Zebra Technologies 160S, 105Se User Manual

0 (0)

Z E B R A V A L U E - L I N E TM

S-Series

User's Guide

For the Zebra 105Se

and 160S™ Printers

Proprietary Statement

This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Corporation.

Product Improvements

Continuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and signs are subject to change without notice.

FCC Compliance Statement

Note: This equipment has been tested and found to comply with the limits for a Class A digital Device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a comm ercial environment. This equipment generates, uses and can radiate radio fre quency energy and, if not installed and used in accordance with the instructions manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which

case the user will be re quired to correct the interference at his own expense.

In order to insure compliance, this printer must be used with a Shielded Power Cord and Shielded Communication Cables.

“The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies Corporation could void the user’s authority to operate the equipment.”

Canadian DOC Compliance Statement

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in the radio interference regulations of the Canadian Depart ment of Communications.

Liability Disclaimer

Zebra Technologies Corporation takes steps to assure that its published Engineering specifications and Manuals are correct; however, errors do occur. Zebra Technologies Corporation reserves the right to correct any such errors and disclaims liability resulting therefrom.

No Liability for Consequential Damage

In no event shall Zebra Technologies Corporation or anyone else involved in the creation, production or delivery of the accompanying product (including hardware and software) be liable for any damages whatsoever (including, without limitation, damages for loss of business profits, business interruption, loss of business information, or other pecuniary loss) arising out of the use of or the results of use of or inability to use such product, even if Zebra Technologies Corporation has been advised of the possibility of such damages. Because some states do not allow the exclusion or limitation of liability for consequential or incidental damages, the above limitation may not apply to you.

Copyrights

The copyrights in this manual and the label printer described therein are owned by Zebra Technologies Corporation. All rights are reserved. Unauthorized reproduction of this manual or the software in the label printer may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil li ability.

© Zebra Technologies Corporation. All rights reserved.

All product and brand names are trademarks of their respective companies. All rights resesrved.

Table of Contents

Introduction

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

Model Designation . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Communication Capabilities . . . . . . . . . . . . . . . . . . 1-2

Thermal Transfer Printer Internal Functions . . . . . . . . . . 1-2

Print Mechanism Capabilities . . . . . . . . . . . . . . . . . . 1-2

Media Transport Mechanism Capabilities . . . . . . . . . . .

1-2

Additional System Requirements . . . . . . . . . . . . . . . . . . 1-3

Media and Ribbon Requirements . . . . . . . . . . . . . . . . . . 1-3

Warnings and Precautions . . . . . . . . . . . . . . . . . . . . . . 1-4

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

230 VAC Operation . . . . . . . . . . . . . . . . . . . . . . . 1-4

Use of Shielded Cable. . . . . . . . . . . . . . . . . . . . . . 1-4

Ribbons and Printhead Wear . . . . . . . . . . . . . . . . . . 1-5

Repacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Printing Considerations . . . . . . . . . . . . . . . . . . . . . 1-6

Print Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Media Handling . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Zebra Programming Language II (ZPL II®) . . . . . . . . . .

1-8

Bar Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Standard Fonts . . . . . . . . . . . . . . . . . . . . . . . . .

1-9

Standard Printer Font Example . . . . . . . . . . . . . . . .

1-12

Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-12

Zebra S-Series User’s Guide

i

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Communications Interface . . . . . . . . . . . . . . . . . . . 1-13 Environmental Ranges . . . . . . . . . . . . . . . . . . . . . 1-13 Options and Accessories . . . . . . . . . . . . . . . . . . . . 1-13

Installation

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Reporting Damage. . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Storage and Reshipping . . . . . . . . . . . . . . . . . . . . . . . 2-1 Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

