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Customer Order # 11991L
Manufacturer Part # 11991LB Rev. 2
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Model Designation...................................................................................................1
System Overview.....................................................................................................2
Communication Capabilities ..............................................................................2
Print Mechanism Capabilities.............................................................................2
Additional System Requirements ............................................................................3
Media and Ribbon Requirements.............................................................................4
230 VAC Operation............................................................................................4
Ribbons and Printhead Wear ..............................................................................5
Storage and Reshipping ...........................................................................................8
Power Connection....................................................................................................8
AC Voltage Selection Procedure........................................................................8
AC Power Fuse Replacement .............................................................................9
115 VAC Operation..........................................................................................10
230 VAC Operation..........................................................................................10
Site Requirements ..................................................................................................10
Ribbon Loading (105Se)........................................................................................11
Ribbon Loading (160S)..........................................................................................14
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Rewind Mode ................................................................................................... 17
Removing Used Ribbon (105Se)........................................................................... 19
Removing Used Ribbon (160S)............................................................................. 20
Initial Printer Power Up......................................................................................... 21
Operating Your Zebra S-Series Printer ................................................................. 23
Printer Operating Modes ....................................................................................... 23
Media Transport Modes ................................................................................... 24
Front Panel Keys ................................................................................................... 26
Front Panel Lights ................................................................................................. 27
Printer Self Tests ................................................................................................... 28
CANCEL Key Self Test................................................................................... 30
FEED Key Self Test......................................................................................... 32
MODE Key Self Test ....................................................................................... 33
PAUSE Key and CANCEL Key Self Test....................................................... 33
FEED Key and CANCEL Key Self Test ......................................................... 34
Extended Printer Diagnostics ................................................................................ 34
Sample ZPL II® Label Formats ............................................................................ 35
Format 1: Simple Text and a Barcode............................................................. 36
Format 2: Saving a Label Format as a Graphic Image.................................... 36
Format 3: Using a Serialized Data Field ......................................................... 37
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Option Switches.....................................................................................................39
Bank 1...............................................................................................................40
Adjusting the Print Darkness............................................................................44
Adjusting the Media Rest Position ...................................................................44
Communications Code......................................................................................45
Hardware Control Signal Descriptions.............................................................47
RS-232 Cabling Requirements .........................................................................47
Interconnect to DTE Devices............................................................................48
Interconnect to DCE Devices ...........................................................................48
Parallel Cabling Requirements .........................................................................49
Parallel Interface...............................................................................................49
Signal Descriptions...........................................................................................50
Overview................................................................................................................51
Cleaning .................................................................................................................51
Exterior Surfaces ..............................................................................................51
Interior ..............................................................................................................51
Printhead and Platen Roller ..............................................................................52
Media, Ribbon, and Label Available Sensors ..................................................57
Cutter Module...................................................................................................57
Lubrication.............................................................................................................58
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Toggle Positioning................................................................................................. 59
Printhead Pressure Adjustment.............................................................................. 59
Black Mark Media Sensor Position Adjustment ................................................... 60
Printer Specifications............................................................................................. 71
Printing Considerations.................................................................................... 71
Bar Codes ......................................................................................................... 73
Communications Interface ............................................................................... 77
Options and Accessories .................................................................................. 77
Peel-Off ................................................................................................................. 79
Media Rewind ....................................................................................................... 79
Fanfold Supply Bin................................................................................................ 80
External ZebraNet™ (Ethernet) Interface ............................................................. 80
Black Mark (Reflective) Sensor ............................................................................ 80
Optional Printer Fonts ........................................................................................... 81
230 VAC Factory Setup ........................................................................................ 82
512 KB DRAM Memory Expansion..................................................................... 82
12-Dot/mm and 6-dot/mm Printhead..................................................................... 82
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230 VAC Power Cord............................................................................................83
ASCII Code Chart..................................................................................................84
Adjusting Darkness for “In-Spec” Bar Codes........................................................85
Label Darkness Levels......................................................................................86
Optional Printer Fonts............................................................................................88
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Zebra S-Series User’s Guide
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Zebra S-Series User’s Guide
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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.
Additional documentation for the Zebra S-Series Printer is available:
®
• The ZPL II Programming Guide (part # 46469L).
• The two-volume Maintenance Manual: Volume 1: General
Maintenance (part # 38452L) contains the information you need to
maintain your printer. Volume 2: Circuit Descriptions and Electrical
Schematics (part # 38453L) contains the information you need to repair
the circuit boards at the component level. You may order both volumes
as a set (part # 31452L).
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Labels located inside the media compartment above the frame support at
the rear of the S-Series Printer include both the serial number and model
designation. If you need to contact our technical support staff for
assistance, please have both the model designation and serial number
available so that we may help you more efficiently.
Zebra S-Series User’s Guide
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The S-Series Printer, when connected to an appropriate ASCII data source,
functions as a complete label, ticket, and tag printing system. Customer-
supplied 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.
Connection to data sources using interfaces other than the type installed in
the printer requires the use of an appropriate interface converter.
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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.
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Command/control data signals are received via the RS-232 port, parallel
port, or DIP switches and are sent to the main logic board. The
microprocessor continuously monitors these signals along with the inputs
received from the control panel and various sensors. The microprocessor
interprets this information and controls the S-Series Printer’s mechanics,
printhead, communications, command interpretation, label formatting,
media control, and mechanical drive.
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The print mechanism has been designed to print random information
labels, tickets, and tags. It uses a thermal printhead that heats a ribbon as it
passes beneath the print elements, melting its ink onto the media (direct
thermal uses heat-sensitive media instead of an inked ribbon). Constant
print speeds may be selected via software control.
2
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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.
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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.
Media may be rewound internally onto standard 3" cores if the rewind
spindle option is installed. With the peel-off option, backing material may
be rewound internally.
Ribbons for the S-Series Printer are supplied on 1" cores in standard
widths and lengths.
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In addition to the Zebra S-Series Printer, you 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 thermal transfer mode).
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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. A wide range of paper, polypropylene,
polyester, and vinyl stock has been specifically engineered to enhance the
printing capabilities of the printer and to ensure against premature
printhead wear.
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. This is especially true if you’re operating in peel-off mode,
where these variables combine with label size, backing content, diecut
depth, and even humidity to affect printer operation.
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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.
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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.
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If you discover shipping damage upon inspection:
• Immediately notify the shipping company of the damage.
• Retain all packaging material for shipping company inspection.
• File a damage report with the shipping company and notify your local
distributor and Zebra Technologies Corporation of the damage. Zebra
Technologies Corporation is not responsible for any damage incurred
during shipment of the equipment and will not repair this damage under
warranty. Immediate notification of damage to the shipping company
or its insuring agency generally results in ensuring any damage claim
validity and ultimate monetary compensation.
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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. 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. If you use a different container, a
procedure similar to the original factory packaging should be followed.
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The S-Series Printer’s AC voltage may be set for either 115 VAC or 230
VAC operation. To match the printer’s power entry selection to the
available power source, refer to Figure 1 and follow the procedure outlined
below:
1. Locate the AC power area at the rear of the printer.
2. Using a small flatblade screwdriver or similar tool, move the voltage
selection switch to the 115 V or 230 V position as required. (The
initial position of the switch depends on how the printer was ordered.)
Make sure that the appropriate fuse is in place.
8
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Figure 1
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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. To replace the fuse, insert the tip of a flatblade screwdriver into the
slot in the end of the fuse holder end cap.
2. Press in slightly on the end cap and turn the screwdriver slightly
counterclockwise. This disengages the end cap from the fuse holder
and allows you to remove the fuse.
3. To install a new fuse, remove the old fuse and insert the new fuse into
the fuse holder.
4. Push the end cap in slightly, then insert the tip of a flatblade
screwdriver into the slot in the end cap and turn clockwise to engage it.
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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.
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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. If not provided, obtain a cord
set with the proper AC power plug. The cord may then be connected
to the standard (international) IEC-type 3-prong AC connector
provided on the S-Series Printer. Refer to “230 VAC Power Cord” on
page 83 for more information.
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The S-Series Printer may be installed on any solid, level surface of
the printer operates must meet the environmental conditions specified (see
page 77).
Since the Zebra S-Series Printer was designed and is fabricated as an
industrial-type unit, it functions satisfactorily in areas such as a warehouse
or factory floor that conform to the specified environmental and electrical
conditions (see page 76).
10
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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.
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1. Align the segments of the ribbon supply spindle. See Figure 2.
Figure 2
2. Place the ribbon roll on the ribbon supply spindle.
3. Open the printhead by moving the handle to the OPEN position.
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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. Be
careful not to crease or wrinkle the ribbon.
6. Remove the hook from the ribbon take-up spindle.
7. Place the leader under the long leg of the hook and wind for several
turns.
8. Close the printhead by moving the lever to the CLOSED position.
12
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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.
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1. Align the segments of the ribbon supply spindle. See Figure 2.
