Z E B R A V A L U E - L I N E TM S -Series User's Guide For the Zebra 105Se™ and 160S™ Printers
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Proprietary Statement 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.
Table of Contents Introduction Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Model Designation . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Communication Capabilities . . . . . . . . . . . . . . . . . . 1-2 Thermal Transfer Printer Internal Functions . . . . . . . . . . 1-2 Print Mechanism Capabilities . . . . . . . . . . . . . . . . . . 1-2 Media Transport Mechanism Capabilities . . . . . . . . . .
Electrical . . . . . . . . . . Communications Interface . Environmental Ranges . . . Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1-13 1-13 1-13 Installation Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Reporting Damage. . . . . . . . . . . . . . . . . . .
Operation Operating Your Zebra S-Series Printer Printer . . . . . . . . . . . 3-1 Printer Operating Modes . . . . . . . . . . . . . . . . . . . . . . 3-1 Media Sensing Modes. . . . . . . . . . . . . . . . . . . . . . 3-1 Transmissive Sensing Mode . . . . . . . . . . . . . . . . . . 3-2 Black-Mark Sensing Mode . . . . . . . . . . . . . . . . . . . 3-2 Media Transport Modes. . . . . . . . . . . . . . . . . . . . . 3-2 Tear-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Peel-Off Mode . . . . .
Sample ZPL II Label Formats . . . . . . . . . . . . . . . Format 1: Simple Text and a Barcode . . . . . . . . . Format 2: Saving a Label Format As a Graphic Image Format 3: Using a Serialized Data Field. . . . . . . . . . . . . . . . . . . . . . . . 3-14 3-15 3-15 3-16 Configuration and Calibration Option Switches . . . . . . . . . . . . . . . . . . Bank 1 (For Serial-Interface Printers Only) . . . . Bank 2 . . . . . . . . . . . . . . . . . . . . . Configuration Mode . . . . . . . . . . . . . . . .
Preventive Maintenance Overview . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . Exterior Surfaces . . . . . . . . . . . . . . . Interior. . . . . . . . . . . . . . . . . . . . . Printhead and Platen Roller . . . . . . . . . . Media, Ribbon, and Label Available Sensors. Cutter Module . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Black-Mark (Reflective) Sensor (105Se Only) . . . . Optional Printer Fonts . . . . . . . . . . . . . . . . . 230 VAC Factory Setup . . . . . . . . . . . . . . . . Memory Option . . . . . . . . . . . . . . . . . . . . 12-Dot/mm and 6-Dot/mm Printheads (105Se Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9-3 9-3 9-4 9-4 Appendix A 230 VAC Power Cord. . . . . . . . . . . . . . . . . . . . . . . . A-1 Appendix B ASCII Code Chart. . . . . . . . . . . . . . . . . . .
Introduction Scope This user’s guide contains descriptive information and operational instructions for the Zebra 105Se and 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.
Communication Capabilities The S-Series Printer comes with either an Electronics Industries Association (EIA) RS-232 serial data interface or a factory-installed parallel interface. In both cases, the required interface cable is not supplied with the printer. Thermal Transfer Printer Internal Functions Command/control data signals are received via the RS-232 port, parallel port, or DIP switches and are sent to the main logic board.
Additional System Requirements In addition to the Zebra S-Series Printer, you will need the following items to form a complete label preparation system: • Label, ticket, or tag stock • An intelligent device, such as a computer, for data entry or entry of ZPL II formats • A data communication cable to connect the controlling device to the printer (remote installations may require additional cables and communication devices, such as modems and/or protocol converters) • Thermal transfer ribbon (if using therma
Continuous roll form paper, fanfold media, or cardstock with optional perforations and registration holes may be used. The standard 160S Printer and 105Se Printer with an optional reflective sensor can use “black-mark media” (media having a black mark printed on the liner side for use in positioning the labels). Since print quality is affected by media and ribbon, printing speeds, and printer operating modes, it is very important to run tests for your applications.
Ribbons and Printhead Wear CAUTION: Ribbons used in the Zebra Technologies Corporation Printer MUST be as wide as or wider than the media. Zebra-brand ribbons provide an extremely smooth backing surface that protects the printhead from abrasion by the media. If the ribbon is narrower than the media, areas of the printhead will be unprotected and subject to premature wear.
