Zebra 105Se User Manual

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ZEBRA VALUE-LINE

-Series

User's Guide

For the Zebra 105

and 160 ™ Printers

™

Proprietary Statement

This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the in- formation anduse of parties operating and maintaining the equipment described herein. Such proprietary in- formati on ma y n ot 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 commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions manual, may cause harmful interference to radio com- munications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required 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 Ca- bles.

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 Department 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 li- ability 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 Corpo- ration 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 impris- onment of up to one year and finesof up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability.

Introduction

Scope ................................1-1

Model Designation .........................1-1

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

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

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

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

PrinterSpecifications........................1-6

Table of Contents

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

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

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

Media Transport Mechanism Capabilities ...........1-2

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

230VACOperation.......................1-4

UseofShieldedCable......................1-4

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

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

PrintingConsiderations.....................1-6

PrintSpeeds...........................1-6

MediaHandling.........................1-6

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

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

ZebraProgrammingLanguageII(ZPLII

BarCodes............................1-8

StandardFonts.........................1-9

StandardPrinterFontExample................1-12

Physical............................1-12

)..........1-8

Zebra S-Series User’s Guide i

Installation

Electrical............................1-12

CommunicationsInterface...................1-13

EnvironmentalRanges.....................1-13

OptionsandAccessories....................1-13

Unpacking..............................2-1

Inspection..............................2-1

ReportingDamage..........................2-1

StorageandReshipping.......................2-1

PowerConnection..........................2-2

ACVoltageSelectionProcedure................2-2

ACPowerFuseReplacement..................2-3

115VACOperation.......................2-3

230VACOperation.......................2-3

SiteRequirements..........................2-4

RibbonLoading(105Se)......................2-4

RibbonLoading(160S).......................2-7

MediaLoading............................2-8

RollMedia...........................2-8

Tear-OffMode.........................2-10

RewindMode.........................2-10

Peel-OffMode.........................2-10

CutterMode..........................2-11

FanfoldMedia.........................2-11

RemovingUsedRibbon(105Se)..................2-12

RemovingUsedRibbon(160S)..................2-13

InitialPrinterPowerUp......................2-14

ii Zebra S-Series User’s Guide

Operation

OperatingYourZebraS-SeriesPrinterPrinter...........3-1

PrinterOperatingModes......................3-1

MediaSensingModes......................3-1

TransmissiveSensingMode..................3-2

Black-MarkSensingMode...................3-2

MediaTransportModes.....................3-2

Tear-OffMode.........................3-2

Peel-OffMode.........................3-3

RewindMode..........................3-3

CutterMode...........................3-3

FrontPanelKeys..........................3-4

PAUSEKey...........................3-4

FEEDKey............................3-4

CANCELKey..........................3-4

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

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

PowerOnSelfTest.........................3-7

PrinterSelfTests..........................3-7

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

CANCELKeySelfTest.....................3-9

PAUSEKeySelfTest.....................3-10

FEEDKeyTest........................3-11

FEEDKeyandPAUSEKeyTest...............3-12

MODEKeyTest........................3-12

PAUSEKeyandCANCELKeyTest.............3-12

FEEDKeyandCANCELKeyTest..............3-13

ExtendedPrinterDiagnostics...................3-13

Zebra S-Series User’s Guide iii

SampleZPLIILabelFormats...................3-14

Format1:SimpleTextandaBarcode.............3-15

Format2:SavingaLabelFormatAsaGraphicImage....3-15

Format3:UsingaSerializedDataField............3-16

Configuration and Calibration

OptionSwitches...........................4-1

Bank1

Bank2..............................4-3

ConfigurationMode.........................4-4

Calibration............................4-4

AdjustingthePrintDarkness..................4-6

AdjustingtheMediaRestPosition...............4-6

AdjustingthePositionoftheTopoftheLabel.........4-6

(ForSerial-InterfacePrintersOnly).............4-2

Interconnections

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

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

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

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

DataSpecifications.......................5-2

RS-232SerialDataPort.......................5-2

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

RS-232CablingRequirements.................5-3

InterconnecttoDTEDevices..................5-4

InterconnecttoDCEDevices..................5-4

ParallelCablingRequirements.................5-5

ParallelInterface........................5-5

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