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 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.
5. Thread the leader and attached ribbon as shown in Figure 4. Be
careful not to crease or wrinkle the ribbon.
6. Place the leader around the ribbon take-up spindle and wind
counterclockwise for several turns.
7. Close the printhead by moving the lever to the CLOSED position.
14
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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.
change the media type, you must re-calibrate the printer. See
“Calibration” on page 43 for details.
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Roll media may contain labels of a fixed length with gaps in between or it
may be formed as one continuous length with no gaps (see “Continuous
Media” on page 91 for a complete definition). Both types of roll media
mount inside the printer in the same manner. To load roll media, refer to
Figures 5 and/or 6 and do the following:
1. Move the media guide and media supply guide as far away from the
printer frame as possible.
2. Place the media roll on the media supply hanger.
3. Push the media supply guide inward until it is just touching the outer
side of the media supply roll. (The guide must not cause pressure or
excessive drag on the media supply roll.)
4. Thread the media through the printhead as shown in the illustrations.
5. Adjust the media guide until it just touches the outer edge of the media
without causing it to buckle.
6. Close the printhead by moving the lever located on the upper
printhead assembly to the CLOSED position.
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Follow the instructions described in “Roll Media” on page 15.
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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.
in the side plate.
4. Align the upper end of the rewind plate with the corresponding
opening in the side plate and slide the rewind plate in so that it stops
against the main frame.
5. Remove the hook from the take-up spindle shaft.
6. Route the media as shown in Figures 5 and 6 and wind it 1-2 times
around a 3" core.
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1. Remove the rewind plate if one is present and store it on the two
mounting screws on the inside of the front panel. Align the notch or
web in the media so that the take label sensor can sense a peeled label.
2. Load media as shown in Figures 5 and 6.
3. Remove the hook from the take-up spindle shaft.
4. Remove several labels from the media backing and then wind the
backing 1-2 times around the media take-up spindle and reinstall the
hook.
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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
lever located on the upper printhead assembly to the CLOSED position.
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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. Adjust the media guide
using the thumb screw to keep the media from drifting left or right.
Fanfold media from outside the printer feeds through one of the two access
slots: one at the bottom of the printer, and one at the rear.
Figure 7
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Figure 8
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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.
Figure 9
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Refer to Figure 10.
1. Turn the knob at the end of the ribbon take-up spindle (1) clockwise
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. Follow the ribbon loading procedure on page 14 to load the new
ribbon.
Figure 10
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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.
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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 either need to use
®
label design software or write a format in ZPL II , which is a
design software, refer to the instructions provided with your software
package to determine how to proceed.
If you are using, or plan to use, ZPL II, make sure you have a copy of the
ZPL II Programming Guide. This guide is available by contacting your
distributor or Zebra Technologies Corporation. For some sample ZPL II
label formats, see page 35. But first, we’ll describe the different operating
modes.
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The S-Series Printer can be configured for several different modes of
operation by sending the proper commands from the host computer.
Operating modes may also be configured via a bank of DIP switches at the
rear of the printer. (See “Option Switches” on page 39 for more
information about DIP switches.)
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There are two basic modes by which the printer can sense the position of
the media: transmissive sensing mode and black mark sensing mode. The
160S comes standard with both transmissive sensing mode and black mark
sensing mode capabilities. The 105Se comes standard with transmissive
sensing mode capability, but may be factory ordered with an additional
black mark sensor.
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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.
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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.
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When the media is in the rest (idle) position, the webbing between labels is
over the tear-off/peel-off bar. 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.
After a label is printed, the media feeds forward until the end of the label is
past the tear-off/peel-off bar. This label position is determined by
commands sent to the printer from the host computer or by front panel
adjustments.
When a quantity of labels is required, a format for printing a batch of
labels can be sent to the printer. Once a label is printed, the media feeds
forward to the start of the next label and printing continues. In this way,
the printer prints the batch and stops when it reaches the quantity required.
When a quantity of individual labels is required, the format for printing a
batch of labels can still be sent to the printer. The operator can use the
PAUSE key to cycle the printing one label at a time. The operator can then
tear off each label before printing the next one.
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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. The backing material is peeled
away from the label and winds around the peel-off spindle or the media
rewind spindle. The media feeds forward until most of the label hangs
loose from the backing. The label is held in this position by that portion of
the backing that has not crossed the tear-off/peel-off bar.
The label available sensor is activated by the label. When the operator
removes the label, the printer backfeeds the media either to the rest (idle)
position or to the printing position and prints the next label.
Note: You do not need to turn the printer OFF when it is necessary to
remove the media backing from the take-up spindle.
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Some applications call for the media to be rewound onto a core as the
labels are printed.
When the media is in the rest (idle) position, the start of the next label is
directly under the printhead. After the label is printed, the media feeds
forward until the start of the next label is under the printhead. The media
never backfeeds in this mode.
When the printer completes a batch of labels, printing stops.
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In this mode the cutter, under software control, automatically cuts
individual labels (or at the end of batches of labels) after printing. The
optional cutter catch tray gathers the completed labels.
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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.
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The FEED key forces the printer to feed
one blank label. If the printer is idle, or
if the PAUSE function is active when
the FEED key is pressed, one blank
label feeds from the printer
immediately. If the printer is printing,
then one blank label feeds out after
completion of the current batch of
labels. After one blank label feeds out,
pressing FEED again provides another
blank label.
Figure 11
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The CANCEL key is only recognized in PAUSE mode. Press CANCEL to
cancel the current label format. If no format is printing, then the next one
to be printed is canceled. If no formats are in memory, the CANCEL key
is ignored. If the CANCEL key is pressed for an extended period of time
(3 seconds), the printer cancels all formats in memory and the DATA light
turns OFF.
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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.
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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.
Indicator Light Name
Status
Indication
POWER
ON
Printer is on.
OFF
ON
Normal operation
Head Over Temperature condition. Printing stops until the
printhead cools down. Printing resumes automatically.
Printhead Under Temperature condition. Printing
continues.
PRINTHEAD
Power Supply Over Temperature condition. Printing stops
until the power supply cools down. Printing resumes
automatically.
Flashing
OFF
Printhead Open.
Media and ribbon (if used) are properly loaded.
Paper out.
ON
PAPER/RIBBON
PAUSE
1. In Thermal Transfer Mode: Ribbon is out.
2. In Direct Thermal Mode: Ribbon is in the printer.
Normal operation.
Flashing
OFF
ON
Printer has stopped all printing operations.
Normal operation.
OFF
ON
Labels are printing.
Single Flash
The CANCEL key was pressed and a format was
successfully deleted from the print queue.
DATA
Flashing
Receiving data from host computer.
Slow Flashing
Printer sent a “stop transmitting” command to the host
computer.
DARKEN
ON
ON
ON
Printer is in the Configuration Mode. See page 42 for
more information.
POSITION
CALIBRATE
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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.
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These self tests produce sample labels and provide specific information
that helps determine the operating conditions for the printer.
Each self test is enabled by holding in a specific front panel key or
combination of keys while turning the power switch ON. Keep the key
depressed until the front panel lights turn ON.
When the Power-On Self Test is completed, the selected self test
automatically starts.
Note: When performing self tests, all data interface cables connected to
the rear of the printer must be removed.
When canceling a self test before its actual completion, always
turn the printer power OFF and then back ON to reset the printer.
When performing these self tests in the peel-off mode, the
operator must remove the labels as they become available.
Unless specifically stated, all tests print in tear-off mode in tear-
off printers and in peel-off mode for peel and rewind printers.
If your media is not wide enough, the test labels only print out to
the edge of the label. If your media is too short, the test label
continues printing on the next label.
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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
2"/sec.
3"/sec.
4"/sec.
5"/sec.
6"/sec.
Metric
A*
B
51 mm/sec.
76 mm/sec.
102 mm/sec.
127 mm/sec.
152 mm/sec.
C
D
* Speed “A” for the 105Se with the optional 300 dots-per-inch printhead is
2.4" (61 mm).
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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
permanently (by saving the new
parameters in EEPROM Memory).
Saving new parameters occurs
whenever a printer calibration
procedure is performed. For more
details, refer to “Calibration” on
page 43.
Figure 12
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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. While the printer is PAUSED, pressing the CANCEL key a second
time alters the self test again. When the PAUSE key is pressed, the
printer prints 50 labels at speed “A.”
4. While the printer is PAUSED, pressing the CANCEL key once alters
the self test a third time. When the PAUSE key is pressed, the printer
prints 50 labels at speed “D” (“C” for the 300 dpi ).
Note: On printers with either the rewind or peel option installed, the
peel mode is activated during the first half (steps 1–4) of the
PAUSE Key Self Test. On printers with a rewind option, the
sensors during the test. The first label to print says, “PEEL
OPTION INSTALLED.” Each label must be manually removed
from the sensor path before the next label prints. Steps 1–4 are
then repeated in rewind mode.
