 OCR-B 0.138 0.085 11.72 3.50 2.17 0.46 Height Width Char./Inch Height Width Char./ Inch F 26 13 3 U-L-D 0.171 0.105 9.53 4.33 2.67 0.38 G 60 40 8 U-L-D 0.
6WDQGDUG 3ULQWHU )RQW ([DPSOH 3K\VLFDO Physical Characteristics 105Se 160S Height 15.4" 391 mm 15.4" 391 mm Width 10.5" 267 mm 13.1" 333 mm Length 18.9" 480 mm 18.9" 480 mm 43 lbs. 19.5 kg 55 lbs. 24.9 kg Weight (without options) (OHFWULFDO • 115 VAC +15%/-20% or 230 VAC +15%/-15%; 48-62 Hz • 5 Amps @ 115V, 3 Amps @ 230V • UL 1950 Listed-Certified to CAN/CSA-C22.2 No.
&RPPXQLFDWLRQV ,QWHUIDFH • RS-232 at 110 to 19,200 baud (select from standard rates). Baud rate, data bits, parity, error detection protocol, and XON-XOFF or DTR/DSR handshaking are all switch-selectable. Stop bits are fixed at 1. • Compatibility Mode Parallel Interface. Maximum cable length: 10 ft. (304.8 cm).
78 Zebra S-Series User’s Guide
%®ÏÆ 3HHO 2II Your printer may be equipped with the peel-off option. In the peel-off mode, only the label backing rewinds onto the rewind spindle. The peel/tear bar separates the label from the backing and the label available sensor activates the PAUSE mode to allow the operator to remove a printed label before subsequent labels print. This option cannot be added to a printer equipped with the optional Cutter.
)DQIROG 6XSSO\ %LQ Your printer may be equipped with an optional internal fanfold supply bin. It is used to load fanfold media within the media compartment, and it protects the media from environmental contaminants such as dust and dirt. The fanfold media supply bin is fully adjustable. It accommodates media from 1.57" (40 mm) to 3.54" (90 mm) wide (7.17" [183 mm] wide for the 160S) and 3.5" (89 mm) to 8" (203mm) long. The maximum stack height for 8" long media is 4.5". Stack heights of 6.
2SWLRQDO 3ULQWHU )RQWV The S-Series Printer can be optioned with character fonts in addition to those which are standard in the unit. Only one additional font 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 the ZPL II Programming Guide for further application information.
9$& )DFWRU\ 6HWXS Your Zebra S-Series Printer is factory set for 230 VAC operation if requested when the order is placed. If it is necessary to reconfigure your printer for operation at 115 VAC, see page 10. .% '5$0 0HPRU\ ([SDQVLRQ Note: This option is not available for the 105Se 300 dots/inch printer. This option increases the printer’s dynamic memory capacity from 0.5 MB to 1 MB. This supports longer label lengths and provides more capacity for downloadable fonts and large graphic image files.
®®lcà 9$& 3RZHU &RUG Depending on how your Zebra S-Series printer was ordered, a power cord may or may not be included when the printer is optioned for 230 VAC, 50/60 Hz operation. If a power cord is not supplied, you need to obtain one with the following specifications: • The overall length must be less than 3.8 meters. • It must be rated for at least 5 amps, 250 V. • The CHASSIS GROUND (EARTH) MUST BE CONNECTED to assure safety and reduce electromagnetic interference.
$6&,, &RGH &KDUW 84 Zebra S-Series User’s Guide
$GMXVWLQJ 'DUNQHVV IRU ´,Q 6SHFµ %DU &RGHV All direct thermal and thermal transfer materials do not use the same darkness setting. The best way to check for the proper darkness is to use a bar code verifier that actually measures bars/spaces and calculates the Print Contrast Signal (PCS) ratio. Without the assistance of a verifier, your eyes and/or the scanner to be used in the system may be used for picking the optimum darkness setting.
/DEHO 'DUNQHVV /HYHOV 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 run together. Slightly Dark — Slightly dark labels are not as obvious. The normal bar code is “in-spec”. Small character alphanumerics are bold and could be slightly filled in.
Figure 29 Zebra S-Series User’s Guide 87
2SWLRQDO 3ULQWHU )RQWV Your printer can be optioned with character fonts in addition to those that are standard in the unit. The following pages illustrate the optional fonts in each of the available styles. From time to time, additions may be made to the list of available fonts. Contact Zebra Technologies Corporation or your sales representative for further information. Only one additional font can be installed in the printer at a time. This installation should be performed by a service technician.