AC Voltage Selection Procedure . . . . . . . . . . . . . . . . 2-2 AC Power Fuse Replacement . . . . . . . . . . . . . . . . . . 2-3 115 VAC Operation . . . . . . . . . . . . . . . . . . . . . . . 2-3 230 VAC Operation . . . . . . . . . . . . . . . . . . . . . . . 2-3 Site Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Ribbon Loading (105Se) . . . . . . . . . . . . . . . . . . . . . . 2-4 Ribbon Loading (160S) . . . . . . . . . . . . . . . . . . . . . . . 2-7 Media Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Roll Media . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Tear-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Rewind Mode . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Peel-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Cutter Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Fanfold Media . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Removing Used Ribbon (105Se). . . . . . . . . . . . . . . . . . 2-12 Removing Used Ribbon (160S) . . . . . . . . . . . . . . . . . . 2-13 Initial Printer Power Up . . . . . . . . . . . . . . . . . . . . . . 2-14

ii

Zebra S-Series User’s Guide

Operation

Operating Your Zebra S-Series Printer Printer . . . . . . . . . . .

3-1

Printer Operating Modes . . . . . . . . . . . . . . . . . . . . . .

3-1

Media Sensing Modes. . . . . . . . . . . . . . . . . . . . . . 3-1

Transmissive Sensing Mode . . . . . . . . . . . . . . . . . .

3-2

Black-Mark Sensing Mode . . . . . . . . . . . . . . . . . . . 3-2

Media Transport Modes. . . . . . . . . . . . . . . . . . . . . 3-2

Tear-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Peel-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . .

3-3

Rewind Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Cutter Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4

PAUSE Key . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

FEED Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

CANCEL Key. . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

MODE Key . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Front Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Power On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Printer Self Tests . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

CANCEL Key Self Test. . . . . . . . . . . . . . . . . . . . . 3-9

PAUSE Key Self Test . . . . . . . . . . . . . . . . . . . . . 3-10

FEED Key Test . . . . . . . . . . . . . . . . . . . . . . . .

3-11

FEED Key and PAUSE Key Test . . . . . . . . . . . . . . . 3-12

MODE Key Test . . . . . . . . . . . . . . . . . . . . . . . . 3-12

PAUSE Key and CANCEL Key Test . . . . . . . . . . . . . 3-12

FEED Key and CANCEL Key Test . . . . . . . . . . . . . . 3-13

Extended Printer Diagnostics . . . . . . . . . . . . . . . . . . .

3-13

Zebra S-Series User’s Guide

iii

Sample ZPL II Label Formats . . . . . . . . . . . . . . . . . . . 3-14 Format 1: Simple Text and a Barcode . . . . . . . . . . . . . 3-15 Format 2: Saving a Label Format As a Graphic Image . . . . 3-15 Format 3: Using a Serialized Data Field. . . . . . . . . . . . 3-16

Configuration and Calibration

Option Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Bank 1 (For Serial-Interface Printers Only) . . . . . . . . . . . . . 4-2 Bank 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Adjusting the Print Darkness . . . . . . . . . . . . . . . . . . 4-6 Adjusting the Media Rest Position . . . . . . . . . . . . . . . 4-6 Adjusting the Position of the Top of the Label . . . . . . . . . 4-6

Interconnections

System Components . .

. . . . . . . . . . . . . . . . . . . . . . . 5-1

System Considerations

. . . . . . . . . . . . . . . . . . . . . . . 5-1

Communications Code

. . . . . . . . . . . . . . . . . . . . . 5-1

Interfaces . . . . .

. . . . . . . . . . . . . . . . . . . . . . . 5-1

Data Specifications . . . . . . . . . . . . . . . . . . . . . . . 5-2

RS-232 Serial Data Port . . . . . . . . . . . . . . . . . . . . . . . 5-2

Hardware Control Signal Descriptions

. . . . . . . . . . . . . 5-3

RS-232 Cabling Requirements . . . . . . . . . . . . . . . . . 5-3

Interconnect to DTE Devices . . . . . . . . . . . . . . . . . . 5-4

Interconnect to DCE Devices . . . . . . . . . . . . . . . . . . 5-4

Parallel Cabling Requirements . . . . . . . . . . . . . . . . . 5-5

Parallel Interface .