Printer Specifications Printing Considerations Specification 105Se 160S Resolution (thermal transfer 203 dots per inch Optional Optional 203 dots per or direct thermal) (8 dots per mm) 152 dots per inch 300 dots per inch inch (8 dots (6 dots per mm) (12 dots per mm) per mm) 0.00492" 0.00656" 0.0033" x 0.0039" 0.00492" (0.125 mm) (0.167 mm) (0.084 x 0.100 mm) (0.125 mm) 4.09" 4.09" 4.09" (104 mm) (104 mm) (104 mm) (160 mm) Standard 15" 26" 18" 9.
Media Media Specifications Total media width 105Se 160S Maximum 4.5" 114.3 mm 7.2" 182.9 mm Minimum 0.75" 19.05 mm 2.0" 50.8 mm Maximum Refer to Printing Considerations on page 1-6. Tear-Off 0.63" 16.00 mm 0.63" 16.00 mm Peel-Off 0.50" 12.8 mm 0.50" 12.8 mm Rewind 0.50" 12.8 mm 0.50" 12.8 mm Cutter 1.25" 31.75 mm N/A N/A 0.381 mm 0.015" 0.381 mm 0.0023" 0.0584 mm 0.0023" 0.0584 mm Core size 3.0" 76.2 mm 3.0" 76.2 mm Maximum roll diameter 8.0" 203.2 mm 8.
Ribbon Ribbon Width Zebra recommends using ribbon at least as 4.33" 110 mm 6.89" 175 mm Minimum 0.94" 24 mm 2.0" 51 mm 2:1 media to ribbon roll ratio 984 ft 300 m 984 ft 300 m 3:1 media to ribbon roll ratio 1476 ft 450 m 1476 ft 450 m 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 3.2" 81 mm the printhead from wear.
Standard Fonts 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, heightand 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 Type* Matrix Character Size (in dots) Intercharacter gap Height Width Char./inch Width Char./mm 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 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 0.394 0.315 3.18 10.00 8.00 0.
Font Matrices for 12 dots/mm Printhead Font Type* Matrix Character Size (in dots) Intercharacter gap Height Width Char./inch Height Width A 9 5 1 U-L-D 0.029 0.016 50.80 0.73 0.40 2.00 B 11 7 2 U 0.036 0.023 33.86 0.91 0.58 1.34 C, D 18 10 2 U-L-D 0.059 0.033 25.40 1.49 0.83 1.00 E 42 20 6 OCR-B 0.138 0.066 23.44 3.50 1.67 0.92 F 26 13 3 U-L-D 0.185 0.042 19.06 2.15 1.06 0.76 G 60 40 8 U-L-D 0.198 0.132 6.36 5.02 3.35 0.
Standard Printer Font Example Physical 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) Electrical • 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.
Communications Interface • 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.
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Installation Unpacking 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. Inspection 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.
• 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. Carefully pack the printer in a suitable container to avoid damage during transit. Whenever possible, use the original container and packaging material from the factory.
AC Power Fuse Replacement A user-replaceable AC Power Fuse is located just above the Power ON/OFF Switch (see Figure 2.1). 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. Before replacing the fuse, turn the AC Power Switch OFF and unplug the AC Power Cable.
Site Requirements CAUTION: To ensure that the S-Series Printer has proper ventilation and cooling, do not place any padding or cushioning material on the back of or underneath the unit because this will restrict the air flow. The S-Series Printer may be installed on any solid, level surface of sufficient size and strength to accommodate the unit. The area in which the printer will operate must meet the environmental conditions specified.
2. Place the Ribbon Roll on the Ribbon Supply Spindle. 3. Open the printhead by moving the handle to the OPEN position. 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 2.3): 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. Remove the remaining labels.
Figure 2.
Ribbon Loading (160S) Refer to Figure 2.4 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. Note: Do not load ribbon if the printer is to be used in the Direct Thermal Mode.
Media Loading To load media, move the Printhead Locking Lever to the OPEN position. Refer to Figures 2.5, 2.6, 2.7, and 2.8. 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 the Configuration and Calibration Section.
Figure 2.5 Roll Media Loading Diagrams Figure 2.
Tear-Off Mode Follow the instructions described in Roll Media. Rewind Mode The Rewind Option must be installed in the printer. 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.
Cutter Mode Follow the instructions described in Roll Media with the exception of step 6: first route the media through the Cutter Module (see Figures 2.5 and 2.6) and then close the printhead assembly by moving the lever located on the upper printhead assembly to the CLOSED position. Fanfold Media 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 2.7 and 2.8.
Figure 2.8 Fanfold Media Loading Diagrams (160S) Removing Used Ribbon (105Se) To remove used ribbon, refer to Figure 2.9 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 2-4 to load the new ribbon. Figure 2.