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 13.
Figure 13
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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. Inspect
these labels and determine which one has the best darkness setting for the
application. This value can be entered into the printer by setting the
darkness during the configuration procedure.
The value printed on the FEED
Key Self Test label is added to
(plus) or subtracted from
(minus) the “Darkness” value
specified on the configuration
label. The resulting numeric
value (0 to 30) is the best
darkness value for that specific
media/ribbon combination.
The darkness value can also be
programmed into the ZPL II
formats sent to the printer.
Figure 14
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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.
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This test places the printer in the communications diagnostics mode. In
this mode, the printer prints the ASCII characters and their corresponding
hexadecimal values for any data received from the host computer. A
typical printout from this test is shown in Figure 15.
Note: This label is inverted when printed.
Figure 15
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This test prints a maximum of 500 head test labels. Each label backfeeds
prior to printing and feeds forward to the rest position after printing. A
serialized number prints on each label. Press the PAUSE key or turn the
printer power OFF to stop printing. The labels look like the one in Figure
13 except that a serialized number prints on each label.
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This test prints seven pre-programmed label formats at different speeds.
The printer automatically pauses after each format. The sequence of label
formats is as follows:
Label Format
Quantity
Inches per
second
Left Ribbon Wrinkle Test
Right Ribbon Wrinkle Test
C39 Wrinkle Test
20
20
20
20
20
20
10
10
10
10
10
10
10
10
D*
D*
D*
A
Left Ribbon Wrinkle Test
Right Ribbon Wrinkle Test
C39 Wrinkle Test
A
A
Usable Area Test
D*
D*
D*
D*
A
Head Temperature Test
Upper Smear Test
Lower Smear Test
Usable Area Test
Head Temperature Test
Upper Smear Test
A
A
Lower Smear Test
A
* “C” for the 105Se with the 300 dots/inch printhead.
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Extended diagnostic tests are available. The maintenance manual, Vol. 1:
General Maintenance, provides the information needed to perform these
additional tests.
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®
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. To
learn about ZPL II, contact your distributor or Zebra Technologies
Corporation for a copy of the ZPL II Programming Guide.
For each format, do the following:
1. Save the file.
2. Copy the file to the printer.
• Set up the printer and turn the power ON.
• Use a text editing program (e.g., Windows Write or DOS Editor)
and type in the label format exactly as shown in the sample label
formats on pages 36-37.
• Save the file in a directory for future use. Use the extension “ . zpl”.
• Copy the file to the Zebra S-Series Printer.
“format1.zpl” then type, “COPY FORMAT1.ZPL COM1”.
3. Compare your results with those shown. If your printout does not look
like the one shown, confirm that the file you created is identical to the
format shown, then repeat the printing procedure. If nothing prints,
refer to “Installation” beginning on page 7 to make sure your system is
set up correctly; otherwise, refer to “Troubleshooting” beginning on
page 65.
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)RUPDWꢀꢄꢇꢀꢀ6LPSOHꢀ7H[WꢀDQGꢀDꢀ%DUFRGH
Line # Type this label format:
You’ll 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”.
Line #4: Sets field origin, selects bar code Code 39, sets barcode height at 20 dot rows,
defines field data for bar code as “AAA001”.
Line #5: End of label format.
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Line # Type this label format:
You’ll get this printout:
1
2
3
4
5
6
^XA
^LH30,30
(Same as Format 1, but this format was
also saved in the printer’s memory as a
graphic image named “FORMAT2”.)
^FO20,10^AD^FDZEBRA^FS
^FO20,60^B3N,Y,20,N^FDAAA001^FS
^ISFORMAT2,N
^XZ
7
8
9
^XA
^ILFORMAT2
^XZ
Line#1-4: These commands were described in Format 1.
Line #5: Saves the format in the printer’s memory as a graphic image named “FORMAT 2”, the
“N” indicates “do not print after saving”.
Line #6-7: (See Format 1).
Line #8: Load and print the graphic image saved as “FORMAT2”.
Line #9: (See Format 1).
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)RUPDWꢀꢂꢇꢀꢀ8VLQJꢀDꢀ6HULDOL]HGꢀ'DWDꢀ)LHOG
Line #
Type this label format:
You’ll get this printout:
1
^XA
2
3
4
5
^LH30,30
^FO20,10^AD^FDZEBRA^FS
^FO20,60^B3,,40,,^FDAAA001^FS
^FO20,180^AF^SNSERIAL NUMBER
00000000111,1,Y^FS
6
7
^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.
Line #6: Sets print quality to 10.
Line #7: (See Format 1).
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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.
Figure 16
Figure 17
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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.
Note: Parallel-interface printers
do not require these
configurationparameters,
therefore they have no
If these switches are in the proper
position to match the
communication configuration of
the host computer, and the printer
is not receiving data, refer to
“RS-232 Cabling Requirements”
on page 47 and make sure the
correct interface cable is being
used.
Note: The printer is fixed at 1
stop bit, so make sure
that your host device is
also set at 1 stop bit.
Table 1
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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.
•
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.
•
Some third-party label design software
packages work better if these switches
control the mode.
If you do not want to override ZPL II or the
calibration settings, disable one or more of the
override options by setting switches 1, 4,
and/or 7 to the R (OFF) position and turning
the power ON. With these disabled, the
printer requires ZPL II commands and/or
re-calibration to set print mode, media mode,
and/or media type.
Table 2
To override, set the switches to one of the modes shown in the table. If
you are in the process of printing, this change takes effect on the next label
printed. If you change the switches from active to disabled after printer
power-up, the printer remains in the current mode until a ZPL II command
or re-calibration changes the mode.
Note: For the 105Se, Switch 5 must not be positioned to the right unless
the printer is equipped with the optional black mark sensor.
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The configuration mode allows you to fine-tune the internal printer
configuration settings for your application. In this mode, you can change
the following parameters:
• Printing darkness
• Rest position of the media with respect to the “web” or “interlabel gap”
• Position of printing relative to the top of the label
• Media and ribbon sensor values
• Label length
• Printing method
• Media type (continuous or non-continuous)
You can get a printout of the printer configuration (the values for each of
these parameters) at any time by performing the CANCEL Key Self Test
(see page 30).
If it is ever necessary to reset the printer configuration to the factory
defaults, refer to the “FEED Key and PAUSE Key Self Test” on page 33.
The ZPL II Programming Guide contains information on instructions that
may be sent to the printer to disable the MODE key and set specific label
format values for each of these parameters. If you are not using ZPL II,
refer to the instructions provided with your software package to determine
if you also have this capability.
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&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. If ribbon is sensed, the thermal
transfer print method is configured. If no ribbon is present, the direct
thermal print method is configured.
The results of this calibration are stored in the printer’s memory. These
parameters remain in effect until the next calibration is performed. The
printer configuration printout, which prints when the CANCEL Key Self
Note: If the printer is in the peel-off mode, the operator must “catch”
procedure.
1. Load media and ribbon (if used). Make sure the media sensor is
properly positioned (see “Media and Ribbon Sensor Sensitivity
Adjustment” on page 63).
Note: To use the black mark sensing mode, make sure you set the Bank
2 DIP switches appropriately (see page 41).
2. Turn the power switch ON. When the Power-On Self Test is
complete, the POWER, PAUSE, and PAPER/RIBBON lights are ON.
3. Briefly press the MODE key three times. PAUSE and CALIBRATE
lights turn ON.
4. Press UP (FEED Key) to calibrate. The printer feeds some media.
The MODE lights flash ON and OFF to indicate that the settings have
been saved in memory.
5. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF.
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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.
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This procedure sets the end-of-label position relative to the tear-off bar or
cutter.
1. Briefly press the MODE key twice. PAUSE and POSITION lights
turn ON.
2. Press UP or DOWN to adjust the current setting.
3. Briefly press the MODE key twice. 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.
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This procedure positions the printing on the label relative to the top edge
of the label.
1. Briefly press the MODE key twice, then press and hold for about five
seconds until the lights change. PAUSE, DARKEN, and
CALIBRATE lights turn ON.
2. Press UP or DOWN to adjust the current setting.
3. Briefly press the MODE key twice. 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.
44
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Figure 18
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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.
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The method of interfacing the Zebra S-Series Printer to a data source
depends on the communication options installed in the printer. Depending
data port or a parallel port.
'DWDꢀ6SHFLILFDWLRQV
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). 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.
When communicating via the parallel port, the previously mentioned
parameters are not considered.
56ꢆꢇꢈꢇ 6HULDO 'DWD 3RUW
The connections for the standard interface are made through the DB-25S
connector on the rear panel. For all RS-232 input and output signals, the
S-Series Printer follows both the Electronics Industries Association’s
(EIA) RS-232 and the Consultative Committee for International Telegraph
and Telephone (CCITT) V.24 standard signal level specifications.
