Zebra 105S, 105SE, 160S Maintenance Manual
Zebra S-Series
Maintenance Manual
Volume 1: General Maintenance
Zebra Technologies Corporation
333 Corporate Woods Parkway
Vernon Hills, IL, US A 60061-3109
Telephone: +1 (847) 634-6700
Fax: +1 (847) 913-8766
38452L Rev. 3 Copyright 1995 Zebra Technologies Corporation. All rights reserved.
Zebra Technologies Europe Limited
Zebra House
The Valley Cen tre, Gordan R oad
High Wycombe, Buckinghamshire
HP13 6EQ, UK
Telephone: +44 (0) 1494 472872
Fax: +44 (0) 1494 450103
R
Zebra S-Series Printer
Maintenance Manual
(Volume 1, Rev. 3)
Registration Form
ZEBRA TECHNOLOGIES CORPORATION
To receive Maintenance Manual revisions and updates,
complete this form and fax or mail it to Zebra Technologies
at the fax number or address shown below.
Company __________________________________________
Address ____________________________________________
City________________________________________________
State, Zip ___________________________________________
Phone # (_______) __________________________________
Contact: ___________________________________________
Zebra Technologies Corporation
333 Corporate Woods Parkway
Vernon Hills, Illinois, USA 60061-3109
ATTN: Technical Training
FAX Number: +1 (847) 913-8766
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ii 38452L Rev. 3
TABLEOFCONTENTS
ComplianceandCopyrightStatements ..........i
THEZEBRAS-SERIESSYSTEM
Printer Specifications.....................1-1
MediaHandling......................1-1
PrintingConsiderations..................1-2
MediaConsiderations...................1-2
RibbonConsiderations..................1-3
Zebra Programming LanguageII(ZPLII
BarCodes.........................1-3
Standard Printer Fonts...................1-4
Physical Size.......................1-5
ElectricalRequirements..................1-6
CableRequirements....................1-6
115 VAC Applications..................1-6
230VAC Applications..................1-6
Environmental OperatingRange.............1-6
Communication Specifications................1-7
SerialDataCommunications Overview..........1-7
ParallelDataCommunicationsOverview.........1-9
®
).......1-3
GETTINGREADYTOPRINT
Controls andIndicators....................2-2
FrontPanelControls...................2-2
FrontPanelLEDs.....................2-3
MediaLoading........................2-4
RibbonLoading........................2-6
MediaCalibration.......................2-7
AdjustingthePrint Darkness.................2-7
AdjustingtheTear-Off Position................2-8
AdjustingthePosition of theTopof theLabel........2-9
AdjustingtheMediaSensor Positions............2-9
Upper MediaSensor....................2-9
Lower MediaSensor..................2-11
OptionSwitches.......................2-12
Bank 1..........................2-13
Bank 2..........................2-14
38452L Rev.3 iii
PRINTERDIAGNOSTICS
Power ON SelfTest......................3-1
Printer SelfTests.......................3-1
CANCELKeySelf Test..................3-3
PAUSEKeySelfTest...................3-4
FEED KeySelf Test....................3-5
MODE KeySelfTest...................3-6
FEED, PAUSEand CANCEL Keys...........3-6
PAUSEKeyand CANCEL Key.............3-7
FEED Keyand CANCELKey..............3-7
FEED Keyand PAUSEKey...............3-7
ExtendedPrinterDiagnostics.................3-9
PAUSEKeyLoopbackTest................3-9
FEED KeyLoopbackTest...............3-10
PREVENTIVEMAINTENANCE
Field MaintenanceFunctions.................4-1
Tools Required........................4-1
CleaningtheS-Seriesprinter.................4-1
CleaningthePrinthead....................4-2
CleaningtheSnapPlate....................4-2
CleaningtheCutterModule..................4-4
Lubricating theCutterModule................4-4
RecommendedPreventiveMaintenanceSchedule......4-5
CORRECTIVEMAINTENANCE
Tools Required........................5-2
TestEquipment Required...................5-2
105SPrintheadReplacement.................5-3
160SPrintheadReplacement.................5-5
Printhead Adjustments....................5-7
PrintQualityAdjustments.................5-7
Printhead Parallelism Adjustment.............5-8
Wear PlatePositionAdjustment..............5-9
Printhead Position Adjustment.............5-10
Printhead PressureAdjustment.............5-11
StripPlateAdjustment.................5-12
Printhead VoltageAdjustment................5-12
AdjustmentProcedure..................5-13
MediaSensor Position Adjustment.............5-15
ReflectiveSensorAdjustment................5-17
MediaSensor andRibbonSensorSensitivityAdjustment.5-17
TakeLabelSensor Alignment................5-19
iv 38452L Rev.3
MediaTrackingAdjustments................5-20
Rewind Mode......................5-20
Peel-Off Mode......................5-21
SpindleAdjustment and Maintenance...........5-22
TensionMeasurement Procedure............5-22
SpindleTensionAdjustment..............5-22
Removing theAdapterBoard................5-24
InstallingtheAdapterBoard................5-24
Removing theMain LogicandPower SupplyBoards...5-24
InstallingtheMainLogic and PowerSupplyBoards....5-28