Removing Used Ribbon (160S) Refer to Figure 2.10. 1. Turn the knob at the end of the Ribbon Take-Up Spindle (1) clockwise until it stops. This will cause 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.
Initial Printer Power Up After you finish loading the ribbon and media, continue reading through “Operation” and “Configuration and Calibration.” Perform the following initial printer power-up steps as you come to them: 1. Power On Self Test (POST) 2. Calibration Subsequent power-ups will not necessarily require step 2 to be performed. See “Operation” and “Configuration and Calibration” for further information.
Operation Operating Your Zebra S-Series Printer Now that your printer is ready for operation, how does it work? The Zebra S-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 use label design software or write a format in ZPL II®, which is a programming language for creating label formats.
Transmissive Sensing Mode 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. Black-Mark Sensing Mode In Black-Mark Sensing Mode, you use media having black marks printed on the back of the label liner for each label.
Peel-Off Mode 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 TearOff/Peel-Off Bar at an extremely sharp angle.
Front Panel Keys PAUSE Key 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. FEED Key The FEED key forces the printer to feed one blank label.
MODE Key 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.” Front Panel Lights Refer to Figure 3.1 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.
Indicator Light Name POWER Status Indication ON Printer is ON. OFF Normal operation. Head Over Temperature condition. Printing stops until the printhead cools down. Printing resumes automatically. PRINTHEAD ON Printhead Under Temperature condition. Printing continues. Power Supply Over Temperature condition. Printing stops until the power supply cools down. Printing resumes automatically. PAPER/ RIBBON Flashing Printhead Open. OFF Media and ribbon (if used) are properly loaded. ON Paper out.
Power On Self Test 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 will turn ON and OFF to ensure proper operation. At the end of this self test, only the POWER light will remain lit. If other lights are also lit, refer to the Troubleshooting Section.
If your media is not wide enough, the test labels will only print out to the edge of the label. If your media is too short, the test label will continue printing on the next label. 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.
CANCEL Key Self Test 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 3.2. 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). Saving new parameters occurs whenever a Printer Calibration procedure is performed.
PAUSE Key Self Test This self test is actually comprised of four individual test features. 1. The initial self test prints 15 labels at speed “A” then automatically PAUSES the printer. Each time 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. Now each time the PAUSE key is pressed the printer prints 15 labels at speed “D” (“C” for the 300 dpi 105Se). 3.
This self test can be used to provide the test printouts required when making adjustments to the printer’s mechanical assemblies. See the sample printout in Figure 3.3. FEED Key Self Test The CANCEL Key Self Test should be performed before this self test. Information 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.
FEED Key and PAUSE Key Self Test 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 will be active until Power is turned OFF. Whenever the printer is reset to factory defaults, a Media Calibration procedure must be performed immediately. MODE Key Self Test This test places the printer in the Communications Diagnostics Mode.
FEED Key and CANCEL Key Test This test prints seven pre-programmed label formats at different speeds. The printer automatically pauses after each format.
Sample ZPL II 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 experimenting 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 copy of the ZPL II Programming Guide.
Format 1: Simple Text and a Barcode Line Type this label format: Youll get this printout: # 1 2 3 4 5 ^XA ^LH30,30 ^FO20,10^AD^FDZEBRA^FS ^FO20,60^B3N,Y,20,N^FDAAA001^FS ^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”.
Format 3: Using a Serialized Data Field Line Type this label format: Youll get this printout: # 1 2 3 4 5 6 7 ^XA ^LH30,30 ^FO20,10^AD^FDZEBRA^FS ^FO20,60^B3,,40,,^FDAAA001^FS ^FO20,180^AF^SNSERIAL NUMBER 00000000111,1,Y^FS ^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.
Configuration and Calibration Option Switches These switches are located at the rear of the printer above the Signal Interface Cable Connection. See Figure 4.2. 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. Figure 4.1 Option Switches Figure 4.
Bank 1 (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.
Bank 2 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: Bank 2 Switch Print Mode 321 • Lets you use a single ZPL II label format for many different printers—without worrying if the format contains a mode command that is inappropriate for your printer configuration.
Configuration Mode The Configuration Mode allows you to fine-tune the internal printer configuration settings for your application.
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. If ribbon is sensed, the Thermal Transfer Print Method is configured. If no ribbon is present, the Direct Thermal Print Method is configured.
Adjusting the Print Darkness This procedure sets the darkness of the printing on the label. Use the lowest setting which 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 will 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.
Interconnections System Components Figure 5.1 System Components System Considerations Communications Code 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. Interfaces The method of interfacing the Zebra S-Series Printer to a data source depends on the communication options installed in the printer.