iv Zebra S-Series User’s Guide

Preventive Maintenance

Overview..............................6-1

Cleaning...............................6-1

ExteriorSurfaces........................6-1

Interior..............................6-1

PrintheadandPlatenRoller...................6-2

Media,Ribbon,andLabelAvailableSensors..........6-3

CutterModule..........................6-3

Lubrication...........................6-4

Adjustments

TogglePositioning.........................7-1

PrintheadPressureAdjustment...................7-1

Black-MarkMediaSensorPositionAdjustment..........7-2

TransmissiveMediaSensorPositionAdjustment..........7-2

UpperMediaSensor......................7-3

LowerMediaSensor......................7-4

MediaandRibbonSensorSensitivityAdjustment.........7-5

Troubleshooting

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

Options

Peel-Off...............................9-1

CutterModule............................9-1

MediaRewind............................9-1

FanfoldSupplyBin.........................9-2

ZebraNet(Ethernet)Interface....................9-2

Zebra S-Series User’s Guide v

Appendix A

Appendix B

Appendix C

Appendix D

Black-Mark(Reflective)Sensor(105SeOnly)...........9-2

OptionalPrinterFonts........................9-3

230VACFactorySetup.......................9-3

MemoryOption...........................9-4

12-Dot/mmand6-Dot/mmPrintheads(105SeOnly)........9-4

230VACPowerCord........................A-1

ASCIICodeChart..........................B-1

AdjustingBarCodeDarkness....................C-1

OptionalPrinterFonts.......................D-1

Glossary

Index

vi Zebra S-Series User’s Guide

Scope

This user’s guide contains descriptive information and operational in-

structions for the Zebra 105Se and 160S thermal transferdemand 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 Mainte-

•

nance (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

Introduction

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 re-

mote 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 mechanics, 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 impor-

tant 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 en-

hance 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 appli- cations. 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:Referto“Installation”forinstructionsonconfiguringyour printer for 230 VAC operation before connecting to a 230 VAC power source.

Use of Shielded Cable

CAUTION:Refertothe“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.

Referto“Installation”forfurtherrepackinginstructions.

Zebra S-Series User’s Guide 1-5

Printer Specifications

Printing Considerations

Specification 105Se 160S

Resolution (thermal transfer or direct thermal)

Dot size 0.00492"

Maximum print width 4.09"

Standard Maximum print length

Bar code modulus (X) dimension

Thin film printhead with Energy Control

memory

With 512 KB

addl memory

203 dots per inch (8 dots per mm)

(0.125 mm)

(104 mm) 15"

(381 mm) 39"

(991 mm) 5 mil to 50 mil 6.6 mil to 66 mil 3.33 mil to 33.3 mil 5 mil to

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.

Optional 152 dots per inch (6 dots per mm)

0.00656" (0.167 mm)

4.09" (104 mm)

26" (660 mm)

39" (991 mm)

Optional 300 dots per inch (12 dots per mm)

0.0033" x 0.0039" (0.084 x 0.100 mm)

4.09" (104 mm)

18" (457 mm)

N/A 25"

203 dots per inch (8 dots per mm)

0.00492" (0.125 mm)

6.30" (160 mm)

9.5" (241 mm)

(635 mm)

50 mil

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

Minimum

Total thickness (includes liner)

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 mm-4mm 0.079"- 0.157" 2 mm -4 mm Maximum internal fanfold media pack

size (LxWxH)

Mark thickness (measur- ing parallel to label/tag edge)

Mark width (measuring perpendicular to label/tag edge)

Mark-to-mark registration tolerance + /- 0.016" +/- 0.4 mm +/- 0.016" +/- 0.4 mm Mark location Mark

Mark density > 1.0 ODU (Optical Density Unit) Density of the back of the media on

which the black mark is printed

Maximum (Printhead po- sition may need to be ad- justed above 0.01")

Minimum 0.0023" 0.0584 mm 0.0023" 0.0584 mm

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

Tear-Off 0.63" 16.00 mm 0.63" 16.00 mm Peel-Off 0.50" 12.8 mm 0.50" 12.8 mm Rewind 0.50" 12.8 mm 0.50" 12.8 mm Cutter 1.25" 31.75 mm N/A N/A

0.015" 0.381 mm 0.015" 0.381 mm

8.0" x 7.2" x

6.2"

Minimum 0.12" 3 mm 0.12" 3 mm Maximum 0.43" 11 mm 0.43" 11 mm

Minimum 0.43" 11 mm 0.43" 11 mm Maximum Full media width. Full media width.

must

printers mainframe when loaded in the printer).

0.5 ODU maximum

203.2 mm x

182.8 mm x

157.4 mm

be located on the inside of the media (closest to the

8.0" x 7.2" x

6.2"

203.2 mm x

182.8 mm x

157.4 mm

Zebra S-Series User’s Guide 1-7

Ribbon

Ribbon Width

Zebra recommends using ribbon at least as wide as the media you are using to protect the printhead from wear.

Standard Lengths

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

Maximum 4.33" 110 mm 6.89" 175 mm Minimum 0.94" 24 mm 2.0" 51 mm

105Se 160S

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®)

Downloadable graphics 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°)

Bitmap and scalable fonts

Programmable quantity with print pause

Communicates in printable ASCII characters

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

Serialized fields

In-Spec OCR-A and OCR-B

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

Bar Codes

Code 11, Code 49, Code 93

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

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

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

Industrial 2 of 5, Standard 2 of 5

Plessey

MAXICODE

1-8 Zebra S-Series User’s Guide

UPC-A

PDF 417

POSTNET

MSI

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

Interleaved 2 of 5

3of9

Data Matrix

Standard Fonts

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

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

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

Note:See“Options”fortheavailabilityofadditionalfonts.