EPROMSoftwareInstallation................5-29
MainDriveBelt— Removal, Replacement& Adjustment.5-31
Rewind DriveBelt—Removal,Replacement & Adjustment5-32
AC Power FuseReplacement................5-33
BatteryReplacement....................5-34
CutterAdjustmentsand Replacement Instructiions.....5-34
InternalAccess.....................5-35
CutterMotor Removal andInstallation.........5-35
CutterMechanicalAssemblyRemoval and Installation 5-37
Drive Link AssemblyInstallation............5-38
CutterCircuitBoardRemoval and Installation.....5-38
OpticalSensorRemoval andInstallation........5-39
Lower Drive Arm MechanicalAlignment.......5-39
Upper DriveArmAlignment..............5-40
TROUBLESHOOTING
Troubleshooting........................6-1
Power-ON Troubleshooting................6-1
GeneralTroubleshooting.................6-2
CutterModule Troubleshooting..............6-4
SampleLabels.........................6-5
FactoryAssistance.....................6-11
Returning Equipment....................6-11
105Sand160SMECHANICALDRAWINGSandPARTSLISTS
MechanicalPartsand Assemblies...............7-1
105SeMECHANICALDRAWINGSandPARTSLISTS
MechanicalPartsand Assemblies...............8-1
38452L Rev.3 v
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vi 38452L Rev. 3
1 TheZebraS-SeriesSystem
Inthissection... Page
PrinterSpecifications.....................................................................1-1
MediaHandling.........................................................................1-1
PrintingConsiderations............................................................1-2
MediaConsiderations...............................................................1-2
RibbonConsiderations.............................................................1-3
ZebraProgrammingLanguageII(ZPLII
BarCodes...................................................................................1-3
StandardPrinterFonts..............................................................1-4
PhysicalSize..............................................................................1-5
ElectricalRequirements...........................................................1-6
CableRequirements..................................................................1-6
115VACApplications..............................................................1-6
230VACApplications..............................................................1-6
EnvironmentalOperatingRange............................................1-6
CommunicationSpecifications.....................................................1-7
SerialDataCommunicationsOverview.................................1-7
ParallelDataCommunicationsOverview.............................1-9
®
).........................1-3
PrinterSpecifications
Media Handling
• Tear-Offmode:Labelsareproducedinstrips.
• Rewindmode: RequiresMediaRewindoption.Labelsarer ewound
• Peel-Offmode: RequiresPeel-OffoptionorMediaRewindoption.
• Cuttermode RequiresCutterModuleoption(105Seonly).Mediaiscut
internallyontoa3"-inner-diametercardboardcore.
Labelsaredispensedandpeeledfromtheliner.The
linercanberewounddirectlyontothespindleusing
the“J”Hookorontoa3"-inner-diametercar dboardcore.
afterprinting;undersoftwarecontrol.
38452L Rev.3 Page1-1
S
-Series Maintenance Manual: Volume 1 TheS-Series System
Ribbon Considerations
Ribbon Specifications 105S/105
Ribbon width
To protect the printhead fromwear, Zebra recommends using
ribbon at least as wide as the media you are using.
Standard
lengths
Roll size Inner diameter of core 1.0" 25.4 mm 1.0" 25.4 mm
2:1 media to ribbon roll ratio 984 ft 300 m 984 ft 300 m
3:1 media to ribbon roll ratio 1476 ft 450 m 1476 ft 450 m
Outside diameter of full ribbon roll 3.2" 81.2 mm 3.2" 81.2 mm
Maximum 4.5" 114 mm 6.89" 175 mm
Minimum 0.75" 19 mm 2.0" 50.8 mm
Se
160
S
Zebra Programming Language II (ZPL II®)
• Downloadable graphic s
(with data compression)
• Bit image data transfer and printing,
including mixing of text and graphics
• Format inversion
• Mirror image printing
• Four-position field rotation
(0, 90, 180, 270 degrees)
• Slew command
• Programmable quantity with print pause
• Communicates in p rintable ASCII
characters
• Controlled via m ainframe, mini, PC,
Zebra-Mate or other data-entry device
• Serialized fields
• In-spec OCR-A and OCR-B
• UPC/EAN at nominal 100% magnification
(6 dot/mm and 12 dot/mm printheads only)
Bar Codes
The following bar codes are available:
• Code 11, Code 49, Code 93
• Code 39 (Supports ratios of 2:1, 3:1, 5:2,
and 7:3)
• Code 128 (Supports serialization in subsets B
and C and UCC Case C C o d es )
• CODABAR (Supports ratios of 2:1, 3:1 and
5:2)
• Interleaved 2 of 5 (Supports ratios of 2:1,
3:1 and 5:2; also supports Modulus 10
Check Digit)
• Industrial 2 of 5, Standard 2 of 5
• Plessey
• MSI
• CODABLOCK and MAXICODE
• E/EAN-8, E/EAN-13, EAN EXTENSIONS
• UPC-A, UPC-E, UPC EXTENSIONS
• PDF 417 and POSTNET
• Data Matrix
38452L Rev. 3 Page 1-3
TheS-Series System
Standard Printer Fonts
Fonts A, B, C, D, E, F, G, H, and GS 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.