56ꢆꢁꢂꢁꢀ3LQRXWV
Pin No.
Description
Frame Ground for Cable Shield
1
2
TXD (Transmit Data) output from the printer
RXD (Receive Data) input to the printer
RTS (Request to Send) output from the printer
DSR (Data Set Ready) input to the printer
Signal Ground
3
4
6
7
20
DTR (Data Terminal Ready) output from the printer
Note: Pins 5, 8, 10-19, and 21-25 are unused and unterminated.
Table 3
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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.
When DTR/DSR handshaking is selected via DIP Switch #7 at the rear of
the printer, the Data Terminal Ready (DTR) control signal output from the
printer controls when the host computer may send data. DTR ACTIVE
(positive voltage), permits the host to send data. When the printer places
DTR in the INACTIVE (negative voltage) state, the host must not send
data.
Note: When XON/XOFF handshaking is selected, data flow is
controlled by the ASCII Control Codes DC1 (XON) and DC3
(XOFF). The DTR control lead does not have an effect.
56ꢆꢁꢂꢁꢀ&DEOLQJꢀ5HTXLUHPHQWV
The required cable must have a 25-pin “D” Type (DB-25P) male connector
on one end, which is plugged into the mating (DB-25S) female connector
located at the upper rear of the printer. Tighten the locking screws.
The other end of the signal interface cable connects to an appropriate point
at the host computer. This cable is one of two types depending on the
specific interface requirements. Refer to page 48 for information on the
standard and null modem cables.
Data cables must be fully shielded and fitted with metal or metallized
connector shells. Shielded cables and connectors are required to prevent
radiation and reception of electrical noise.
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.
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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
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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. Figure 20 illustrates the
connections required for this cable.
Figure 20
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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.
Data cables must be fully shielded and fitted with metal or metallized
connector shells. Shielded cables and connectors are required to prevent
radiation and reception of electrical noise.
To minimize electrical noise pickup in the cable:
• Keep data cables as short as possible (maximum length: 10 ft.).
• Do not bundle the data cables tightly with power cords.
• Do not tie data cables to power wire conduits.
3DUDOOHOꢀ,QWHUIDFH
The parallel interface provides a means of communication that is typically
faster than the previously mentioned serial interface method. In this
method, the bits of data which make up a character are sent all at one time
over several wires in the cable, one bit per wire.
Data signals are defined as either HIGH or LOW, while control signals are
either Active or Inactive. Some control signals are active HIGH while
others are active LOW. The voltage levels which represent these
conditions are:
Data Signal
HIGH
Voltage Level
+5 VDC
LOW
0 VDC
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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.
Description
1
The nStrobe printer input has internal 3.3 kW pull-up resistors to 5 V
(I = 1.5 mA) and is designed to receive a signal driven open collector
OL
V
<= 0.8 V. This pin is a signal from the host computer. The nStrobe
OL
input is debounced on a LOW going edge to require an active width
greater than 0.5 ms before data is latched.
2-9
Data inputs have TTL input characteristics with internal 3.3 kW pullups
and represent 1 TTL unit load or less. The data inputs are positive logic
with a HIGH voltage level corresponding to a logic 1. Pin 2 through Pin
9 = D0 through D7 respectively.
10
11
The nAck output is an active LOW pulse used to indicate termination.
nAck is a driven open collector with a 3.3 kW internal pull-up. The
output sinks 7 mA to a V <= 0.4 V.
OL
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. Busy is a
driven open collector with a 3.3 kW internal pull-up. The output sinks 7
mA to a V <= 0.4 V.
OL
12
13
The PError signal is active HIGH whenever the printer is out of media or
ribbon.
The Select signal function is determined by an additional configuration
option which becomes active when the port is present. In the default
condition, select is active HIGH whenever the parallel port is powered
up and the parallel port is enabled. In the non-default condition, select
is active LOW whenever the printer is printing.
14
15
nAutoFd (not connected).
Not defined.
16
Logic Gnd.
17
FRAME GROUND is at the same potential as Logic Gnd (pin 16).
FUSED 5 V - 1 A maximum.
18
19-30
SIGNAL GROUNDS are the Logic Grounds and Returns for all input
and output signals.
31-35
36
NOT USED - These leads should be left unconnected.
NSelectIn (not connected).
50
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This section contains preventive maintenance information for the Zebra
S-Series Printer. These procedures may be performed by the operator.
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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.
,QWHULRU
Remove any accumulated dirt/lint from the interior of the printer using a
soft bristle brush and/or vacuum cleaner. This area should be inspected
after every four rolls of media.
&OHDQLQJꢀ6FKHGXOH
AREA
Printhead
METHOD
Isopropyl alcohol
INTERVAL
After every roll of media (or 500
ft. of fanfold media) when
printing direct thermal or after
every roll of ribbon when printing
in thermal transfer mode.
Platen Roller
Isopropyl alcohol
Air blow
Upper and Lower Media
Sensors
Media Path
Isopropyl alcohol
Air blow
Ribbon Sensor
Peel/Tear Bar
Isopropyl alcohol
Air blow
As needed.
Monthly.
Label Available Sensor
Cutter Module
Isopropyl alcohol and/or air blow
As needed.
Table 4
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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.
Figure 21
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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. Open the printhead by moving the printhead handle to the OPEN
position.
2. Remove the media and ribbon (if present).
3. Moisten an applicator tip with Zebra Technologies Corporation-
recommended solvent and wipe the print elements from end to end.
(The print elements form the gray/black strip just behind the chrome
strip.) Allow a few seconds for the solvent to evaporate.
4. Rotate the platen roller and clean thoroughly with the solvent.
5. Brush/vacuum any accumulated paper lint and dust away from the
rollers and the media and ribbon sensors.
6. Reload ribbon and/or media, close and latch the printhead, restore
power (if necessary) and continue printing after the self test.
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Extend the LifeofYourPrinthead
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. The
second has printed over 1 million linear inches of thermal transfer labels and has been
properly maintained. The third printhead has printed far fewer labels, but without
proper care and maintenance, signs of abrasion and contamination build-up are
evident.
Less Than 1 Million Inches
(Without Proper Care)
Over 1 Million Inches
(Properly Maintained)
New
Preventive Maintenance
For optimum performance, clean the printhead regularly after every roll of thermal
transfer ribbon or after every roll of direct thermal labels. Take care when handling or
cleaning the printhead by removing any jewelry that may scratch the printhead and
use a grounding strap or anti-static mat to discharge static electricity that could
damage the printhead.
To start, only use the pre-soaked (isopropyl alcohol) cleaning swabs provided in the
preventive maintenance kit. First, turn off the printer and open the printhead. Lightly
blow or brush away any loose dust and lint particles within the print mechanism (i.e.,
rollers, media/ribbon sensors, and printhead). NEVER use any hard, metallic, or
abrasive objects — such as a screwdriver — to remove adhesives or other
contaminants that may have built up on the printhead.
Next, press the swab tip against the printhead and swipe the print elements from end to
end. Then, turn the platen rollers while wiping them from side to side. Repeat this
step until the swab no longer shows dirt.
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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.
Ensure that the thermal transfer ribbon is as wide or wider than the label media to
prevent exposing the elements to the more abrasive label material.
Ribbon Backcoating and Buildup- Printhead contamination from direct thermal media
or thermal transfer ribbon may occur in applications requiring high burn settings, high
head pressure, high speed, or high volume. This contamination builds up on the
printhead elements, creating a barrier to the heat transformation required to produce
high quality images. Contaminant buildup occurs gradually and results in poor print
quality that may look like faded print or failed print element(s). This build up is very
resistant to cleaning with the pre-soaked swabs and is difficult to remove.
In order to avoid ribbon backcoating and buildup:
•
Use thermal transfer ribbons that have been specially cured to provide backcoat
protection for high demand applications. These ribbons — sometimes referred to
as anti-stick ribbons — also dissipate static and provide more lubrication.
Follow the recommended Printhead Preventive Maintenance procedures.
Use our Save-a-Printhead cleaning film to remove printhead contamination
buildup quickly and easily.
•
•
Save-a-Printhead Cleaning Film
What is Save-a-Printhead cleaning film? A specially coated film that removes
contamination buildup without damaging the printhead.
What are the benefits of Save-a-Printhead cleaning film?
•
•
•
Extends the life of your printhead.
Reduces maintenance downtime and the cost of replacing a printhead.
An inexpensive, easy and quick way to remove contaminants without having to
remove the printhead.
When should you use Save-a-Printhead cleaning film? When you see degrading print
quality that looks like faded print or a failed print element(s) that cannot be corrected
by cleaning with the pre-soaked cleaning swabs.
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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. Again, clean the printhead per the recommended Preventive Maintenance
procedures.
8. Reload media and ribbon, close and latch the printhead.
9. Print labels and inspect for improved print quality. If quality has not improved,
contact our Technical Support staff.
*Only one pass is required to remove contamination buildup.