. . . . . . . . . . . . . . . . . . . . . . . 5-5

Signal Descriptions

. . . . . . . . . . . . . . . . . . . . . . . 5-6

iv

Zebra S-Series User’s Guide

Preventive Maintenance

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Exterior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Printhead and Platen Roller . . . . . . . . . . . . . . . . . . . 6-2 Media, Ribbon, and Label Available Sensors. . . . . . . . . . 6-3 Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Adjustments

Toggle Positioning . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

Printhead Pressure Adjustment . . . . . . . . . . . . . . . . . . . 7-1

Black-Mark Media Sensor Position Adjustment . . . . . . . . . .

7-2

Transmissive Media Sensor Position Adjustment. . . . . . . . . . 7-2

Upper Media Sensor . . . . . . . . . . . . . . . . . . . . . .

7-3

Lower Media Sensor . . . . . . . . . . . . . . . . . . . . . .

7-4

Media and Ribbon Sensor Sensitivity Adjustment . . . . . . . . .

7-5

Troubleshooting

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Options

Peel-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Media Rewind . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Fanfold Supply Bin . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 ZebraNet (Ethernet) Interface . . . . . . . . . . . . . . . . . . . . 9-2

Zebra S-Series User’s Guide

v

Black-Mark (Reflective) Sensor (105Se Only) . . . . . . . . . . . 9-2 Optional Printer Fonts . . . . . . . . . . . . . . . . . . . . . . . . 9-3 230 VAC Factory Setup . . . . . . . . . . . . . . . . . . . . . . . 9-3 Memory Option . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 12-Dot/mm and 6-Dot/mm Printheads (105Se Only) . . . . . . . . 9-4

Appendix A

230 VAC Power Cord. . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B

ASCII Code Chart. . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Appendix C

Adjusting Bar Code Darkness. . . . . . . . . . . . . . . . . . . . C-1

Appendix D

Optional Printer Fonts . . . . . . . . . . . . . . . . . . . . . . . D-1

Glossary

Index

vi

Zebra S-Series User’s Guide

Introduction

Scope

This user’s guide contains descriptive information and operational instructions for the Zebra 105Se and 160S thermal transfer demand printers. It contains information on how to set up and operate the printer as well as adjustment and maintenance procedures that can be performed by the operator. Information covering the use and operation of Zebra S-Series Printer options is also included.

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 will need to maintain your printer. Volume 2: Circuit Descriptions and Electrical Schematics (part # 38453L) contains the information you will need to repair the circuit boards at the component level. You may order both volumes as a set by ordering part # 31452L.

Model Designation

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.

System Overview

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.

Zebra S-Series User’s Guide

1-1

Communication Capabilities

The S-Series Printer comes with either an Electronics Industries Association (EIA) RS-232 serial data interface or a factory-installed parallel interface. In both cases, the required interface cable is not supplied with the printer.

Thermal Transfer Printer Internal Functions

Command/control data signals are received via the RS-232 port, parallel port, or DIP switches and are sent to the main logic board. 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 me-

chanics, printhead, communications, command interpretation, label formatting, media control, and mechanical drive.

Print Mechanism Capabilities

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.

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.

Media Transport Mechanism Capabilities

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 three-inch 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 one-inch cores in standard widths and lengths.

1-2

Zebra S-Series User’s Guide

Additional System Requirements

In addition to the Zebra S-Series Printer, you will need the following items to form a complete label preparation system:

Label, ticket, or tag stock

An intelligent device, such as a computer, for data entry or entry of ZPL II formats

A data communication cable to connect the controlling device to the printer (remote installations may require additional cables and communication devices, such as modems and/or protocol converters)

Thermal transfer ribbon (if using thermal transfer mode)

Media and Ribbon Requirements

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.

Zebra S-Series User’s Guide

1-3

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.

Warnings and Precautions

Installation

CAUTION: To ensure that the Zebra S-Series Printer has proper cooling, do not place any padding or cushioning material on the back of, or underneath, the unit.