The scal able smooth font Ø (CG Triumvirate™ Bold Condensed) is expandable
on a dot-by-dot basis, height- and-width independent, while maintaining smooth
edges. Maximum character size depends on the available memory.
IBM Code Page 850 international character sets are available in fonts A, B, C,
D, E, F, G, and Ø through software control.
S
-Series Maintenance Manual: Volume 1
Figure 1.1 Sample of Default Fonts
Font Matrices for 6 dots/mm Printhead (105S/105Seonly)
Font Matrix Type* Character Size
Inches Millimeters
gap
Height
A 9 5 1 U-L-D 0.059 0.039 25.40 1.50 1.00 1.00
B 11 7 2 U 0.072 0.059 16.93 1.83 1.50 0.67
C, D 18 10 2 U-L-D 0.118 0.079 12.70 3.00 2.00 0.50
E 21 10 3 OCR-B 0.138 0.085 11.72 3.50 2.17 0.46
F 26 13 3 U-L-D 0.171 0.105 9.53 4.33 2.67 0.38
G 60 40 8 U-L-D 0.394 0.315 3.18 10.00 8.00 0.13
H 17 11 4 OCR-A 0.112 0.098 10.16 2.83 2.50 0.40
GS 24 24 0 SYMBOL 0.157 0.157 6.35 4.00 4.00 0.25
Ø Default: 15 x 12 U-L-D Scalable
* U = Uppercase, L = Lowercase, D = Descenders
Page 1-4 38452L Rev. 3
Width
Inter-
character
Height
Width
Char./inch
Height
Width
Char./mm
S
-Series Maintenance Manual: Volume 1 TheS-Series System
Font Matrices for 8 dots/mm Printhead (105S, 105Seand 160S)
Font Matrix Type* Character Size
Inches Millimeters
gap
Height
A 9 5 1 U-L-D 0.044 0.029 33.90 1.13 0.75 1.33
B 11 7 2 U 0.054 0.044 22.60 1.38 1.13 0.89
C, D 18 10 2 U-L-D 0.088 0.059 16.95 2.25 1.50 0.67
E 28 15 5 OCR-B 0.138 0.098 10.17 3.50 2.50 0.40
F 26 13 3 U-L-D 0.128 0.079 12.71 3.25 2.00 0.50
G 60 40 8 U-L-D 0.295 0.236 4.24 7.50 6.00 0.17
H 21 13 6 OCR-A 0.103 0.093 10.71 2.63 2.38 0.42
GS 24 24 0 SYMBOL 0.118 0.118 8.48 3.00 3.00 0.33
Ø Default: 15 x 12 U-L-D Scalable
* U = Uppercase, L = Lowercase, D = Descenders
Width
Inter-
character
Height
Width
Char./inch
Height
Width
Char./mm
Font Matrices for 12 dots/mm Printhead (105S/105Se)
Font Matrix Type* Character Size
Inches Millimeters
gap
Height
A 9 5 1 U-L-D 0.029 0.016 50.80 0.73 0.40 2.00
B 11 7 2 U 0.036 0.023 33.86 0.91 0.58 1.34
C, D 18 10 2 U-L-D 0.059 0.033 25.40 1.49 0.83 1.00
E 42 20 6 OCR-B 0.138 0.066 23.44 3.50 1.67 0.92
F 26 13 3 U-L-D 0.185 0.042 19.06 2.15 1.06 0.76
G 60 40 8 U-L-D 0.198 0.132 6.36 5.02 3.35 0.26
H 34 22 8 OCR-A 0.112 0.072 20.32 2.84 1.82 0.80
GS 24 24 0 SYMBOL 0.079 0.079 12.70 2.00 2.00 0.50
Ø Default: 15 x 12 U-L-D Scalable
* U = Uppercase, L = Lowercase, D = Descenders
Width
Inter-
character
Height
Width
Char./ inch
Height
Physical Size
Physical
Characteristics 105
S
/105
Se
160S
Width
Char./mm
Height 15.4" 391 mm 15.4" 391 mm
Width 10.5" 267 mm 13.1" 333 mm
Depth 18.9" 480 mm 18.9" 480 mm
Weight (without options) 43 lbs. 19.5 kg 55 lbs. 24.9 kg
38452L Rev. 3 Page 1-5
TheS-Series System
Electrical Requirements
• 115VAC+15%/−20%or230VAC+15%/−15%,48-62Hz
• 5Amps@115V,3Amps@230V
• UL1950Listed-Certifiedt oCAN/CSA- C22.2No.950-M89
• ClassifiedtoIEC950andComplieswithFCCandCanadianDOCclass“A”rules
• CarriestheCEmarkofcompliance
Cable Requirements
TheACPowerCordhasathree-prongfemaleconnectorononeend.This
connectormustbepluggedintothematingcon nectorattherearoftheS-Seri es
printer.