*Each strip of film can be used up to 10 times.
*Discard the strip when residue buildup or other contamination is apparent.
Note: In the case that a replacement printhead is needed, product from
the Original Equipment Manufacturer (OEM) is strongly
recommended to ensure that your printer and part warranties
remain intact, and that the product performs optimally.
How to Order Save-a-Printhead Cleaning Film Kits
There are five kits to accommodate the different width printers. Each kit contains
three 10" long strips of film. Reference the following table to order the kit for your
printer:
Order kit number:
46902
For Printers with Print Widths:
3.0"-4.0"
44902
4.0"-5.0"
48902
5.0"-6.0"
38902
6.0"-7.0"
22902
8.0"-9.0"
56
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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.
&XWWHUꢀ0RGXOH
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.
When the stationary cutter blade becomes gummed up with label adhesive
or paper debris, clean it with a cotton swab moistened with isopropyl
alcohol. If the cutter performs unsatisfactorily after it has been cleaned,
refer to Volume 1 of the Maintenance Manual.
Figure 22
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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.
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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. If your printer has two toggles and you are using
media too narrow to accommodate both toggles, position one toggle over
the center of the media and decrease the pressure on the unused toggle.
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If printing is too light on one side, or if thick media is used, you may need
to adjust the printhead pressure. Refer to Figure 23 and follow the
procedure below.
1. Perform a PAUSE Key Self Test (see page 31).
2. Lower the darkness setting until the printing is gray.
3. Loosen the toggle position locking nut(s) located inside the “U”
shaped bracket at the top of the toggle.
4. Slide toggle(s) in the direction of the light printing.
5. Using the knurled adjusting nuts on the shaft(s) of the toggle(s),
increase or decrease spring pressure until the left and right edges of the
printed area are equally dark.
6. Increase darkness to optimum level for the media being used.
7. Retighten the toggle position locking nut(s).
Note: Printhead life can be maximized by using the lowest pressure that
produces the desired print quality.
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Figure 23
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This sensor position requires no adjustment or calibration by the user.
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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. However, if position adjustments are needed, follow
these procedures beginning with the upper sensor.
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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). When using tag stock, position the upper sensor directly
over the hole or notch.
4. Tighten the Phillips head screw.
Note: To adjust the upper section of the transmissive media sensor for
the outside half of the media width, call a service technician.
Figure 24
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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.)
Note: If the sensor is being moved inward and a large loop of wire
develops, remove the cover from the electronics side of the
printer and gently pull the wires through. It is important that the
wires be properly clamped so that they are not rubbed by any
belts.
Figure 25
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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.
This adjustment may need to be performed if the paper/ribbon light comes
ON with (1) the media and ribbon properly installed for thermal transfer
mode or (2) media only properly installed for the direct thermal mode.
The following procedure is used to perform the media and ribbon sensor
and sensitivity range adjustment:
1. Turn the printer OFF.
2. Open the printhead.
3. Remove as many labels as needed to create at least 12" of blank
backing material. Load the blank backing material under the
printhead.
Note: Be sure that blank backing material is positioned between the
upper and lower media sensors.
4. Remove the ribbon. (Sliding it as far from the printer wall as possible
has the same effect as removing it.)
5. Close the printhead.
6. Hold down the PAUSE, FEED, and CANCEL keys while turning the
printer ON. Once the printer is ON, release the keys.
7. The following two sets of lights begin flickering, signifying that the
adjustment has been made:
• The PRINTHEAD and PAPER/RIBBON lights
• The DARKEN and POSITION lights
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.
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8. Open the printhead.
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.
Figure 26
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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
ACTION
No AC power applied to the
printer.
Ensure that the AC power
cable is connected to a
working voltage source.
All indicator lights never light.
Faulty AC power fuse.
Refer to page 9 for fuse
replacement procedures.
No voltage available from the Call a service technician.
internal power supply.
An improper configuration was Reload factory defaults, then
Printer locks up when running set.
Power-On Self Test.
set correct parameters (see
the instructions that begin on
page 28).
POWER light ON, other lights ROM CRC test has failed.
all OFF or all ON and the
Call a service technician.
printer locks up.
CALIBRATE light is OFF but Dynamic RAM failed.
all other lights are on.
Call a service technician.
Call a service technician.
CALIBRATE light and
POSITION light OFF but all
other lights ON.
FONT ROM error.
Printhead under-temperature Wait until printhead warms up.
condition.
If condition persists and print
quality is affected, move
printertowarmerenvironment.
If print quality is acceptable,
no action is required.
PRINTHEAD light is ON,
printing continues.
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SYMPTOM
DIAGNOSIS
ACTION
Media incorrectly loaded or not Load media correctly. See
loaded.
Misadjusted media sensor.
Media not calibrated.
of media sensor and/or
calibrate media. See “Media
and Ribbon Sensor Sensitivity
Adjustment” on page 63 and
“Calibration” on page 43.
Printer stops. PAUSE light
and PAPER/RIBBON light
both ON.
Printer stops. PAUSE light ON Ribbon incorrectly loaded or
Load ribbon correctly. See
page 11 for the 105Se and
page 14 for the 160S.
and PAPER/RIBBON light
FLASHING.
not loaded.
Malfunctioning ribbon sensor. Call a service technician.
Printer stops. PAUSE light ON Printhead is not fully closed.
Close printhead completely.
Call a service technician.
and PRINTHEAD light
FLASHING.
Printhead open sensor not
detecting its position flag.
Printhead element is
overheated.
Printer resumes printing when
the printhead element cools. If
condition persists, move
printer to a cooler
Printer stops. PAUSE light
and PRINTHEAD light both
ON.
environment.
Power supply is overheated. Printer resumes printing when
the power supply cools. If
condition persists, move
printer to a cooler
environment.
Dots missing in printed area of Printhead element going bad. Call a service technician.
label.
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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
labels.
necessary.
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
edge guides.
Refer to “Media Loading” on
page 15.
(For Peel-Off Mode)
Excessive vertical drift in top- Incorrect media loading.
of-form registration.
See “Media Loading” on
page 15.
Dirty head or ribbon rollers.
See “Printhead and Platen
Roller” on page 52 for
printhead cleaning
instructions.
Light vertical lines running
through all labels.
Light printing or no printing on Printhead needs balancing.
left or right side of the label.
Adjust toggle pressure and/or
position. See “Toggle
Positioning” on page 59.
°
Short printed lines at 45 to
label edge on left or right side
of label.
Positioning” on page 59.
Fine gray lines on blank labels Wrinkled ribbon.
at angles.
See “Wrinkled ribbon.” on
page 68 under SYMPTOM.
Truncated print, no print, or
FEED button operates
incorrectly while using non-
continuous media.
Media or ribbon improperly
loaded.
See “Media Loading” on
page 15; “Ribbon Loading
(105Se)” on page 11; and
“Ribbon Loading (160S)” on
page 14.
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SYMPTOM
DIAGNOSIS
Wrinkled ribbon.
ACTION
See “Wrinkled ribbon.” on
page 68 under SYMPTOM.
Long tracks of missing print on
several labels.
Print element damaged.
Call a service technician.
Glue material from back of
labels causing media
In Peel-Off Mode, skewed or movement problems.
stuck labels.
Refer to "Cleaning" beginning
on page 51 and perform
maintenance and cleaning of
the printer.
Media and backing not
properly aligned in printer.
See “Media Loading” on
page 15.
Ribbon fed through machine See “Ribbon Loading (105Se)”
incorrectly.
on page 11 and “Ribbon
Loading (160S)” on page 14.
Incorrect darkness setting.
Set to the lowest value needed
for good print quality. See
“Adjusting the Print Darkness”
on page 44.
Wrinkled ribbon.
Incorrect printhead position or Adjust toggle pressure and/or
pressure. position. See page 59.
Media not feeding properly; it Make sure the media is snug
is walking from side to side.
by adjusting the media guide.
See “Media Loading” on
page 15.
Continuing symptoms.
Call a service technician.
Call a service technician.
Continued wrinkled ribbon.
Strip plate needs adjusting.
was not moving.
recalibrate. See page 43.
Incorrect media sensor
position.
See media sensor position
adjustments on page 60.
Misregistration and misprint of
1 to 3 labels.
Media or ribbon improperly
loaded.
See “Media Loading” on
page 15; “Ribbon Loading
(105Se)” on page 11; and
“Ribbon Loading (160S)” on
page 14.
Incorrect media sensor
position or sensitivity.
See “Media and Ribbon
Sensor Sensitivity Adjustment”
on page 63.
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SYMPTOM
DIAGNOSIS
ACTION
incorrectly.
and calibrate the printer.
Then, cycle the power
ON/OFF switch.
Changes in parameter settings
did not take effect.
If problem continues, there
may be a problem on the main
logic board.
Call a service technician.