230 VAC Operation

CAUTION: Refer to “Installation” for instructions on configuring your printer for 230 VAC operation before connecting to a 230 VAC power source.

Use of Shielded Cable

CAUTION: Refer to the “Interconnections” Section.

Zebra printers comply with FCC “Rules and Regulations”, Part 15, Subpart J, for Class A Equipment, using fully shielded data cables. Use of unshielded cables may increase radiated emissions above the Class A limits and is not recommended.

Zebra printers comply with international regulations governing radiated emissions when using fully shielded data cables. Use of unshielded cables may increase radiated emissions above the regulated limits.

1-4

Zebra S-Series User’s Guide

Ribbons and Printhead Wear

CAUTION: Ribbons used in the Zebra Technologies Corporation Printer MUST be as wide as or wider than the media. Zebra-brand ribbons provide an extremely smooth backing surface that protects the printhead from abrasion by the media. If the ribbon is narrower than the media, areas of the printhead will be unprotected and subject to premature wear.

Repacking

CAUTION: If shipment of your printer is necessary, carefully pack the printer in a suitable container to avoid damage during transit. Whenever possible, use the original container from the factory. If the original container is not available, an optional packing kit can be purchased from Zebra. When using a different container, a procedure similar to the original factory packaging should be followed.

Refer to “Installation” for further repacking instructions.

Zebra S-Series User’s Guide

1-5

Printer Specifications

Printing Considerations

Specification

 

105Se

 

 

160S

Resolution (thermal transfer

203 dots per inch

Optional

Optional

 

203 dots per

or direct thermal)

(8 dots per mm)

152 dots per inch

300 dots per inch

 

inch (8 dots

 

 

 

(6 dots per mm)

(12 dots per mm)

 

per mm)

Dot size

 

0.00492"

0.00656"

0.0033" x 0.0039"

 

0.00492"

 

 

(0.125 mm)

(0.167 mm)

(0.084 x 0.100 mm)

 

(0.125 mm)

Maximum print width

4.09"

4.09"

4.09"

 

6.30"

 

 

(104 mm)

(104 mm)

(104 mm)

 

(160 mm)

 

Standard

15"

26"

18"

 

9.5"

Maximum

memory

(381 mm)

(660 mm)

(457 mm)

 

(241 mm)

print length

With 512 KB

39"

39"

N/A

 

25"

 

 

 

add’l memory

(991 mm)

(991 mm)

 

 

(635 mm)

Bar code modulus

5 mil to 50 mil

6.6 mil to 66 mil

3.33 mil to 33.3 mil

5 mil to

(“X”) dimension

 

 

 

 

50 mil

Thin film printhead with Energy Control

Print Speeds

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.

Media Handling

Tear-off mode: Produced in strips.

Peel-off mode: Requires Peel-Off option or Media Rewind option. Labels are dispensed and peeled from the liner, and the liner is rewound internally.

Rewind mode: Requires Media Rewind option. A full roll of printed labels is rewound internally.

Cutter mode: Requires Cutter Module option. Media cut after printing; under software control.

1-6

Zebra S-Series User’s Guide

Media

Media Specifications

105Se

 

160S

 

 

 

 

 

 

 

 

 

 

Total media width

Maximum

4.5"

 

114.3 mm

 

7.2"

 

182.9 mm

 

 

 

 

 

 

 

 

 

 

 

 

Minimum

0.75"

 

19.05 mm

 

2.0"

 

50.8 mm

 

 

 

 

 

 

 

 

 

Maximum

 

Refer to “Printing Considerations” on page 1-6.