115 VAC Applications
AStandardUS-style,three-pronggroundedmaleplugisattachedtotheother
endoftheACPowerCord.Thisconnectormustbepluggedintoanearby
electricaloutlet.
S
-Series Maintenance Manual: Volume 1
230 VAC Applications
AnACPowerCordmayormaynotbeincludedwiththeprinter.Forthose
locationsthatcannotuseeitherofthethreepowercordslistedbelow,aproper
groundedACPowerCordmustbeobtainedandinstalledbytheuser(SeeFigure
1.2).Thecablemustthenbepluggedintoanearbyelectricaloutlet.
Part Number ACPowerCableDescription
44618 Detachable Power Cord(US Standard 3-prongplug -115VAC)
44629 Detachable Power Cord(ContinentalEurope3-prongplug-230VAC)
44637 Detachable Power Cord(British 3-prongplug- 230VAC)
Figure1.2ACPowerCable
Environmental Ranges
Operating +41°Fto +104°F(+5°C to +40°C)
Temperature
Non-condensing
relativehumidity
Page1-6 38452L Rev.3
Storage -40°Fto +158°F(-40°Cto +70°C)
Operating 20%to 85%
Storage 20%to 85%
S
-Series Maintenance Manual: Volume 1 TheS-Series System
Communication Specifications
Both serial and parallel dat a communication interfaces are available for the
S-Series printers. The S-Series printer sends and receives standard ASCII
(American Standard Code for Information Interchange) data characters.
With ZPL II
communications. Refer to the user’s gui de for further information.
Serial Data Communications Overview
The S-S eries printers have a D ata Terminal Equipment (DTE) port that supports
RS-232 serial data communications. The RS-232 interf ace has a standard 25-pin
DB25-S connector located at the rear of the printer. For all RS-232 input and
output signals, the S-Series printer follows the EIA RS-232 and CCITT V.24
specifications for signal levels.
The baud rate, number of data bits, and parity are user-selectable via DIP
switches at the rear of the printer. Parity only applies to data transmitted by the
printer. The parity associated with received data is ignored. Further information
on the settings of these switches is contained in the printer’s user ’s guide.
®
, the Error Det ection Protocol feature provides virtually error-free
Figure 1.3 RS-232 Signal/ASCII Code Data Conditions
Serial Data Signal Levels
Serial data signals are defined as either MARK or SPACE, while control signals
are either ON or OFF. The output levels for the S-S eries printers are as follow s:
MARK or OFF = - 7 to - 10 Volts
SPACE or ON = +7 to +10 Volts
Serial Interface Connector Pinout and Description
A D B25-S connector is located at the rear of the Zebra S-Series printer and
provides serial data communications to a host using RS-232 signaling.
The pinout s and signal descriptions for the DTE port are as follows:
38452L Rev. 3 Page 1-7
TheS-Series System
Pin No. Serial Data Port Signal Description
1 Frame Ground
2 Transmit Data: TXD is the serial data output of the Zebra S-Series printer.
It is on this lead that printer status information is transmitted
to the host.
3 Receive Data: RXD is the serial data input to the Zebra S-Series printer from
the host.
4 Request ToSend: RTS is an output from the Zebra S-Series printer.
It is a constantly active output to the host computer.
6 Data Set Ready: DSR is an input to the Zebra S-Series printer from the host.
7 Signal Ground: Tied to logic ground. This lead serves as the voltage
reference between the two communicating devices.
9 Reserved: For Future Use.
20 Data Terminal Ready: DTR is an output from the Zebra S-Series printer
and is the control line between the printer and the host. When the DTR
control line from the printer is in the ON condition, the host is allowed to
send data to the printer. When DTR is in the OFF condition, the host is not
allowed to send data. This condition occurs when the printer is configured
for DTR/DSR data flow control and the communication buffer is within
512 characters of its capacity.
5, 8, 10-19,
21-25
Unterminated: These leads are not used.