Scalable Smooth Fonts (Optional) Figure 30 Bitmap Smooth Fonts (Optional) Figure 31 Zebra S-Series User’s Guide 89
Point Size Examples Figure 32 90 Zebra S-Series User’s Guide
ÆÆAÃá Alphanumeric — Indicating letters, numerals, and characters such as punctuation marks. Backfeed — 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 printhead. Backfeed occurs when you’re operating the printer in tear-off or peel-off mode. Bar code — A code by which alphanumeric characters can be represented by a series of adjacent stripes of different widths.
Diagnostics — Information about what printer functions are not working. This information is used for troubleshooting. 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 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 (e.g., Times, Helvetica).
Print speed — The speed at which printing occurs. For thermal transfer printers, this speed is expressed in terms of ips (inches per second). Zebra offers printers that can print from 2 ips to 12 ips. Printhead wear — The degradation of the surface of the printhead and/or the print elements over time. Heat and abrasion can cause printhead wear.
Tag — A type of media having no adhesive backing but featuring a hole or notch by which the tag can be hung. Usually tags are made of cardboard or other durable material. Take label sensor — See “Label available sensor” on page 92. Thermal direct printing — See “Direct thermal printing” on page 92. 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.
clà A Accessories, 77 Adjustments Bar Code Darkness, 85 Black Mark Media Sensor Position, 60 Label Position, 44 Media Rest Position, 44 Media Sensitivity, 63 Print Darkness, 44 Printhead Pressure, 59 Ribbon Sensor Sensitivity, 63 Toggle Positioning, 59 Transmissive Media Sensor Position, 60 ASCII Code Chart, 84 B Bar Codes Darkness Adjustment, 85 Specifications, 73 Black Mark Media Sensor Position, 60 Black Mark Sensing Mode, 24 Black Mark Sensor Option, 80 C Cabling Requirements, 47 Calibration, 43 CAN
M Maintenance, 51 Media Handling Specifications, 72 Media Loading Cutter Mode, 18 Fanfold Media, 18 Peel-Off Mode, 17 Rewind Mode, 17 Roll Media, 15 Tear-Off Mode, 17 Media Requirements, 4 Media Rest Position, 44 Media Rewind Option, 79 Media Sensing Modes Black Mark Sensing Mode, 24 Transmissive Sensing Mode, 24 Media Sensor Sensitivity, 63 Media Specifications, 72 Media Transport Modes Cutter Mode, 25 Peel-Off Mode, 25 Rewind Mode, 25 Tear-Off Mode, 24 MODE Key Self Test, 33 MODE Key, 27 Model Designation
R Removing Used Ribbon (105Se), 19 Removing Used Ribbon (160S), 20 Repacking, 5 Reporting Damage, 7 Reshipping, 8 Rewind Mode, 17, 25 Ribbon Loading (105Se), 11–13 Loading (160S), 14 Requirements, 4 Sensor Sensitivity, 63 Specifications, 73 Roll Media, 15 RS-232 Serial Data Port DCE Devices, 48 DTE Devices, 48 Hardware Control Signal Descriptions, 47 Parallel Cabling Requirements, 49 Parallel Interface, 49 RS-232 Cabling Requirements, 47 Signal Descriptions, 50 S Serial Number, 1 Signal Descriptions, 50 Si
98 Zebra S-Series User’s Guide
Warranty Information All Zebra products are sold with warranties. Refer to the User’s Guide for warranty information specific to each product. Here is some general information: 3ULQWHU 3URGXFWV Printers. All printers (excluding printheads) are warranted against defect in material or workmanship for twelve (12) months from the purchase date. Proof of purchase or shipment date is required to validate the warranty period.
To qualify for this warranty, the printhead must be returned to the factory or to an authorized service center. Customers are not required to purchase Zebra supplies (media and/or ribbons) for warranty qualification. However, if it is determined that the use of other manufacturer supplies has caused any defect in the printhead for which a warranty claim is made, the user is responsible for Zebra’s labor and material charges required to repair the defect.
:DUUDQW\ ([FOXVLRQV &RQGLWLRQV 6WDWHPHQW The warranties provided above are the only warranties applicable. No other warranties, expressed or implied, are given. Zebra does not make any IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE in connection with its sale of products or services.
4 Warranty Statement