 

 

 

 

 

 

 

 

 

 

 

 

Label length

 

Tear-Off

0.63"

 

16.00 mm

 

0.63"

 

16.00 mm

 

 

 

 

 

 

 

 

 

Minimum

Peel-Off

0.50"

 

12.8 mm

 

0.50"

 

12.8 mm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Rewind

0.50"

 

12.8 mm

 

0.50"

 

12.8 mm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Cutter

1.25"

 

31.75 mm

 

N/A

 

N/A

 

 

 

 

 

 

 

 

 

 

Total

Maximum (Printhead po-

 

 

 

 

 

 

 

thickness

sition may need to be ad-

0.015"

 

0.381 mm

 

0.015"

 

0.381 mm

(includes

justed above 0.01")

 

 

 

 

 

 

 

liner)

 

 

 

 

 

 

 

 

 

Minimum

 

0.0023"

 

0.0584 mm

 

0.0023"

 

0.0584 mm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Core size

 

 

3.0"

 

76.2 mm

 

3.0"

 

76.2 mm

 

 

 

 

 

 

 

 

 

 

Maximum roll diameter

 

8.0"

 

203.2 mm

 

8.0"

 

203.2 mm

 

 

 

 

 

 

 

 

 

 

Interlabel gap (0.115"/3 mm preferred)

0.079" - 0.157"

2 m m - 4 mm

 

0.079"- 0.157"

 

2 mm -4 mm

 

 

 

 

 

 

 

 

 

 

Maximum internal fanfold media pack

8.0" x 7.2" x

 

203.2 mm x

 

8.0" x 7.2" x

 

203.2 mm x

size (L x W x H)

 

6.2"

 

182.8 mm x

 

6.2"

 

182.8 mm x

 

 

 

 

 

157.4 mm

 

 

 

157.4 mm

 

 

 

 

 

 

 

 

Additional Specifications for Black-Mark Media (optional on 105Se)

Mark thickness (measur-

Minimum

0.12"

 

3 mm

 

0.12"

 

3 mm

ing parallel to label/tag

 

 

 

 

 

 

 

 

Maximum

0.43"

 

11 mm

 

0.43"

 

11 mm

edge)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Mark width (measuring

Minimum

0.43"

 

11 mm

 

0.43"

 

11 mm

perpendicular to label/tag

 

 

 

 

 

 

Maximum

Full media width.

 

Full media width.

edge)

 

 

 

 

 

 

 

 

 

Mark-to-mark registration tolerance

+ /- 0.016"

 

+/- 0.4 mm

 

+/- 0.016"

+/- 0.4 mm

 

 

 

 

 

 

 

Mark location

 

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)

 

 

 

 

 

 

 

 

 

 

 

Density of the back of the media on

0.5 ODU maximum

 

 

 

 

which the black mark is printed

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Zebra S-Series User’s Guide

1-7

Ribbon

Ribbon Width

 

 

105Se

 

160S

Zebra recommends using ribbon at least as

 

 

 

 

 

 

 

Maximum

4.33"

 

110 mm

6.89"

 

175 mm

wide as the media you are using to protect

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the printhead from wear.

Minimum

0.94"

 

24 mm

2.0"

 

51 mm

 

 

 

 

 

 

 

 

 

Standard

2:1 media to ribbon roll ratio

 

984 ft

 

300 m

984 ft

 

300 m

Lengths

 

 

 

 

 

 

 

 

3:1 media to ribbon roll ratio

 

1476 ft

 

450 m

1476 ft

 

450 m

 

 

 

 

 

 

 

 

 

 

 

 

 

Roll size

Inner diameter of core

 

1.0"

 

25.4 mm

1.0"

 

25.4 mm

 

 

 

 

 

 

 

 

 

 

Outside diameter of full roll of ribbon

3.2"

 

81 mm

3.2"

 

81 mm

 

 

 

 

 

 

 

 

 