S
-Series Maintenance Manual: Volume 1
COMM PORT
MAX232
11
12
9
10
14
13
8
+5 V
7
4
F
1 Amp
Figure 1.4 Serial DTE Port Interface
RS-232
J7
1
2
3
4
6
7
9
20
Frame Ground
RS-23 2
RS-23 2
Request To Send
Data Set Ready
Signal Ground
Reserved for
Future Use
Data Terminal
Ready
Transmit
Receive
Page 1-8 38452L Rev. 3
S
-SeriesMaintenanceManual:Volume1 TheS-Series System
Parallel Data Communications Overview
TheS-Seriesprintermayhaveaparalleldatacommunicationsportinsteadofthe
previouslymentionedserialdataport.TheParallelInterfacehasastandard
36-pinconnectorlocatedattherearoftheprinter.Inthisdatacommunica tion
method,thebitsofdatawhichmakeupeachcharacteraresentallatonetime
overseveralwiresinthecable,onebitperwire.
ParallelDataSignalLevels
ParalleldatasignalsaredefinedaseitherHIGHorLOW,whileControlSignals
areeitherActiveorInactive.ThedistinctionisduetothefactthatsomeControl
SignalsareactiveHIGHwhileothersareactiveLOW.Thevoltagelevelswhich
representtheseconditionsare:
DataSignal Voltage Level
HIGH +5VDC
LOW 00 VDC
ParallelInterfaceConnectorPinoutandDescription
Thefollowingchartprovidesadesc riptionofeachofthepinsintheparallel
connector.Astandardparalleldatacablewillprovidetherequired
interconnectionbetweenthehostandtheS-Seriesprinter.
Pin No. ParallelDataPort Signal Description
1 The
STROBEprinter input has internal3.3kÙpull-upresistorsto 5V (IOL=1.5mA) and is
designed to receive a signaldriven opencollector V
<=0.8V.This pin is a signalfromthe
OL
host computer.Its LOW goingedge willlatch the dataat theeight DATA inputs.Datais
non-transparentlylatched soas to avoid hold time requirementsonthe DATA signals. The
STROBEinput isdebounced torequirean activewidthgreaterthan 0.5µsecbefore datais
latched.
Ù
2-9 DATAinputshave TTL input characteristicswith internal3.3k
pullups andrepresent
1TTLunit load orless.The DATAinputs arepositivelogicwith a HIGHvoltagelevel
corresponding toa logic1.Pin 2throughPin 9= D0throughD7respectively.
10 The
ACKoutput is a 12microsecondactiveLOWpulse indicating thatthe printer is readyto
accept data. The active LOW state precedesBUSY by7 microseconds.
Ù
collector with a 3.3k
internalpull-up.The output sinks 7 mA to a VOL<=0.4V.
ACKis driven open
11 The BUSY output is active HIGHwheneverthe printercannotaccept datadueto any
normalorabnormal condition,includingBufferOverflow,Head Open,Over Temperature,
and Media Error conditions.BUSYis driven opencollector with a 3.3k
The output sinks 7mAto a V
OL
<=0.4V.
Ù
internalpull-up.
12 ThePAPEROUTsignalisactiveHIGHwhenevertheprinterisoutofmediaorribbon.
13 The SELECT signal function is determined byanadditional configuration option which
becomes active when the portispresent. Inthe default condition,SELECT is active HIGH
whenever theparallel portis powered upand the parallelportis enabled.Inthe non-default
condition, SELECT willgoactive LOW whenever the printeris printing.
18 +5VDC Supplyprovidesan output of +5VDCat a maximum currentrating of 50mA.
(InternalFuse Protected)
32 The
ERROROutput (Pin 15)is active LOW whenever anyerrorconditionis present.
ERRORis driven opencollector witha 3.0kÙinternalpull-up. The output sinks 7mAto a
<=0.4V.
V
OL
Ù
35 +5VDC Pull-Up provides an output of +5VDC throughan internal 3.0k
16,17,19-
SIGNALGROUNDSaretheLogicGroundsandReturnsforallInputandOutpu tsignals.
resistor.
30,33
14,15,31,
NOT USED-Theseleadsshouldbe left unconnected.
34,36
38452L Rev.3 Page1-9
TheS-Series System
S
-Series Maintenance Manual: Volume 1
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Page 1-10 38452L Rev. 3
2 GettingReadytoPrint
Inthissection... Page
ControlsandIndicators..................................................................2-2
FrontPanelControls.................................................................2-2
FrontPanelLEDs......................................................................2-3
MediaLoading.................................................................................2-4
RibbonLoading...............................................................................2-6
MediaCalibration...........................................................................2-7
AdjustingthePrintDarkness........................................................2-7
AdjustingtheTear-OffPosition....................................................2-8
AdjustingthePositionoftheTopoftheLabel..........................2-9
AdjustingtheMediaSensorPositions.........................................2-9
UpperMediaSensor.................................................................2-9
LowerMediaSensor.................................................................2-11
OptionSwitches..............................................................................2-12
Bank1.........................................................................................2-13
Bank2.........................................................................................2-14
ThissectionofthemanualisintendedtosupplementtheUser’sGuideby
providingadditionalinformationtoaidtheservicetechnicianin
troubleshootingandmaintainingtheprinter.