Data Specifications When communicating via the serial data port (RS-232), the baud rate, number of data bits, and the parity are user-selectable (see “Configuration and Calibration” for acceptable setting combinations). Parity only applies to data transmitted by the printer, since it ignores the parity of received data. The S-Series Printer is fixed at 1 stop bit, so make sure that your host is also set at 1 stop bit.
Hardware Control Signal Descriptions 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 CTS is in the INACTIVE condition (negative voltage), the printer will not transmit any data.
To minimize electrical noise pickup in the cable: • Keep data cables as short as possible. • Do not bundle the data cables tightly with power cords. • Do not tie data cables to power wire conduits. Interconnect to DTE Devices 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 5.2 illustrates the connections required for this cable. Figure 5.
Parallel Cabling Requirements 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.
Signal Descriptions The following chart provides a description of each of the pins in the parallel connector. A standard parallel data cable will provide the required interconnection between the computer and the printer. Parallel Connector Pin Assignments Description Pin No. 1 The nStrobe printer input has internal 3.3 kW pull-up resistors to 5 V (IOL= 1.5 mA) and is designed to receive a signal driven open collector V OL <= 0.8 V. This pin is a signal from the host computer.
Preventive Maintenance Overview This section contains preventive maintenance information for the Zebra S-Series Printer. These procedures may be performed by the operator. Cleaning Exterior Surfaces 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.
Printhead and Platen Roller 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 page 6-3 after every roll of ribbon (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. Figure 6.
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 will be lost. Permanent parameter settings stored in EEPROM will be 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 6.1, and perform the following steps: 1.
Clean the stationary cutter blade with a cotton swab moistened with isopropyl alcohol when it becomes gummed up with label adhesive or paper debris. If the cutter performs unsatisfactorily after it has been cleaned, refer to Volume 1 of the Maintenance Manual. Figure 6.2 Cleaning the Cutter Blade Lubrication CAUTION: Some commercially available lubricants will damage the printer if used.
Adjustments Toggle Positioning Note: The 105Se 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 7.1 Printhead Pressure Adjustment (105Se shown) Black Mark Media Sensor Position Adjustment This sensor position requires no adjustment or calibration by the user. Transmissive Media Sensor Position Adjustment 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.
Upper Transmissive Media Sensor Position Adjustment To adjust the upper media sensor, refer to Figure 7.2 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.
Lower Transmissive Media Sensor Position Adjustment 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.
Media and Ribbon Sensor Sensitivity Adjustment 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 exceptionally thick or thin backing, which could require re-adjustment of the Sensor Sensitivity.
Note: If only one pair of lights is flickering, it indicates that the adjustment was not successful. Go back to step 1 and start over. 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 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 7.4.). 12.
Troubleshooting 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 All indicator lights never light. DIAGNOSIS ACTION No AC Power applied to the Ensure that the AC power cable is con- printer. nected to a working voltage source. Faulty AC power fuse. Refer to Installation for fuse replacement procedures.
SYMPTOM DIAGNOSIS ACTION Printer stops. PAUSE light ON Ribbon incorrectly loaded or Load ribbon correctly. See Ribbon and PAPER/ RIBBON light not loaded. Loading in Installation. Malfunctioning Ribbon Sensor. Call a service technician. Printhead is not fully closed. Close printhead completely. Printhead Open Sensor not de- Call a service technician. FLASHING. Printer stops. PAUSE light ON and PRINTHEAD light FLASHING. tecting its position flag. Printer stops.
SYMPTOM DIAGNOSIS ACTION Truncated print, no print, or Media or ribbon improperly See Media Loading and Ribbon Load- FEED button operates incor- loaded. ing instructions in Installation. Wrinkled ribbon. See Wrinkled Ribbon in this table. Print element damaged. Call a service technician. In Peel-Off Mode, skewed or Glue material from back of la- Refer to Preventive Maintenance and stuck labels. bels causing media movement perform maintenance and cleaning of problems. the printer.
SYMPTOM DIAGNOSIS ACTION ZPL II was sent to printer, but Communications parameters or See Operation and perform MODE not recognized. The DATA DIP switches are set incor- Key Self Test. Check for format or light remains OFF. rectly. overrun errors. Reset Communication parameters if needed. Prefix and delimiter characters Set the characters in the printer to set in printer configuration do match ZPL II format. Check Configu- not match the ones sent in the ration Label for correct characters.