Zebra Programming Language II (ZPL II®)

nDownloadable graphics with data compression

nBit image data transfer and printing, including mixing of text and graphics

nFormat inversion

nMirror image printing

nFour-position field rotation (0°, 90°, 180°, 270°)

nBitmap and scalable fonts

nProgrammable quantity with print pause

Bar Codes

nCode 11, Code 49, Code 93

nCode 39 (Supports ratios of 2:1, 3:1, 5:2, 7:3)

nCode 128 (Supports serialization in subsets B and C and UCC Case C Codes)

nCODABAR (Supports ratios of 2:1, 3:1, and 5:2)

nIndustrial 2 of 5, Standard 2 of 5

nPlessey

nMAXICODE

nCommunicates in printable ASCII characters

nControlled by a mainframe, minicomputer, PC, or other data entry device

nSerialized fields

nIn-Spec OCR-A and OCR-B

nUPC/EAN [nominal 100% magnification (6 dots/mm and 12 dots/mm only)]

nUPC-A

nPDF 417

nPOSTNET

nMSI

nE/EAN-8, E/EAN-13, EAN EXTENSIONS

nInterleaved 2 of 5

n3 of 9

nData Matrix

1-8

Zebra S-Series User’s Guide

Standard Fonts

The scalable smooth font (CG Triumvirate™ Bold Condensed) is expandable on a dot-by-dot basis, heightand width-independent, while maintaining smooth edges. Maximum size depends on available memory.

Fonts A, B, C, D, E, F, G, and H are expandable up to 10 times, heightand width-independent; however, fonts E and H (OCR-A and OCR-B) are not considered in-spec when expanded.

IBM Code Page 850 international character sets are standard in fonts A, B, C, D, E, F, G, and through software control.

Note: See “Options” for the availability of additional fonts.

Font Matrices for 8 dots/mm Printhead (105Se and 160S)

Font

 

 

Matrix

 

 

 

 

(in dots)

 

 

Height

 

Width

 

Inter-

character

 

 

 

A

9

 

5

 

 

1

B

11

 

7

 

 

2

C, D

18

 

10

 

 

2

E

28

 

15

 

 

5

F

26

 

13

 

 

3

G

60

 

40

 

 

8

H

21

 

13

 

 

6

GS

24

 

24

 

 

0

0Default: 15 x 12

Type*

gap

U-L-D

U

U-L-D

OCR-B

U-L-D

U-L-D

OCR-A

SYMBOL

U-L-D

Character Size

 

Inches

Height

Width

0.044

0.029

0.054

0.044

0.088

0.059

0.138

0.098

0.128

0.079

0.295

0.236

0.103

0.093

0.118

0.118

Char./inch

33.90

22.60

16.95

10.17

12.71

4.24

10.71

8.48

Millimeters

Height

Width

Char./mm

1.130.75 1.33

1.381.13 0.89

2.251.50 0.67

3.502.50 0.40

3.252.00 0.50

7.506.00 0.17

2.632.38 0.42

3.00 3.00 0.33

Scalable

* U = Uppercase, L = Lowercase, D = Descenders

Zebra S-Series User’s Guide

1-9

Font Matrices for 6 dots/mm Printhead

Font

 

 

Matrix

 

 

 

 

(in dots)

 

 

Height

 

Width

 

Inter-

character

 

 

 

A

9

 

5

 

 

1

B

11

 

7

 

 

2

C, D

18

 

10

 

 

2

E

21

 

10

 

 

3

F

26

 

13

 

 

3

G

60

 

40

 

 

8

H

17

 

11

 

 

4

GS

24

 

24

 

 

0

 

 

 

 

 

 

 

0Default: 15 x 12

gap

Type*

 

Height

U-L-D

0.059

U

0.072

U-L-D

0.118

OCR-B

0.138

U-L-D

0.171

U-L-D

0.394

OCR-A

0.112

SYMBOL

0.157

U-L-D

 

Character Size

Inches

 

Millimeters

 

Width

Char./inch

Height

Width

 

Char./mm

0.039

25.40

1.50

1.00

 

1.00

0.059

16.93

1.83

1.50

 

0.67

0.079

12.70

3.00

2.00

 

0.50

0.085

11.72

3.50

2.17

 

0.46

0.105

9.53

4.33

2.67

 

0.38

0.315

3.18

10.00

8.00

 

0.13

0.098

10.16

2.83

2.50

 

0.40

0.157

6.35

4.00

4.00

 

0.25

 

 

 

 

 

 