38452L Rev.3 Page2-1
Getting Ready to Print
Controls and Indicators
All of the printer controls and indicators are located on the front of the unit except for the
Power ON/OFF Switch,whichis located at the rear of the printer.
Front Panel Controls
AC Power ON/OFF Switch
Controls appli cation of AC Power t o
the printer. When powered ON, the
printer will perform a Power ON Self
Test as it begins operation. Turning the
printer ON while holding down certain
front panel keys will cause additional
printer self tests to occur once the
Power ON Self Test is complete. The
AC Power Switch should be turned
OFF prior to connecting or
disconnecting any cables.
PAUSE Key
The PAUSE Ke y stops and restarts the
printing process. If the printer is idle
(not printing) when the PAUSE Key is
pressed, no printing can take place. If
the PAUSE Key is pressed while
printing is in progress, the printing
stops onc e the current label is
completed.
S
-Series Maintenance Manual: Volume 1
FEED Key
CANCEL Key
Pressing the PAUSE Key a second time
resumes the printing process.
The FEED Key forces the printer to
feed one blank label. If the printer is
idle (not pri nting) or if the PAUSE
function is active when the FEED Key
is pressed, one blank label feeds from
the pri nter immediately. If the printer
is printing, one blank label feeds out
after completion of the current batch of
labels. After one blank label is fed out,
pressing the FEED Key again will
provide a second blank label.
The CANCEL Key is only recognized
when the PAUSE function is active.
Press the CANCEL Key and the current
label format will be canceled. If no
format is printing, the next one to be
printed will be cancel ed. If there are no
formats in the printer, the CANCEL
Key is ignored. If the CANCEL Key is
pressed f or an extended period of time
(3 seconds), the printer will perform a
“Cancel All Formats” operation.
Figure 2.1 Front Panel Controls
Page 2-2 38452L Rev. 3
S
-SeriesMaintenanceManual:Volume1 GettingReadytoPrint
MODEKey
TheMODEKeycausestheprintertoentertheConfigurationMode.Inthis
Mode,thePrintDarkness,MediaTear-OffPosition,andLabelTopPosition
settingscanbeadjusted.
TheMediaCalibrationprocedureisalsoactivatedbytheMODEkey.
Refertotheuser’sguidefordetailsontheConfigurationModeandtheMedia
Calibrationprocedures.
Front Panel LEDs
RefertoFigure2.1forthelocationoftheLEDs.
NOTE:IfanoperatingconditionwhichcausesanLEDtobeONconstantlyand
onewhichcausesthesameLEDtoflashoccuratthesametime,theLEDwill
flash.
LED Name Status Indication
POWER ON Printer isON.The AC Power ON/OFF Switch isintheONposition
and the powercord is connected.
PRINTHEAD OFF Normaloperation.
ON PrintheadOverTemperature condition.Printing stops untilthe
printheadcools down.Printingresumes automatically.
PrintheadUnderTemperature condition.Printingcontinues.
Flashing PrintheadOpen.
PAPER/
RIBBON
PAUSE OFF Normaloperation.
DATA OFF Idle, nodatabeing received.
DARKEN ON
POSITION ON
CALIBRATE ON
OFF Mediaandribbon (if used) are properlyloaded.
ON Paper out.
Flashing 1.InThermal TransferMode: Ribbon is out.
2.InDirectThermalMode: Ribbon is in the printer.
ON Printer has stopped allprintingoperations.
ON Labelsareprinting.
Single
flash
Flashing Receiving datafromhost computer.
Slow
flashing
TheCANCELkeywas pressed and a format was successfully
deleted fromthe print queue.
Printer senta “stoptransmitting data”(X-OFF)commandtothehost
computer.
Printer isintheConfiguration Mode.See theModeKeyoperation
for moreinformation.