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

Font Matrix

(indots)

Height

Width

Inter-

C, D

0 Default: 15 x 12 U-L-D Scalable

95 1

11 7 2

18 10 2

28 15 5

26 13 3

60 40 8

21 13 6

24 24 0

Type* CharacterSize

character

gap

U-L-D 0.044 0.029

U 0.054 0.044

U-L-D 0.088 0.059

OCR-B 0.138 0.098

U-L-D 0.128 0.079

U-L-D 0.295 0.236

OCR-A 0.103 0.093

SYMBOL 0.118 0.118

Height

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

Inches Millimeters

Width

33.90

22.60

16.95

10.17

12.71

4.24

10.71

8.48

Char./inch

Height

1.13 0.75 1.33

1.38 1.13 0.89

2.25 1.50 0.67

3.50 2.50 0.40

3.25 2.00 0.50

7.50 6.00 0.17

2.63 2.38 0.42

3.00 3.00 0.33

Width

Char./mm

Zebra S-Series User’s Guide 1-9

Font Matrices for 6 dots/mm Printhead

Font Matrix

(indots)

Height

Width

C, D

95 1

11 7 2

18 10 2

21 10 3

26 13 3

60 40 8

17 11 4

24 24 0

Default: 15 x 12

Inter-

Type* Character Size

character

gap

U-L-D 0.059 0.039

U 0.072 0.059

U-L-D 0.118 0.079

OCR-B 0.138 0.085

U-L-D 0.171 0.105

U-L-D 0.394 0.315

OCR-A 0.112 0.098

SYMBOL 0.157 0.157

U-L-D

Height

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

Inches Millimeters

Width

Char./inch

25.40

16.93

12.70

11.72

9.53

3.18

10.16

6.35

Scalable

Height

1.50 1.00 1.00

1.83 1.50 0.67

3.00 2.00 0.50

3.50 2.17 0.46

4.33 2.67 0.38

10.00 8.00 0.13

2.83 2.50 0.40

4.00 4.00 0.25

Width

Char./mm

1-10 Zebra S-Series User’s Guide

Font Matrices for 12 dots/mm Printhead

Font Matrix

(indots)

Height

Width

C, D

95 1

11 7 2

18 10 2

42 20 6

26 13 3

60 40 8

34 22 8

24 24 0

Default: 15 x 10

Inter-

Type* Character Size

character

gap

U-L-D 0.029 0.016

U 0.036 0.023

U-L-D 0.059 0.033

OCR-B 0.138 0.066

U-L-D 0.185 0.042

U-L-D 0.198 0.132

OCR-A 0.112 0.072

SYMBOL 0.079 0.079

U-L-D

Height

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

Inches Millimeters

Width

50.80

33.86

25.40

23.44

19.06

6.36

20.32

12.70

Scalable

Char./inch

Height

0.73 0.40 2.00

0.91 0.58 1.34

1.49 0.83 1.00

3.50 1.67 0.92

2.15 1.06 0.76

5.02 3.35 0.26

2.84 1.82 0.80

2.00 2.00 0.50

Width

Char./mm

Zebra S-Series User’s Guide 1-11

Standard Printer Font Example

Physical

Physical Characteristics 105Se 160S

Height Width Length Weight (without options)

15.4" 391 mm 15.4" 391 mm

10.5" 267 mm 13.1" 333 mm

18.9" 480 mm 18.9" 480 mm

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. 950- M89; 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

Non-condensing relative humidity

Operating 20% to 85%

Storage 20% to 85%

−40°C to +70°C

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

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.

Installation

• File a damage report with the shipping company and notify your lo-

cal 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/OFFSwitch(seeFigure2.1).Fora115VACinstallation,thereplacement 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

ontheS-SeriesPrinter. 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)

RefertoFigure2.4throughoutthisprocedure.

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

Figure 2.4 Ribbon Loading Diagram

2-6 Zebra S-Series User’s Guide

Ribbon Loading (160S)

RefertoFigure2.4throughoutthisprocedure.

Note: When placing the ribbon roll on the Ribbon Supply Spindle,

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.AlignthesegmentsoftheRibbonSupplySpindle.SeeFigure2.2.

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

Figure2.3):

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

Media Loading

To load media, move the Printhead Locking Lever to the OPEN position.RefertoFigures2.5,2.6,2.7,and2.8.Whenthemediaisloaded, close the printhead by moving the lever on the upper printhead mechanism to the CLOSED position.

Note: The first time you load media and whenever you subsequently

Roll Media

Roll media may contain labels of a fixed length with gaps in between or itmaybeformedasonecontinuouslengthwithnogaps(seeContinu-

ousMediaintheGlossary).Bothtypesofrollmediamountinsidethe

printerinthesamemanner.Toloadrollmedia,refertoFigure2.5 and/or2.6anddothefollowing:

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.)

change the media type you must re-calibrate the printer. See the Configuration and Calibration Section.

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.

2-8 Zebra S-Series User’s Guide

Figure 2.5 Roll Media Loading Diagrams

Figure 2.6 105Se Roll Media Loading (with Peel-Off)

Zebra S-Series User’s Guide 2-9

Tear-Off Mode

Follow the instructions described in Roll Media.