Scalable

* U = Uppercase, L = Lowercase, D = Descenders

1-10

Zebra S-Series User’s Guide

Font Matrices for 12 dots/mm Printhead

Font

 

 

Matrix

 

 

 

 

(in dots)

 

 

Height

 

Width

 

Inter-

character

 

 

 

A

9

 

5

 

 

1

B

11

 

7

 

 

2

C, D

18

 

10

 

 

2

E

42

 

20

 

 

6

F

26

 

13

 

 

3

G

60

 

40

 

 

8

H

34

 

22

 

 

8

GS

24

 

24

 

 

0

 

 

 

 

 

 

 

0Default: 15 x 10

Type*

gap

U-L-D

U

U-L-D

OCR-B

U-L-D

U-L-D

OCR-A

SYMBOL

U-L-D

Character Size

 

Inches

 

 

Millimeters

Height

Width

Char./inch

Height

 

Width

Char./mm

0.029

0.016

50.80

0.73

 

0.40

2.00

0.036

0.023

33.86

0.91

 

0.58

1.34

0.059

0.033

25.40

1.49

 

0.83

1.00

0.138

0.066

23.44

3.50

 

1.67

0.92

0.185

0.042

19.06

2.15

 

1.06

0.76

0.198

0.132

6.36

5.02

 

3.35

0.26

0.112

0.072

20.32

2.84

 

1.82

0.80

0.079

0.079

12.70

2.00

 

2.00

0.50

 

 

Scalable

 

 

 

* U = Uppercase, L = Lowercase, D = Descenders

Zebra S-Series User’s Guide

1-11

Standard Printer Font Example

Physical

Physical Characteristics

105Se

160S

 

 

 

 

 

Height

15.4"

391 mm

15.4"

391 mm

 

 

 

 

 

Width

10.5"

267 mm

13.1"

333 mm

 

 

 

 

 

Length

18.9"

480 mm

18.9"

480 mm

 

 

 

 

 

Weight (without options)

43 lbs.

19.5 kg

55 lbs.

24.9 kg

 

 

 

 

 

Electrical

115 VAC +15%/-20% or 230 VAC +15%/-15%; 48-62 Hz

5 Amps @ 115V, 3 Amps @ 230V

UL 1950 Listed-Certified to CAN/CSA-C22.2 No. 950M89; classified to IEC 950; complies with FCC and Canadian DOC class “A” rules

Carries the CE mark of compliance.

1-12

Zebra S-Series User’s Guide

Communications Interface

RS-232 at 110 to 19,200 baud (select from standard rates). Baud rate, data bits, parity, error detection protocol, and XON-XOFF or DTR/DSR handshaking are all switch-selectable. Stop bits are fixed at 1

Compatibility Mode Parallel Interface. Maximum cable length: 10 ft. (304.8 cm)

Environmental Ranges

Operating temperature

 

+41°F to +104°F

+5°C to +40°C

Storage temperature

 

-40°F to +158°F

−40°C to +70°C

Non-condensing relative

Operating

20% to 85%

 

humidity

Storage

20% to 85%

 

 

 

Options and Accessories

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.

Zebra S-Series User’s Guide

1-13

Installation

Unpacking

When unpacking the Zebra S-Series Printer, make sure you save all packing materials. Once the printer is out of the box, raise the printer’s Media Access Door and remove the power cord.

Inspection

Inspect the printer for possible damage incurred during shipment.

Check all exterior surfaces for damage.

Raise the Media Access Door and inspect compartment for damage to components.

Reporting Damage

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 will generally result in ensuring any damage claim validity and ultimate monetary compensation.

Storage and Reshipping

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:

Zebra S-Series User’s Guide

2-1

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.

CAUTION: Do not package the printer in a rigid container without utilizing shock mounts or shock-absorbing packing material. A rigid container will allow shock on the outside to be transmitted undamped to the unit, which may cause damage.

Power Connection

AC Voltage Selection Procedure

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 2.1 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. See Figure 2.1.