38452L Rev.3 Page2-3
GettingReadytoPrint
MediaLoading
S
-Series Maintenance Manual: Volume 1
TEAR-OFF
Figure2.2 RollMedia Loading
PEEL-OFF
105Se
TEAR-OFF PEEL-OFF
REWIND CUTTER
REWIND
160S
Figure 2.3 RollMedia LoadingDiagrams
Page2-4 38452L Rev.3
S
-SeriesMaintenanceManual:Volume1 GettingReadytoPrint
TEAR-OFF
REARSUPPLY
BOTTOMSUPPLY
CUTTER
INTERNALSUPPLY
105Se
Figure2.4 Fanfold MediaLoadingDiagrams
BOTTOMSUPPLY
Figure 2.5 FanfoldMedia LoadingDiagrams (160S)
REARSUPPLY
38452L Rev.3 Page2-5
GettingReadytoPrint
RibbonLoading
S
-Series Maintenance Manual: Volume 1
Figure 2.6 105Se RibbonLoadingDiagram
Figure 2.7160S RibbonLoadingDiagram
Page2-6 38452L Rev.3
S
-SeriesMaintenanceManual:Volume1 GettingReadytoPrint
MediaCalibration
IMPORTANT:Performthemediacalibrationprocedurew henmediais
firstinstalledorwhenadifferenttypeofmediaorribbonisinstalled.
Duringthisprocedure,theprinterautomaticallydeterminesthemediatype,label
length,mediaandribbonsensorsettings,andprintingmethod.
NOTE:Makesurethatthemediaandribbonrollsarepositionedagainstthe
innerspindlestops.
1. PresstheMODEkeythreetimes.ThePAUSEandCALIBRATElightsturn
on.
2. PressFEEDtocalibrate.Theprinterfeedssomemedia.TheMODElights
willflashonandofftoindicatethatthesettingshavebeensavedinmemory.
3. PressPAUSEtoexitPAUSEmode;thePAUSElightturnsoff.
AdjustingthePrintDarkness
Duetodifferencesintypesofmedia/ribbonandthewearontheprinthead,it
maybenecesarytoadjustthedarknesssetting(burntemperature)ofthe
S-Seriesprintheadtoachieveproperprinting.Usethefollowingprocedureto
adjustthedarkness;turningtheprinterOFFisnotrequiredforthenewsettingto
takeeffect.
CAUTION
Setthedarknesstothelowestpossibleforthedesiredprint
quality.Darknesssettoohighforagivenribbonmaycause
printheaddamage,inksmearing,ribbonwrin kle,and/orburning
throughoftheribbon.
1. Beginprintingabatchoflabels.Useaselftestlabel(seePrinter
Diagnostics)orpreferably,oneofyourownformats.
2. PausetheprintingbypressingthePAUSEkey.
3. PresstheMODEkeyoncetoplacetheprinterin“DarknessAdjustMode.”
TheDARKENlightturnson.
4. PresstheUPorDOWNkeytoadjustthecurrentsetting.
5. PressPAUSEtoressumeprinting;checkthenewsetting.
6. Repeatsteps2through5forfurtheradjustment.
7. Whendarknessiscorrect,pressPAUSEonceandMODEthreetimes.The
MODElightswillflashonandofftoindicatethatthesettingshavebeen
savedinmemory.
8. PressPAUSEtoresumeprinting.Monitorthenewsetting,adjustingif
necessary.
38452L Rev.3 Page2-7
TheS-Series System
Printing C onsiderations
S
-Series Maintenance Manual: Volume 1
Specification 105S/105
Resolution (thermal transfer
or direct thermal)
Dot size (square) 0.00492"
Maximum print width 4.09" (104 mm) 4.09" (104 mm) 4.09" (104 mm) 6.30" (160 mm)
Standard 512 KB
Maximum
print length
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
Programmable constant
printing speeds
Thin film printhead with Energy Control
memory
With 1 MG memory 39" (991 mm) 39" (991 mm) 18" (457 mm) 25" (635 mm)
203 dots per inch
(8 dots per mm)
(0.125 mm)
15" (381 mm) 26" (660 mm) N/A 9.5" (241mm)
2" (51 mm), 3" (76 mm), 4" (102 mm), 5" (127 mm), or 6" (152 mm) per second.
The 105S and 105Se with optional 300 dots/inch resolution support
2.4" (61 mm), 3" (76 mm), and 4" (102 mm) per second.
Optional
152 dots per inch
(6 dots per mm)
0.00656"
(0.167 mm)
Se
Optional
300 dots per inch
(12 dots per mm)
0.0033" x 0.0039"
(0.083 x 0.100 mm)
160
203 dots per inch
(8 dots per mm)
0.00492"
(0.125 mm)
Media Considerations
Media Specifications 105S/105
Se
160
S
S
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 39" (991 mm) 25" (635 mm)
Tear-Off 0.63" 16.00 mm 0.63" 16.00 mm
Label length
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 thickness
(includes liner)
Maximum
position may need adjustment
if thickness is above 0.01")
(Printhead
0.012" 0.304 mm 0.012" 0.304 mm
Minimum 0.0023" 0.058 mm 0.0023" 0.058 mm
Core size 3.0" 76.2 mm 3.0" 76.2 mm
Maximum roll diameter 8.0" 203 mm 8.0" 203 mm
Interlabel gap
(0.115"/3 mm preferred)
Minimum mark length
Black mark
sensing
(thickness)
Minimum mark width
0.079" -
0.157"
2 mm - 4 mm 0.079" -
0.157"
2 mm - 4 mm
.118” 3 mm .118” 3 mm
.393” 10 mm .393” 10 mm
(extending in from the liner
or tag stock edge)
Maximum internal fanfold media
pack size (L x W x H)
8.0" x 4.5"
x 6.2"
203 x 114
x 158 mm
8.0" x 7.2"
x 6.2"
203 x 183
x 158 mm
Page 1-2 38452L Rev. 3
Getting Ready to Print
Adjusting the Tear-Off Position
This procedure sets the rest position of the media over the Tear Bar after
printing. The possible adjustment range is approximately plus or minus 80 dot
rows. Power need not be turned off to reset this parameter.