Communications parameters See “MODE Key Self Test” on
or DIP switches are set
incorrectly.
page 33. Check for format or
overrun errors. Reset
communication parameters if
needed.
ZPL II was sent to printer, but
not recognized. The DATA
light remains off.
Prefix and delimiter characters Set the characters in the
set in printer configuration do printer to match ZPL II format
not match the ones sent in the (see page 35). Check the
ZPL II label formats.
configuration label for correct
characters. If problem
continues, check the ZPL II
format for changed ^CC, ^CT,
and ^CD instructions.
Printer does not operate in the Bank 2 DIP switches set to
Check Bank 2 DIP switch
mode specified in ZPL II or by override ZPL II and calibration. settings. See page 41.
calibration.
Printer not set up correctly.
See page 43 to recalibrate the
printer. Also, see page 41 to
check Bank 2 DIP switch
settings.
Printer does not feed media
with black marks correctly.
Sensor is broken. (No red
light is visible when looking
through the front of the printer
with the printhead open.)
Call a service technician.
In cutter mode, skewed or
stuck labels.
Cutter is dirty.
Follow cutter module cleaning
procedure on page 57.
Cutter is dirty.
Follow cutter module cleaning
procedure on page 57.
The cutter is not cutting labels
cleanly.
Cutter blades are dull.
Replace the cutter module.
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SYMPTOM
DIAGNOSIS
Cutter is dirty.
ACTION
Follow cutter module cleaning
procedure on page 57.
Labels are jamming in cutter,
or labels are being cut more
than once.
Label length is too short.
Media jammed in cutter.
Increase label length.
Remove media, clean cutter
module (see page 57).
For printers with the cutter
option installed: printing
stops. PAPER/RIBBON,
PAUSE, and CANCEL LEDs
on.
Connecting cable not
connected to cutter module.
Plug cable into cutter module.
Cutter module is dirty.
Clean cutter module (see
page 57).
End of the media is not
Reposition media so that the
positioned correctly on top of end is on top of the platen.
the platen.
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Specification
105Se
160S
Resolution (thermal transfer or 203dotsperinch
Optional 152 dots per
inch (6 dots per mm)
Optional 300 dots per 203 dots per inch
direct thermal)
(8 dots per mm)
inch (12 dots per mm)
(8 dots per mm)
Dot size
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)
Maximum print width
4.09" (104 mm)
4.09" (104 mm)
4.09" (104 mm)
6.30" (160 mm)
Standard
15"
26"
18"
9.5"
memory
(381 mm)
(660 mm)
(457 mm)
(241 mm)
Maximum print
length
With 512 KB
additional
memory
39"
(991 mm)
39"
(991 mm)
N/A
25"
(635 mm)
Bar code modulus (“X”)
dimension
5 mil to 50 mil
6.6 mil to 66 mil
3.33 mil to 33.3 mil
5 mil to 50 mil
Thin film printhead with Energy Control
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Programmable constant printing speeds of 2" (51 mm), 3" (76 mm), 4"
(102 mm), 5" (127 mm), and 6" (152 mm) per second.
The 105Se with optional 300 dots/inch resolution supports programmable
constant printing speeds of 2.4" (61 mm), 3" (76 mm), and 4" (102 mm)
per second.
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0HGLDꢀ+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.
printing; under software control.
0HGLD
Media Specifications
105Se
160S
Maximum
4.5"
114.3 mm
7.2"
2.0"
182.9 mm
Total media width
Label length
Minimum
0.75"
19.05 mm
50.8 mm
Maximum
Minimum
Refer to “Printing Considerations” on page 71.
Tear-Off
Peel-Off
Rewind
Cutter
0.63"
0.50"
0.50"
1.25"
0.015"
16.00 mm
12.8 mm
12.8 mm
31.75 mm
0.381 mm
0.63"
0.50"
0.50"
N/A
16.00 mm
12.8 mm
12.8 mm
N/A
Maximum (Printhead
position may need to be
adjusted above 0.01”)
0.015"
0.381 mm
Total thickness
(includes liner)
Minimum
0.0023"
3.0"
0.0584 mm
76.2 mm
0.0023"
3.0"
0.0584 mm
76.2 mm
Core size
Maximum roll diameter
8.0"
203.2 mm
8.0"
203.2 mm
Interlabel gap (0.115”/3 mm preferred)
0.079" - 0.157"
2 mm - 4 mm
0.079" - 0.157"
2 mm - 4 mm
Maximum internal fanfold media pack size
(L x W x H)
8.0" x 7.2" x 203.2 mm x 182.8
6.2" mm x 157.4 mm
8.0" x 7.2" x 203.2 mm x 182.8
6.2" mm x 157.4 mm
Additional Specifications for Black Mark Media (optional on 105Se)
Mark thickness (measuring
parallel to label/tag edge)
Minimum
Maximum
Minimum
Maximum
0.12"
0.43"
0.43"
3 mm
11 mm
11 mm
0.12"
0.43"
0.43"
3 mm
11 mm
11 mm
Mark width (measuring
perpendicular to label/tag edge)
Full media width.
Full media width.
Mark-to-mark registration tolerance
Mark location
+/-0.016"
+/-0.4 mm
+/-0.016"
+/-0.4 mm
Mark must be located on the inside of the media (closest to the printer’s
mainframe when loaded in the printer).
Mark density
>1.0 ODU (Optical Density Unit)
0.5 ODU maximum
Density of the back of the media on which the
black mark is printed
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5LEERQ
Ribbon Width
105Se
160S
Zebra recommends using ribbon Maximum
4.33"
0.94"
110 mm
24 mm
6.89"
2.0"
175 mm
51 mm
at least as wide as the media
Minimum
you are using to protect the
printhead from wear.
Standard 2:1 media to ribbon roll ratio
984 ft.
1476 ft.
1.0"
300 m
450 m
984 ft.
1476 ft.
1.0"
300 m
450 m
lengths
3:1 media to ribbon roll ratio
Roll size
Inner diameter of core
25.4 mm
81 mm
25.4 mm
81 mm
Outside diameter of full roll of ribbon
3.2"
3.2"
Š
=HEUDꢀ3URJUDPPLQJꢀ/DQJXDJHꢀ,,ꢀꢉ=3/ꢀ,, ꢊ
•
•
Downloadable graphics with data compression
•
•
Communicates in printable ASCII characters
Bit image data transfer and printing, including mixing of
text and graphics
Controlled by a mainframe, minicomputer, PC, or other
data entry device
•
•
•
Format inversion
•
•
•
Serialized fields
Mirror image printing
In-Spec OCR-A and OCR-B
Four-position field rotation (0°, 90°, 180°, 270°)
UPC/EAN (nominal 100% magnification [6 dots/mm and
12 dots/mm only])
•
•
Bitmap and scalable fonts
Programmable quantity with print pause
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•
•
•
•
•
•
•
Code 11, Code 49, Code 93
Code 39 (supports ratios of 2:1, 3:1, 5:2, 7:3)
Interleaved 2 of 5
•
•
•
•
•
•
•
UPC-A
PDF 417
POSTNET
CODABAR (supports ratios of 2:1, 3:1, 5:2)
Industrial 2 of 5, Standard 2 of 5
Plessey
MSI
E/EAN-8, E/EAN-13, EAN EXTENSIONS
DataMatrix
Code 128 (supports serialization in subsets B and C and
UCC Case C Codes)
MAXICODE
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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.
Note: See “Optional Printer Fonts” on page 81 for the availability of
additional fonts.