Rewind Mode

The Rewind Option must be installed in the printer. To initially configure the printer for this mode, follow these steps:

1. Remove the Media Rewind Plate from its storage location in front of the printhead inside the media compartment.

2. Invert the Rewind Plate so that the lip on the attached Hook Plate points down.

3. Insert the Hook Plate lip a short distance (1/2") into the lower opening in the Side Plate.

4. 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.RoutethemediaasshowninFigures2.5and2.6,windit1-2times around a 3" core.

Peel-Off Mode

After loading the media, follow these steps:

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.LoadmediaasshowninFigures2.5and2.6.

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.

2-10 Zebra S-Series User’s Guide

Cutter Mode

Follow the instructions described in Roll Media with the exception of step6:firstroutethemediathroughtheCutterModule(seeFigures2.5 and2.6)andthenclosetheprintheadassemblybymovingtheleverlocated on the upper printhead assembly to the CLOSED position.

Fanfold Media

To load fanfold media, place the fanfold media in the bottom or to the rear of the media compartment or Fanfold Supply Bin (105Se only) and threaditthroughtheprintheadasshowninFigures2.7and2.8.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 2.7 Fanfold Media Loading Diagrams (105Se)

Zebra S-Series User’s Guide 2-11

Figure 2.8 Fanfold Media Loading Diagrams (160S)

Removing Used Ribbon (105Se)

To remove used ribbon, refer to Figure 2.9 and follow the steps below.

1. Pull the hook out slightly, then rotate the hook back-and-forth several times as shown and remove it from the spindle.

2. Grasp the used ribbon and remove it from the Ribbon Take-Up Spindle.

3. Remove the empty core from the Ribbon Supply Spindle.

4.FollowtheRibbonLoadingprocedureonpage2-4toloadthenewribbon.

Figure 2.9 Removing Used Ribbon (105Se)

2-12 Zebra S-Series User’s Guide

Removing Used Ribbon (160S)

Refer to Figure 2.10.

1. Turn the knob at the end of the Ribbon Take-Up Spindle (1) clockwise until it stops. This will cause the Ribbon Release Bars to pivot down (2), easing the spindle’s “grip” on the wound ribbon.

2. Slide the ribbon off of the Ribbon Take-Up Spindle. Once the used ribbon has been removed, ensure that the arrow on the knob aligns with the indented notch in the Ribbon Take-Up Spindle (see inset).

3. Remove the empty core from the Ribbon Supply Spindle.

4.Followtheribbonloadingprocedureonpage2-7toloadthenewribbon.

Figure 2.10 Removing Used Ribbon (160S)

Zebra S-Series User’s Guide 2-13

Initial Printer Power Up

After you finish loading the ribbon and media, continue reading through

“Operation”and“ConfigurationandCalibration.”Performthefollow-

ing initial printer power-up steps as you come to them:

1. Power On Self Test (POST)

2. Calibration

Subsequent power-ups will not necessarily require step 2 to be performed.See“Operation”and“ConfigurationandCalibration”forfurther information.

2-14 Zebra S-Series User’s Guide

Operating Your Zebra S-Series Printer

Now that your printer is ready for operation, how does it work? The Zebra S-Series Printer is designed to receive instructions from a host computer, such as an IBM-compatible PC. To create a label, you will either need to use label design software or write a format in ZPL II which is a programming language for creating label formats. If you are using label 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 was available at the time you ordered your printer, but if you do not have a copy then submit the mail- or fax-in card in the front of this book to get a copy. For some sample ZPL II label formats, refer to the information at the end of this chapter. But first, we’ll describe the different operating modes.

Printer Operating Modes

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 therearoftheprinter.(See“ConfigurationandCalibration”formore information about DIP switches.)

Operation

Media Sensing Modes

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.

Zebra S-Series User’s Guide 3-1

Transmissive Sensing Mode

In Transmissive Sensing Mode, a sensor detects a light shining through a web, notch, or hole in non-continuous media. In this way, the printer determines the position of the label/tag.

Black-Mark Sensing Mode

In Black-Mark Sensing Mode, you use media having black marks printed on the back of the label liner for each label. To determine the label length and top of label, the printer’s Black Mark Sensor detects the black mark similar to the way in which the Transmissive Sensor detects the notch or gap in the media.

Media Transport Modes

Tear-Off Mode

When the media is in the rest (idle) position, the webbing between labels is over theTear-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 will feed forward to the start of the next label and printing will continue. In this way, the printer will print the batch and stop 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.

3-2 Zebra S-Series User’s Guide

Peel-Off Mode

Rewind Mode

When the media is in the rest (idle) position, the start of the label to be printed is slightly in front of the printhead. To print a label, the printer first backfeeds the media until the start of the label is directly under the printhead and then prints the entire label.

In this mode, once the label is printed, the media passes over the TearOff/Peel-Off Bar at an extremely sharp angle. 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 located on the printer in a position where it 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. When it is necessary to remove the media backing from the Take-Up Spindle, you do not need to turn the printer OFF.

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 will stop.

Cutter Mode

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.

Zebra S-Series User’s Guide 3-3

Front Panel Keys

PAUSE Key

The PAUSE key stops and restarts the printing process. If the printer is idle (not printing) when the PAUSE key is pressed, no printing can occur. If the PAUSE key is pressed while printing is in progress, the printing stops once the current label is complete. Pressing the PAUSE key a second time resumes the printing process.