NOTE: The printer configura tion label reports the actual number of dot rows,
not the number of presses of the buttons used for adjustment.
1. Press the MODE key twice. The PAUSE and POSITION lights turn on.
2. Press the UP or DOWN key to adjust the current setting.
3. Press the MODE key twice. The MODE lights will flast on and off to
indicate that the settings have been saved in memory.
4. Press PAUSE to exit the PAUSE mode; the PAUSE light turns off.
S
-Series Maintenance Manual: Volume 1
This illustration shows how higher values move the label further out from
the printer (moves the tear line closer to the leading edge of the next label)
while lower values move the label into the printer (moves the tear line
closer to the edge of the printed label).
Figure 2.8 Tear-Off Position Adjustment
Page 2-8 38452L Rev. 3
S
-SeriesMaintenanceManual:Volume1 GettingReadytoPrint
AdjustingthePositionoftheTopoftheLabel
1. PresstheMODEkeytwice,thenpressandholdt heMODEkeyforabout
fiveseconds,untilthelightsc hange.PAUSE,D ARKEN,andCAL IBRATE
lightsturnon.
2. PresstheUPorDOWNkeytoadjustthecurrentsetting.
3. PresstheMODEkeytwice.TheMODElightswillflashonandoffto
indicatethatthesettingshavebeensavedinmemory.
4. PressPAUSEtoexitthePAUSEmode;thePAUSElightturnsoff.
AdjustingtheMediaSensorPositions
ThissensorisnotusedifBlackMarksens ingisselected.
NOTE:Ifyou’reusingcontinuousmedi a,donotperformt hisadjustment.
Leavethemediasensoratthefactory-setposition.
Non-continuousmediahasanotchoropeningbetweeneachlabel.Tomonitor
labelmovementyouneedtoalignthemediasensorwiththisnotchoropening.
Themediasensorconsistsoftwopartsthatmustbeproperlyalignedwiththe
notchoredgeofthelabel.Thefactory-setpositionshouldbesufficientformost
applications.Ifnot,performtheappropriateadjustments.
Adjusting the Upper Media Sensor
Toadjustfortheinsidehalfofthemedia:
1. Removetheribbon.Locatetheuppermediasensor(Figure2.9-A).
2. Loosen,butdonotremove,thePhillipsheadscrew.
3. Slidetheuppersensoralongtheslottoanypositionalongtheweb,except
wheretheroundedcornersofthelabelaredetected.Whenusingtagstock,
positiontheuppersensordirectlyovertheholeornotch.
4. Tightenthescrew.
38452L Rev.3 Page2-9
Getting Ready to Print
To adjust for the outside half of the media (160S ONLY):
1. R emove the ribbon. Locate the upper media sensor (Figure 2.9-A).
2. R emove the printer’s left side panel and reroute the media sensor cable to
provide a dditional slack.
3. R emove the Phillips head screw to release the upper section of the sensor
and wire cover.
4. Lift the upper media sensor assembly and move the sensor and the wire
cover to the outside half. Carefully pull the wires through the tie wrap.
You may need to set aside the sensor wire cover if the adj ustment is far to
the outside.
5. Replace and tighten the Phillips head screw.
6. Make sure the wires are routed back into the g roove of the media sensor
bracket.
7. Replace the printer ’s left side panel.
S
-Series Maintenance Manual: Volume 1
Figure 2.9 Upper Media Sensor
A
Page 2-10 38452L Rev. 3
S
-Series Maintenance Manual: Volume 1 Getting Ready to Print
Lower Media Sensor Adjustment
1. Locate the lower media sensor assembly under the rear idler roller
(Figure 2.10-A). (It is a spring clip holding a circuit boa rd.)
2. Slide the sensor until the two brass-colored infrared emitters are under the
upper medi a sensor. Gently pull wires out as needed (wires should have a
little slack).
3. 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. Clamp the wires so that they do not rub any
belts.
A
Figure 2.10 Lower Media Sensor
38452L Rev. 3 Page 2-11
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