SYMPTOM For printers with the Cutter Option installed: Printing stops. PAPER/RIBBON, PAUSE, and CANCEL LEDs on. DIAGNOSIS ACTION Media jammed in Cutter. Remove media, clean Cutter Module. Connecting cable not con- Plug cable into Cutter Module. nected to Cutter Module. Cutter Module is dirty. Clean Cutter Module. End of the media is not posi- Re-position media so that the end is on tioned correctly on top of the top of the platen. platen.
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Options Peel-Off 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.
Fanfold Supply Bin 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.
Optional Printer Fonts 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.
512 KB DRAM Memory Expansion (Not available for 105Se 300 dots/inch) 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. Extra memory may be installed at the factory or in the field.
Appendix A - 230 VAC Power Cord 230 VAC Power Cord Depending on how the Zebra 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 will 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.
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Appendix B - ASCII Code Chart HEX CHAR HEX CHAR HEX CHAR HEX 00 01 CHAR NUL 20 space 40 @ 60 SOH 21 ! 41 A 61 a 02 STX 22 42 B 62 b 03 ETX 23 # 43 C 63 c 04 EOT 24 $ 44 D 64 d 05 ENQ 25 % 45 E 65 e 06 ACK 26 & 46 F 66 f 07 BEL 27 47 G 67 g 08 BS 28 ( 48 H 68 h 09 HT 29 ) 49 I 69 i 0A LF 2A * 4A J 6A j 0B VT 2B + 4B K 6B k 0C FF 2C , 4C L 6C l 0D CR 2D - 4D M 6D m 0E SO 2E .
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Appendix C - Adjusting Bar Code Darkness Adjusting Darkness For “In-Spec” Bar Codes 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 will calculate 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.
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. 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.
Figure C.
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Appendix D - Optional Printer Fonts 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.
CG Triumvirate™ - Normal 0123456789.,?!AaBbCc CG Triumvirate™ - Bold 0123456789.,?!AaBbCcDd CG Triumvirate™ - Italic 0123456789.,?!AaBbCcDdEe CG Triumvirate™ - Bold Italic 0123456789.,?!AaBb CG Times™ - Normal 0123456789.,?!AaBbCcDdEeFfGg CG Times™ - Bold 0123456789.,?!AaBbCcDdEeFfGgHh CG Times™ - Italic 0123456789.,?!AaBbCcDdEeFfGgHhIi CG Times™ - Bold Italic 0123456789.,?!AaBbCcDdEeFf CG Palacio™ - Normal 0123456789.,?!AaBbCcDdEeFf CG Palacio™ - Bold 0123456789.
Figure D.
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Glossary 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.
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, the printer will not print additional labels. Once the label has been taken, printing resumes. Also called “take-label sensor”.
ribbon wrinkle A wrinkling of the ribbon caused by improper alignment of the strip plate and/or printhead pressure. This wrinkle can be seen just above the strip plate. Ribbon wrinkle can cause voids in the print and/or the spent ribbon to rewind unevenly. This is a condition that should be corrected by performing adjustment procedures. roll media Media that comes supplied rolled up on a core (usually cardboard). Contrast this with fanfold media, which comes folded in a rectangular stack.
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Index 115 VAC Operation . . . . . . . . . . . . . . . . . . . . . 2-3 Printhead and Platen Roller . . . . . . . . . . . 6-2 12-Dot/mm and 6-Dot/mm Printhead . . . . . . . . 9-4 Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 230 VAC Operation . . . . . . . . . . . . . . . . . . . . . 2-3 230 VAC Power Cord . . . . . . . . . . . . . . . . . . . A-1 Communications A Communications Capabilities Diagnostic Test . . . . .
FEED Key and PAUSE Key Self Test . . . . . . 3-12 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 FEED Key Self Test . . . . . . . . . . . . . . . . . . . . 3-11 Front Panel Keys CANCEL Key . . . . . . . . . . . . . . . . . . . . . . 3-4 FEED Key . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 M Media MODE Key . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Fanfold . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 PAUSE Key . . . . . . . . . . . . . . . . . . .
O Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Operating Modes Reflectivity and Contrast . . . . . . . . . . . . . 1-3 Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Printer Operating Modes Peel-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Media Sensing. . . . . . . . . . . . . . . . . . . . . . 3-1 Rewind . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Loading System Considerations . . . . . . . . . . . . . . . . . . . 5-1 105Se . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Communications Code (ASCII) . . . . . . . . 5-1 160S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Data Specifications . . . . . . . . . . . . . . . . . . 5-2 Ribbon Requirements . . . . . . . . . . . . . . . . . . . . 1-3 Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Ribbon Sensor Sensitivity Adjustment . . . . . . .
333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.A. Telephone +1 847.634.6700 Facsimile +1 847.913.