FEED Key

The FEED key forces the printer to feed one blank label. 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.

CANCEL Key

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 will be 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.

3-4 Zebra S-Series User’s Guide

Figure 3.1

Printer Front Panel

MODE Key

The MODE key puts the printer in Configuration Mode. In this mode, you can adjust the Print Darkness, Media Tear-Off Position, and Label TopPosition,orperformaCalibration.See“ConfigurationandCali-

bration.”

Front Panel Lights

RefertoFigure3.1forthelocationofthelights.

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.

Zebra S-Series User’s Guide 3-5

Indicator Light

Name Status Indication

POWER ON Printer is ON.

OFF Normal operation.

Head Over Temperature condition. Printing stops until the printhead cools down. Printing resumes automatically.

PRINTHEAD

Flashing Printhead Open. OFF Media and ribbon (if used) are properly loaded.

Printhead Under Temperature condition. Printing continues. Power Supply Over Temperature condition. Printing stops until the

power supply cools down. Printing resumes automatically.

PAPER/ RIBBON

PAUSE OFF Normal operation.

DATA

DARKEN ON POSITION ON CALIBRATE ON

ON Paper out. Flashing 1. In Thermal Transfer Mode: Ribbon is out.

2. In Direct Thermal Mode: Ribbon is in the printer.

ON Printer has stopped all printing operations. OFF Normal operation, no data being received. ON Labels are printing. Single flash The

Flashing Receiving data from host computer. Slow

flashing

CANCEL

from the print queue.

Printer sent a stop transmitting command to the host computer.

Printer is in the Configuration Mode. See Configuration and Calibra-

tion for more information.

key was pressed and a format was successfully deleted

3-6 Zebra S-Series User’s Guide

Power On Self Test

A Power On Self Test (POST) is performed each time the printer is turned ON. This test checks for proper initialization of various electronic circuits and establishes starting parameters as those stored in the printer’s memory. During this test sequence, the front panel lights will turn ON and OFF to ensure proper operation. At the end of this self test, only the POWER light willremainlit.Ifotherlightsarealsolit,refertotheTroubleshootingSec-

tion.

Printer Self Tests

Introduction

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.

Notes: 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.

Zebra S-Series User’s Guide 3-7

If your media is not wide enough, the test labels will only print out to the edge of the label. If your media is too short, the test label will continue printing on the next label.

Some of the printer self tests produce labels at varying print speeds. These speeds may be referred to as “inches per second,” “millimeters per second,” or by alphabetic letter designation (i.e., “A,” “B,” “C,” etc.). The following chart shows the relationships between the different speeds.

Letter

Designation English Metric

A* 2"/sec. 51 mm/sec.

B 3"/sec. 76 mm/sec. C 4"/sec. 102 mm/sec.

5"/sec. 127 mm/sec.

D 6"/sec. 152 mm/sec.

* Speed “A” for the 105Se with the optional 300 dots-per-inch printhead is 2.4" (61 mm).

3-8 Zebra S-Series User’s Guide

CANCEL Key Self Test

This self test prints a single label which contains a listing of the printer’s current configuration parameters stored in Configuration (EEPROM) Memory. Press the CANCEL key while turning the AC Power Switch ON. See Figure 3.2.

The configuration may be changed either temporarily (for specific label formats or ribbon and label stock), or permanently (by saving the new parameters in EEPROM Memory). Saving new parameters occurs whenever a Printer Calibration procedure is performed. Refer to the procedure in“ConfigurationandCalibration.”

Figure 3.2 CANCEL Key Test

Sample Printout

Zebra S-Series User’s Guide 3-9

PAUSE Key Self Test

This self test is actually comprised of four individual test features.

1. The initial self test prints 15 labels at speed “A” then automatically PAUSES the printer. Each time the PAUSE key is pressed, an additional 15 labels print out.

2. While the printer is PAUSED, pressing the CANCEL key once alters the self test. Now each time the PAUSE key is pressed the printer prints 15 labels at speed “D” (“C” for the 300 dpi 105Se).

3. While the printer is PAUSED, pressing the CANCEL key a second time alters the self test again. Now, each time 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. Now, each time the PAUSE key is pressed the printer prints 50 labels at speed “D” (“C” for the 300 dpi 105Se).

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 rewind plate must be removed for proper function of the peel sensors during the test. The first label to print will say, “PEEL OPTION INSTALLED”. Each label must be manually removed from the sensor path before the next label will print. Steps 1–4 will then be repeated in Rewind Mode.

Figure 3.3 PAUSE Key Test Sample Printout

3-10 Zebra S-Series User’s Guide

This self test can be used to provide the test printouts required when making adjustments to the printer’s mechanical assemblies. See the sampleprintoutinFigure3.3.

FEED Key Self Test

The CANCEL Key Self Test should be performed before this self test. Information on the “Configuration” printout (CANCEL Key Self Test) can be used with the results of this self test to determine the best Darkness setting for a specific media/ribbon combination.

The FEED Key Self Test will print 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 that 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.

Optionally, the Darkness value can be programmed into the ZPL II formats sent to the printer.