Font Matrices for 8 dots/mm Printhead (105Se and 160S)
Font
Matrix
Type
Character Size
(in dots)
Inches
Width
Millimeters
Width
Height
Width
Inter-
character
gap
Height
Char./Inch Height
Char./
Inch
A
B
9
5
1
2
2
5
3
8
6
0
U-L-D
U
0.044
0.054
0.088
0.138
0.128
0.295
0.103
0.118
0.029
0.044
0.059
0.098
0.079
0.236
0.093
0.118
33.90
22.60
16.95
10.17
12.71
4.24
1.13
1.38
2.25
3.50
3.25
7.50
2.63
3.00
0.75
1.13
1.50
2.50
2.00
6.00
2.38
3.00
1.33
0.89
0.67
0.40
0.50
0.17
0.42
0.33
11
18
28
26
60
21
24
7
C,D
E
10
15
13
40
13
24
U-L-D
OCR-B
U-L-D
U-L-D
OCR-A
SYMBOL
U-L-D
F
G
H
10.71
8.48
GS
0
Default: 15 x 12
Scalable
* U = Uppercase, L = Lowercase, D = Descenders
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Font Matrices for 6 dots/mm Printhead
Font
Matrix
Type
Character Size
(in dots)
Inches
Width
Millimeters
Width
Height
Width
Inter-
character
gap
Height
Char./Inch Height
Char./
Inch
A
B
9
5
1
2
2
3
3
8
4
0
U-L-D
U
0.059
0.072
0.118
0.138
0.171
0.394
0.112
0.157
0.039
0.059
0.079
0.085
0.105
0.315
0.098
0.157
25.40
16.93
12.70
11.72
9.53
1.50
1.83
3.00
3.50
4.33
10.00
2.83
4.00
1.00
1.50
2.00
2.17
2.67
8.00
2.50
4.00
1.00
0.67
0.50
0.46
0.38
0.13
0.40
0.25
11
18
21
26
60
17
24
7
C,D
E
10
10
13
40
11
24
U-L-D
OCR-B
U-L-D
U-L-D
OCR-A
SYMBOL
U-L-D
F
G
3.18
H
10.16
6.35
GS
0
Default: 15 x 12
Scalable
* U = Uppercase, L = Lowercase, D = Descenders
Font Matrices for 12 dots/mm Printhead
Font
Matrix
Type
Character Size
(in dots)
Inches
Width
Millimeters
Width
Height
Width
Inter-
character
gap
Height
Char./Inch Height
Char./
Inch
A
B
9
5
1
2
2
6
3
8
8
0
U-L-D
U
0.029
0.036
0.059
0.138
0.185
0.198
0.112
0.079
0.016
0.023
0.033
0.066
0.042
0.132
0.072
0.079
50.80
33.86
25.40
23.44
19.06
6.36
0.73
0.91
1.49
3.50
2.15
5.02
2.84
2.00
0.40
0.58
0.83
1.67
1.06
3.35
1.82
2.00
2.00
1.34
1.00
0.92
0.76
0.26
0.80
0.50
11
18
42
26
60
34
24
7
C,D
E
10
20
13
40
22
24
U-L-D
OCR-B
U-L-D
U-L-D
OCR-A
SYMBOL
U-L-D
F
G
H
20.32
12.70
GS
0
Default: 15 x 10
Scalable
* U = Uppercase, L = Lowercase, D = Descenders
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Physical Characteristics
105Se
160S
Height
15.4"
10.5"
391 mm
267 mm
480 mm
19.5 kg
15.4"
13.1"
391 mm
333 mm
480 mm
24.9 kg
Width
Length
18.9"
18.9"
Weight (without options)
43 lbs.
55 lbs.
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• 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. 950-M89; classified
to IEC 950; complies with FCC and Canadian DOC class “A” rules
• Carries the CE mark of compliance
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• 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).
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Operating temperature
+41°F to +104°F
–40°F to +158°F
+5°C to + 40°C
–40°C + 70°C
Storage temperature
Non-condensing relative humidity
Operating
Storage
20% to 85%
20% to 85%
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• Peel-Off capability only*
• Cutter Module
• Cutter Catch Tray
• Media Rewind with rewind and peel-off capabilities*
• Fanfold Supply Bin
• ZebraNet™
• Black Mark (Reflective) Sensor (105Se only)
• Scalable and bit-mapped smooth fonts
• Additional 512 KB memory (not available for 105Se [300 dots/inch])
* Peel-Off and Media Rewind options are mutually exclusive of the Cutter
option.
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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.
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Your printer may be factory equipped with a cutter module that cuts labels
after they have been printed. In addition, an optional cutter catch tray can
be added to gather the labels once they have been cut.
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Your printer may be equipped with a media rewind option. This option
supports both the rewind and peel-off modes of operation.
In rewind mode, both labels and backing material rewind internally onto a
user-supplied 3" core. A rewind bracket guides the media back to the
rewind spindle after printing.
This option cannot be added to a printer equipped with the optional Cutter.
(See Peel-Off Option above for peel-off mode of operation.)
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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 6.5" may be achieved with
media less than 3.5" long.
The fanfold supply bin may be installed in the field by the operator. To
install the fanfold supply bin, follow the instructions included with the
option.
Note: The fanfold supply bin, peel-off option, and rewind option are
mutually exclusive. The fanfold supply bin may not be installed
in S-Series Printers with the peel-off option or the rewind option.
Fanfold media may be used with the rewind spindle installed by
using one of the external fanfold supply access slots (at the
bottom and rear of the printer).
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ZebraNet allows you to connect your printer to your ethernet network.
This interface option is available for both 10Base-2 and 10Base-T
networks.
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Note: For the 105Se printer only.
The reflective sensor utilizes continuous media with black marks printed
on the back of the label liner. The black mark sensor determines the label
length and the top of the label by detecting the black mark (similar to the
way a transmissive sensor detects the gap or notch).
This option is in addition to the standard transmissive sensor and is
software- or switch-selectable.
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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.
Once an optional font is installed in the printer, the configuration printout
from the CANCEL Key Self Test indicates the font type.
The following optional Scalable Smooth Fonts are presently available
(each is supplied as a complete set of standard, bold, italic, and bold italic
styles):
• CG Triumvirate™
• CG Times™
• Futura™
• Univers®
• CG Palacio™
The following Bitmap Smooth Fonts (supplied in bold style only) are
presently available:
• CG Triumvirate™ Bold
• CG Times™Bold
• CG Triumvirate™ Bold Condensed • CG Palacio™ Bold
• Futura™ Bold, Univers® Bold
Note: Type sizes of 6 pt, 8 pt, 10 pt, 12 pt, 14 pt, 18 pt, 24 pt, 30 pt, and
36 pt are available.
Examples of these optional fonts can be found on pages 89-90.
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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.
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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. Extra memory may
be installed at the factory or in the field.
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Note: This option is available on the 105Se printer only.
Optional 300 dot-per-inch and 152 dot-per-inch printhead densities
satisfy specified requirements for printing UPC/EAN symbologies or
high-density graphics and small, crisp text.
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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. This is done by
the third wire in the power cord (see Figure 27).
Figure 27
• The plug cap should bear the certification mark of a known international
safety organization (see Figure 28).
Figure 28
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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
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. What follows is a simple yet
effective method for adjusting the darkness to print “in-spec” bar codes.
1. Load media according to the appropriate media loading and ribbon
loading instructions beginning on page 11. Ensure that the proper
print method has been selected.
2. With power OFF, press and hold the FEED key.
4. Print a label, then press the PAUSE key. The label contains several bar
codes as well as other printer information. Normal bar codes are
printed in a horizontal format as they feed out of the printer. Rotated
bar codes are printed in a vertical format.
5. Compare the test label printed to the bar codes in Figure 29 on
page 87. If the test label appears too dark or too light, increase or
decrease the darkness setting accordingly.
6. Resume printing by pressing the PAUSE key again. Print a few labels
at the new setting and verify that proper “in-spec” bar codes are being
printed. Repeat steps 4, 5, and 6 until satisfied.
7. To stop printing test labels, press the PAUSE key, then press the
CANCEL key.
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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. The rotated bar code spaces are small when compared to
the “in-spec” code, possibly making the code unreadable.
Slightly Light — Slightly light labels are, in some cases, preferred to
slightly dark for “in-spec” bar codes. Both normal and rotated bar codes
are “in-spec”, but small alphanumeric characters may not be complete.
Too Light — Light labels are obvious. Both normal and rotated bar codes
have incomplete bars and spaces. Small alphanumeric characters are
unreadable.
In-Spec — The “in-spec” bar code can only be confirmed by a verifier, but
it should exhibit some very visible characteristics. The normal bar code
has complete, even bars and clear, distinct spaces. The rotated bar code
also has complete bars and clear distinct spaces. Although it may not look
as good as a slightly dark bar code, it is “in-spec”. In both normal and
rotated styles, small alphanumeric characters appear complete.
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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. 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.
Once an optional font is installed in the printer, the configuration label
printed during the CANCEL Key Self Test indicates the font type as the
“Socket 2 ID”.
Optional Printer Fonts Currently Available
Scalable Smooth Fonts (each is supplied as a Bitmap Smooth Fonts (supplied only in Bold).
complete set of Normal, Bold, Italic, and Bold Type sizes: 6 pt, 8 pt, 10 pt, 12 pt, 14 pt, 18 pt,
Italic styles)
24 pt
CG Triumvirate™
—
CG Triumvirate™
CG Triumvirate™ Condensed
CG Times™
CG Times™
CG Palacio™
Futura™
CG Palacio™
Futura™
®
®
Univers
Univers
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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. Many different code
schemes exist, such as the universal product code (UPC) or Code 39.
Black mark sensing — See “Reflective media sensor” on page 93.
Calibration (of a printer) — A process in which the printer determines
some basic information needed to print accurately with a particular media/
ribbon combination. To do this, the printer feeds some media and ribbon
(if used) through the printer and senses whether to use the direct thermal or
thermal transfer print method; whether continuous or non-continuous
media is used; and, if non-continuous media, the length of individual
labels/tags.
Character set — The set of all letters, numerals, punctuation marks, and
other characters that can be expressed by a particular barcode.
Check digit — A character added to a barcode symbol that indicates to the
scanner that it has read the symbol correctly.