Figure 2.1 AC Power Area

2-2

Zebra S-Series User’s Guide

AC Power Fuse Replacement

A user-replaceable AC Power Fuse is located just above the Power ON/OFF Switch (see Figure 2.1). For a 115 VAC installation, the replacement fuse is a 3AG Fast Blow style rated at 5 Amp/250VAC. For a 230 VAC installation, the fuse is the same style but rated at 3 Amp/250 VAC. Make sure the fuse you use is correct for the voltage source.

Before replacing the fuse, turn the AC Power Switch OFF and unplug the AC Power Cable.

To replace the fuse, insert the tip of a flatblade screwdriver into the slot in the end of the Fuse Holder End Cap. Press in slightly on the End Cap and turn the screwdriver slightly counterclockwise. This will disengage the End Cap from the Fuse Holder and allow you to remove the fuse. To install a new fuse, reverse the procedure.

115 VAC Operation

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.

230 VAC Operation

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 “Appendix A” for more information.

Zebra S-Series User’s Guide

2-3

Site Requirements

CAUTION: To ensure that the S-Series Printer has proper ventilation and cooling, do not place any padding or cushioning material on the back of or underneath the unit because this will restrict the air flow.

The S-Series Printer may be installed on any solid, level surface of sufficient size and strength to accommodate the unit. The area in which the printer will operate must meet the environmental conditions specified.

Since the Zebra S-Series Printer was designed and is fabricated as an industrial-type unit, it will function satisfactorily in areas such as a warehouse or factory floor that conform to the specified environmental and electrical conditions.

Ribbon Loading (105Se)

Refer to Figure 2.4 throughout this procedure.

Note: When placing the ribbon roll on the Ribbon Supply Spindle, make sure that the core is pushed up against the stop on the ribbon supply spindle and that the ribbon is aligned squarely with its core. If this is not done, the ribbon may not cover the inside edge of the printhead, exposing print elements to potentially damaging contact with the media.

Note: Do not load ribbon if the printer is to be used in the Direct Thermal Mode.

CAUTION: Do not use ribbon that is narrower than the media. If the printhead is not protected by the smooth backing of the ribbon, excessive abrasion may cause premature printhead failure.

1. Align the segments of the Ribbon Supply Spindle. See Figure 2.2.

Figure 2.2 Spindle Alignment

2-4

Zebra S-Series User’s Guide

2.Place the Ribbon Roll on the Ribbon Supply Spindle.

3.Open the printhead by moving the handle to the OPEN position.

4.Important.....To make ribbon loading and unloading easier, make a leader for your ribbon roll if it doesn’t already have one (refer to Figure 2.3):

Tear off a strip of media (labels and backing) about 6 to 12 inches long from the roll. Peel off a label from this strip. Remove the remaining labels. 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 the illustration. 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.

Figure 2.3 Making a Leader

Zebra S-Series User’s Guide

2-5

Zebra Technologies 160S, 105Se User Manual

Figure 2.4 Ribbon Loading Diagram

2-6

Zebra S-Series User’s Guide

Ribbon Loading (160S)

Refer to Figure 2.4 throughout this procedure.

Note: When placing the ribbon roll on the Ribbon Supply Spindle, make sure that the core is pushed up against the stop on the ribbon supply spindle and that the ribbon is aligned squarely with its core. If this is not done, the ribbon may not cover the inside edge of the printhead, exposing print elements to potentially damaging contact with the media.

Note: Do not load ribbon if the printer is to be used in the Direct Thermal Mode.

CAUTION: Do not use ribbon that is narrower than the media. If the printhead is not protected by the smooth backing of the ribbon, excessive abrasion may cause premature printhead failure.

1.Align the segments of the Ribbon Supply Spindle. See Figure 2.2.

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 2.3):

Tear off a strip of media (labels and backing) about 6 to 12 inches long from the roll. Peel off a label from this strip. Remove the remaining labels. 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 the illustration. 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.

Zebra S-Series User’s Guide

2-7

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