Figure 3.4 FEED Key Test Sample Printout

Zebra S-Series User’s Guide 3-11

FEED Key and PAUSE Key Self Test

Pressing these two keys at the same time, while turning the Power ON, temporarily resets the Printer Configuration to the factory default values. These values will be active until Power is turned OFF. Whenever

the printer is reset to factory defaults, a Media Calibration procedure must be performed immediately.

MODE Key Self Test

This test places the printer in the Communications Diagnostics Mode. 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 3.5.

Note: This label will be inverted when printed.

Figure 3.5 Results of Communications Diagnostic Test

PAUSE Key and CANCEL Key Test

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 oneinFigure3.3exceptthataserializednumberwillprintoneachlabel.

3-12 Zebra S-Series User’s Guide

FEED Key and CANCEL Key Test

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

Left Ribbon Wrinkle Test Right Ribbon Wrinkle Test C39 Wrinkle Test Left Ribbon Wrinkle Test Right Ribbon Wrinkle Test C39 Wrinkle Test Usable Area Test Head Temperature Test Upper Smear Test Lower Smear Test Usable Area Test Head Temperature Test Upper Smear Test Lower Smear Test

* “C” for the 105Se with the 300 dots/inch printhead

Inches

per second

20 D* 20 D* 20 D* 20 A 20 A 20 A 10 D* 10 D* 10 D* 10 D* 10 A 10 A 10 A 10 A

Extended Printer Diagnostics

Extended diagnostic tests are available. The maintenance manual, Vol. 1: General Maintenance (part # 38452L), provides the information needed to perform these additional tests.

Zebra S-Series User’s Guide 3-13

Sample ZPL II Label Formats

ZPL II®is Zebra Technologies Corporation’s Zebra Programming Language II label design language. ZPL II lets you create a wide variety of labels from the simple to the very complex, including text, bar codes, and graphics.

This section contains three sample label formats for you to begin experimenting with. It is not intended as an introduction to ZPL II. To learn about ZPL II, send in the request card at the beginning of this book for a copy of the ZPL II Programming Guide.

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 (ex: Windows Write or DOS Editor) and

type in the label format exactly as shown in the sample label format shown below.

• Save the file in a directory for future use. Use the extension “ . zpl”.

• Copy the file to the Zebra S-Series Printer.

Note: Typically, computers running DOS use the “COPY” command

to send a file to the Zebra printer. For example, if your file name is “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, referto“Installation”tomakesureyoursystemissetupcorrectly,otherwisereferto“Troubleshooting.”

3-14 Zebra S-Series User’s Guide

Format 1: Simple Text and a Barcode

Line#Type this label format: Youll get this printout:

^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.

Format 2: Saving a Label Format As a Graphic Image

Line#Type this label format: Youll get this printout:

^XA

^LH30,30

^FO20,10^AD^FDZEBRA^FS

^FO20,60^B3N,Y,20,N^FDAAA001^FS

^ISFORMAT2,N

^XZ

^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

“FORMAT2", 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)

(Same as Format 1, but this format was also saved in the printers memory as a graphic im- age named FORMAT2".)

Zebra S-Series User’s Guide 3-15

Format 3: Using a Serialized Data Field

Line#Type this label format: Youll get this printout:

^XA

^LH30,30

^FO20,10^AD^FDZEBRA^FS

^FO20,60^B3,,40,,^FDAAA001^FS

^FO20,180^AF^SNSERIAL NUMBER

00000000111,1,Y^FS ^PQ10

^XZ

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 quantity to 10 Line #7: (See Format 1)

Ten labels should print. The first and last are shown here.

3-16 Zebra S-Series User’s Guide

Option Switches

These switches are located at the rear of the printer above the Signal Interface Cable Connection. See Figure 4.2.

In the tables on the following page, an “R” means the switch is OFF (positioned to the right), while an “L” means the switch is ON (positioned to the left). All switches are in the OFF position when the printer is shipped from the factory.

Configuration and Calibration

Figure 4.1 Option Switches

Figure 4.2 Location of Option Switches

Zebra S-Series User’s Guide 4-1

Bank 1 (For Serial Interface Printers Only)

The S-Series Printer, with the RS-232 Serial Interface, uses eight miniature switches located on the rear of the printer, above the Signal Interface Cable Connector. The ON/OFF positions of these switches establish some of the Printer Configuration Parameters. Bank 1 switches must be properly positioned to establish serial data communications with the host computer. Thereafter, the position of these switches should not be changed.

Note: Parallel-interface

printers do not require these configuration parameters, therefore they have no Bank 1 switches.

If these switches are in the proper position to match the communication configuration of the host computer, and the printer is not receiving data, referto“Interconnections”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.

Bank 1

Switch

321

RRR RRL RLR

RLL

LRR

LRL

LLR

LLL

Switch

4 R L

Switch

65 RR RL LR LL

Switch

R L

Switch

R L

(Serial Interface Printers Only)

Baud Rate

9600 baud 19200 baud 110 baud 300 baud 600 baud 1200 baud 2400 baud 4800 baud

Must be set to 8 Data Bits to use Code

(

7 Data bits 8 Data bits

(If you choose 7 data bits, you must

choose either even or odd parity.)