Continuous media — Label or tagstock that has no web (space between
labels), notch, or gap to separate each label/tag; rather, the media is one
long piece of material.
Core diameter — The inside diameter of the cardboard core at the center
of a roll of media/ribbon.
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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).
Ips “inches-per-second” — The speed at which the label or tag is printed.
Zebra offers printers that can print from 2 ips to 12 ips.
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 does not print additional
labels. Once the label has been taken, printing resumes. Also called
“take-label sensor”.
Label backing (label liner) — The material on which labels are affixed
during manufacture and is discarded or recycled by the end-users. Label
backing (or liner) has a non-stick surface which allows the label to be
easily removed by the end-user and placed in the desired location.
Mark sensing — See “Reflective media sensor” on page 93.
Media — Material onto which data is printed by the printer. Types of
media include tagstock, continuous, fanfold, roll, etc.
Media hanger — The hanger that supports media rolls and provides
consistent media feed to the printhead.
Non-volatile memory — Electronic memory that retains data even when
power is removed.
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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.
Therefore, to maximize the life of your printhead, use the lowest print
darkness setting (sometimes called “burn temperature” or “head
temperature”) and the lowest printhead/toggle pressure necessary. Also,
use ribbon that is as wide or wider than the media to protect the printhead
from the rougher media.
Reflective media sensor — A sensor that detects a black mark on the back
of media by measuring the reflectivity of the media. This mark helps the
printer determine label size and print registration.
Registration — Alignment of printing with respect to the top of a label/
tag.
Ribbon — A band of inked material that is pressed by the printhead
against the media to transfer an image onto the media, which in turn is
pressed against the platen. A ribbon consists of a base film coated with
wax or resin “ink.” Zebra ribbons also have a back coating that protects
the printhead from damage. The ribbon transfers ink onto the media when
heated by the printhead.
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.
Supplies — Supplies is a general term for ribbon and media.
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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. By selectively heating the ribbon, you can
form an image on the media. See also “Ribbon” on page 93.
Transmissive media sensor — A sensor that is located behind the
printhead; detects the presence of media and, for non-continuous media,
the position of the web, hole, or notch that separates each label.
Void — A space where printing should have occurred but, due to some
error condition, did not occur. A void can cause a bar code symbol to be
read incorrectly or not be read at all.
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Communications Interface, 77
Configuration Mode
A
Accessories, 77
Adjustments
Adjusting Label Position, 44
Adjusting Media Rest Position, 44
Adjusting Print Darkness, 44
Calibration, 43
Bar Code Darkness, 85
Black Mark Media Sensor Position, 60
Label Position, 44
Media Rest Position, 44
Media Sensitivity, 63
Print Darkness, 44
Configuration, 39
Cutter Mode, 18, 25
Cutter Module Option, 79
Printhead Pressure, 59
Ribbon Sensor Sensitivity, 63
Toggle Positioning, 59
Damage, 7
DCE Devices, 48
DTE Devices, 48
Transmissive Media Sensor Position, 60
ASCII Code Chart, 84
F
B
Fanfold Media, 18
Bar Codes
Fanfold Supply Bin Option, 80
FEED Key and CANCEL Key Self Test, 34
FEED Key and PAUSE Key Self Test, 33
FEED Key Self Test, 32
FEED Key, 26
Font Specifications, 74–76
Fonts, 81, 88–90
Front Panel Keys
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
CANCEL Key Self Test, 30
CANCEL Key, 26
Cleaning
CANCEL Key, 26
FEED Key, 26
PAUSE Key, 26
Front Panel Lights, 27
Fuse Replacement, 9
Cutter Module, 57
Exterior Surfaces, 51
Interior, 51
Label Available Sensors, 57
Printhead and Platen Roller, 52
Schedule, 51
I
Inspection, 7
L
Label Position Adjustment, 44
Lubrication, 58
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M
Maintenance, 51
Media Handling Specifications, 72
Media Loading
PAUSE Key, 26
Cutter Mode, 18
Fanfold Media, 18
Peel-Off Mode, 17
Rewind Mode, 17
Peel-Off Option, 79
Roll Media, 15
Tear-Off Mode, 17
230 VAC Operation, 10
Power-On Self Test, 28
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
Printer Operating Modes
Media Sensing, 23
Peel-Off Mode, 25
Media Transport, 24
Rewind Mode, 25
Tear-Off Mode, 24
MODE Key Self Test, 33
MODE Key, 27
Model Designation, 1
CANCEL Key, 30
FEED Key, 32
O
Option Switches
Bank 1, 40
Bank 2, 41
Options
Environmental Ranges, 77
Media Handling, 72
Media, 72
Options and Accessories, 77
Physical, 76
230 VAC Factory Setup, 82
512 KB DRAM Memory Expansion, 82
Black Mark Sensor, 80
Cutter Module, 79
External ZebraNet Interface, 80
Fanfold Supply Bin, 80
Media Rewind, 79
Peel-Off, 79
Print Speeds, 71
Printing Considerations, 71
Ribbon, 73
Printer Fonts, 81
Printhead, 82
Standard Fonts, 74–76
ZPL II, 73
Printhead DPI Option, 82
Printhead Pressure Adjustment, 59
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R
Removing Used Ribbon (105Se), 19
Removing Used Ribbon (160S), 20
Repacking, 5
Reporting Damage, 7
Reshipping, 8
Tear-Off Mode, 17, 24
Transmissive Media Sensor Position
Lower Transmissive Media Sensor, 62
Transmissive Sensing Mode, 24
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
W
DTE Devices, 48
Hardware Control Signal Descriptions, 47
Parallel Cabling Requirements, 49
Parallel Interface, 49
RS-232 Cabling Requirements, 47
Signal Descriptions, 50
Ribbon and Printhead Wear, 5
Shielded Cable, 5
S
Serial Number, 1
ZebraNet Interface Option, 80
ZPL II Label Formats, 35–37
ZPL II Specifications, 73
Signal Descriptions, 50
Site Requirements, 10
Specifications, 71–77
Storage, 8
System Components, 45
System Considerations
Communications Code, 45
Data Specifications, 46
Interfaces, 46
System Overview
Communication Capabilities, 2
Media Transport Mechanism Capabilities, 3
Print Mechanism Capabilities, 2
Thermal Transfer Printer Functions, 2
System Requirements, 3
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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:
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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. The warranty becomes void if the equipment is modified,
improperly installed or used, damaged by accident or neglect, or if any
parts are improperly installed or replaced by the user.
Printheads. Since printhead wear is part of normal operation, the original
printhead is covered by a limited warranty as indicated below. Warranty
period begins on purchase date.
Printhead
Warranty Period
6 months
Barcode label printer printheads
Card printer printheads
12 months
Warranty Statement
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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. The warranty becomes void if the printhead is physically worn
or damaged; also if it is determined that failure to follow the preventive
maintenance schedule listed in the User’s Guide has caused defect in the
thermal printhead for which a warranty claim is made.
Software. Software is warranted to be free of defects in material and
workmanship for 30 days from the date of purchase. In the event of
notification within the warranty period of defects, Zebra will replace the
defective diskette or documentation.
Batteries. Mobile printer batteries are warranted to be free of defects in
material and workmanship for 90 days from date of purchase. In the event
of notification within the warranty period, Zebra will replace the defective
battery provided there has not been damage resulting from user abuse.
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Supplies are warranted to be free from defect in material and workmanship
for a period of six (6) months for media and twelve (12) months for ribbon
from the date of shipment by Zebra. This is provided the user has complied
with storage guidelines, handling, and usage of the supplies in Zebra
printers.
Zebra’s sole obligation under these warranties is to furnish parts and labor
for the repair or possible replacement of products found to be defective in
material or workmanship during the warranty period. Zebra may in its
discretion issue a credit for any such defective products in such amount as
it deems reasonable.
2
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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. While Zebra’s desire is to be responsive to specific needs and
questions, Zebra does not assume responsibility for any specific
application to which any products are applied including, but not limited to,
compatibility with other equipment. All statements, technical information
or recommendations relating to Zebra products are based upon tests
believed to be reliable yet do not constitute a guaranty or warranty.
Zebra’s maximum liability for warranty claims is limited to the invoice
price of the product claimed defective. Zebra does not assume
responsibility for delays or replacement or repair of products. Zebra shall
not under any circumstances whatsoever be liable to any party for loss of
profits, lost data, diminution of good will, or any other special or
consequential damages whatsoever with respect to any claim made under
agreement with Zebra. Specifically for software, Zebra is not liable for
any incidental or consequential damages caused by abuse or
misapplication of the software or by its use in violation of the U.S.
copyright law or international treaty.
No salesperson, representative, or agent of Zebra is authorized to make
any guaranty, warranty, or representation that contradicts the foregoing.
Any waiver, alteration, addition or modification to the foregoing
warranties must be in writing and signed by an executive officer of Zebra
to be valid.
Warranty Statement
3
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