Even parity Parity disabled Odd parity Parity disabled

XON/XOFF control DTR/DSR control

No error detection Error detection active

Data Bits

Page 850.

Communication

Handshake Control

Error Detection Protocol

Table 4.1

)

Parity

4-2 Zebra S-Series User’s Guide

Bank 2

Switch

321

RRL RLL LRL

LLL

--R

Switch

654

RRL

RLL

LLL

--R

Switch

RL LL

-R

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:

Troubleshooting. By using these switches,

Bank 2

Print Mode

Cutter Tear-Off Peel-Off Rewind Override is disabled

Media Mode

Black-mark sensing mode Transmissive sensing mode with

non-continuous media (detects a web/notch)

Transmissive sensing mode with continuous media

Override is disabled

•

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 pack-

•

ages 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 will require ZPL II commands and/or re-calibration to set print mode, media mode, and/or media type.

To override, set the switches to one of the

Media Type

Thermal transfer Direct thermal Override is disabled

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

Table 4.2

mode.

105Se Note: Switch 5 must not be positioned to the right unless the

printer is equipped with the optional black mark sensor.

Zebra S-Series User’s Guide 4-3

Configuration Mode

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“Operation”).

Ifitisevernecessarytoresetthe printer configuration to the factory de-

faults,refertothe“FEEDKeyand PAUSE Key”SelfTestdescriptionin “Operation.”

TheZPLIIProgrammingGuidecontainsinformation 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.

Calibration

IMPORTANT: Perform the Calibration Procedure when media and ribbon are first installed and each time a different type of media or ribbon is installed.

4-4 Zebra S-Series User’s Guide

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 will remain in effect until the next calibration is performed. The Printer Configuration Printout, which prints when the CANCEL Key Self Test is performed, lists these results as well as other printer parameters.

Note: If the printer is in the Peel-Off Mode, the operator must

“catch” the labels as they are peeled away from the backing during this procedure.

1. Load media and ribbon (if used). Make sure the Media Sensor is properlypositioned(see“Adjustments”).

IMPORTANT: To use the Black-Mark Sensing Mode, make sure you settheBank2DIPswitchesappropriately(seepage4-3).

2. Turn the power switch ON. When the Power ON Self Test is complete, the POWER, PAUSE, and PAPER/RIBBON lights will be ON.

3. Press the MODE key three times briefly. PAUSE and CALIBRATE lights turn ON.

4. Press UP (FEED Key) to calibrate. The printer feeds some media. The MODE lights will 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.

Zebra S-Series User’s Guide 4-5

Adjusting the Print Darkness

This procedure sets the darkness of the printing on the label. Use the lowest setting which provides the necessary print quality.

1. Press the MODE key. PAUSE and DARKEN lights turn ON.

2. Press UP or DOWN to adjust the current setting.

3. Press the MODE key three times. The MODE lights will flash ON and OFF to indicate that the settings have been saved in memory.

4. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF.

Adjusting the Media Rest Position

This procedure sets the end-of-label position relative to the Tear-Off Bar or Cutter.

1. Press the MODE key twice briefly. PAUSE and POSITION lights turn ON.

2. Press UP or DOWN to adjust the current setting.

3. Press the MODE key twice briefly. The MODE lights will flash ON and OFF to indicate that the settings have been saved in memory.

4. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF.

Adjusting the Position of the Top of the Label

This procedure positions the printing on the label relative to the top edge of the label.

1. Press the MODE twice briefly then press and hold for about five seconds until the lights change. PAUSE and DARKEN and CALIBRATE lights turn ON.

2. Press UP or DOWN to adjust the current setting.

3. Press the MODE key twice briefly. The MODE lights will flash ON and OFF to indicate that the settings have been saved in memory.

4. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF.

4-6 Zebra S-Series User’s Guide

System Components

Figure 5.1 System Components

System Considerations

Interconnections

Communications Code

The Zebra S-Series Printer sends and receives American Standard Code for Information Interchange (ASCII). This code consists of 128 characters (256 for Code Page 850) including upper and lower case letters, punctuation marks, and various control codes.

Interfaces

The method of interfacing the Zebra S-Series Printer to a data source depends on the communication options installed in the printer. Depending on how the printer was ordered, the interface is either an RS-232 serial data port or a parallel port.

Zebra S-Series User’s Guide 5-1

Data Specifications

When communicating via the serial data port (RS-232), the baud rate, numberofdatabits,andtheparityareuser-selectable(see“Configura-

tionandCalibration”foracceptablesettingcombinations).Parityonly

applies to data transmitted by the printer, sinceit ignores the parity of re-

ceived 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.

RS-232 Serial Data Port

The connections for the standard interface are made through the DB25S 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.

Pin No. Description

1 Frame Ground for Cable Shield 2 TXD (Transmit Data) output from the printer 3 RXD (Receive Data) input to the printer 4 RTS (Request To Send) output from the printer 6 DSR (Data Set Ready) input to the printer 7 Signal Ground 20 DTR (Data Terminal Ready) output from the printer Note:

Pins 5, 8, 10-19, and 21-25 are not used and are unterminated.

Table 5.1 RS-232 Pinouts

5-2 Zebra S-Series User’s Guide

Hardware Control Signal Descriptions

Request To Send (RTS) is a Control Signal from the S-Series Printer to the host computer. RTS is always in the ACTIVE condition (positive voltage) whenever the printer is powered ON.

Data Set Ready (DSR) is a control signal from the host computer to the printer. When DSR is in the ACTIVE condition (positive voltage), the printer can transmit status to the host. When CTS is in the INACTIVE condition (negative voltage), the printer will not transmit any data.

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 will have no effect.

RS-232 Cabling Requirements

The required cable must have a 25-pin “D” Type (DB25P) male connector on one end, which is plugged into the mating (DB25S) 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 will be one of two types depending on the specific interface requirements. Refer to the following pages 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.

Zebra S-Series User’s Guide 5-3

To minimize electrical noise pickup in the cable:

Keep data cables as short as possible.

•

Do not bundle the data cables tightly with power cords.

•

Do not tie data cables to power wire conduits.

•

Interconnect to DTE Devices

Figure 5.2 DTE to DTE Connections

The printer is configured as Data Terminal Equipment (DTE). To connect the printer to other DTE devices (such as the serial port of a PC), use an RS-232 Null Modem (crossover) cable. Figure 5.2 illustrates the connections required for this cable.

Interconnect to DCE Devices

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 5.3 illustrates the connections required for this cable.

Figure 5.3 DCE to DTE Connections

5-4 Zebra S-Series User’s Guide

Parallel Cabling Requirements

The required cable must have a standard 36-pin parallel connector on one end, which is plugged into the mating connector located at the upper rear of the printer. The parallel interface cable is connected using bail clips, instead of screws, in a similar position to that of the serial data cable.

The other end of the parallel interface cable connects to an appropriate point at the host computer.

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.

Parallel Interface

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 +5 VDC LOW 0 VDC

Zebra S-Series User’s Guide 5-5

Voltage Level

Signal Descriptions

The following chart provides a description of each of the pins in the parallel connector. A standard parallel data cable will provide the required interconnection between the computer and the printer.

Parallel Connector Pin Assignments

Pin No. 1 The nStrobe printer input has internal 3.3 kW pull-up resistors to5V(IOL= 1.5 mA) and is

designed to receive a signal driven open collector V the host computer. The nStrobe input is debounced on a LOW going edge to require an ac- tive width greater than 0.5µs 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 Pin9=D0through D7 respectively.

10 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

11 The Busy output is active HIGH whenever the printer

or abnormal condition, including buffer overflow, head open, over temperature, and media er- ror conditions. Busy is a driven open collector with a 3.3 kW internal pull-up. The output sinks 7 mA to a V

12 The PError signal is active HIGH whenever the printer is out of media or ribbon.

<= 0.4 V.

Description

<= 0.8 V. This pin is a signal from

<= 0.4 V.

cannot

accept data due to any normal

13 The Select signal function is determined by an additional configuration option which be-

comes active when the port is present. In the default condition, Select is active HIGH when- ever the parallel port is powered up and the parallel port is enabled. In the non-default

condition, Select will go active LOW whenever the printer is printing. 14 nAutoFd (not connected) 15 Not defined 16 Logic Gnd 17 FRAME GROUND is at the same potential as Logic Gnd (pin 16). 18 FUSED5V-1Amaximum. 19 - 30 SIGNAL GROUNDS are the Logic Grounds and Returns for all input and output signals. 31 - 35 NOT USED - These leads should be left unconnected. 36 NSelectIn (not connected)

5-6 Zebra S-Series User’s Guide

Overview

This section contains preventive maintenance information for the Zebra S-Series Printer. These procedures may be performed by the operator.

Cleaning

Exterior Surfaces

The exterior surfaces of the printer may be cleaned as required by using a lint free cloth. Do not use harsh or abrasive cleaning agents or solvents. If necessary, a mild detergent solution or desktop cleaner may be used sparingly.

Interior

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.

Preventive Maintenance

AREA METHOD INTERVAL

Printhead Isopropyl alcohol After every roll of media (or 500 Platen Roller Isopropyl alcohol Upper and Lower

Media Sensors Media Path Isopropyl alcohol Ribbon Sensor Air blow Peel/Tear Bar Isopropyl alcohol As needed. Label Available Sensor Air blow Monthly. Cutter Module Isopropyl alcohol and/or air blow As needed.

Air blow

Table 6.1 Cleaning Schedule

ft. of fanfold media) when print- ing direct thermal or after every roll of ribbon when printing in thermal transfer mode.

Zebra S-Series User’s Guide 6-1

Printhead and Platen Roller

Inconsistent print quality, such as voids in the bar code or graphics, may indicate a dirty printhead. For optimum performance, Zebra recommendsperformingthecleaningprocedureonpage6-3aftereveryroll of ribbon (after every roll of media, for direct thermal printing).

Note: Label Available Sensors are shown for location purposes only.

They are not standard on all printers.

Figure 6.1 Printhead Cleaning (105Se shown)

6-2 Zebra S-Series User’s Guide

It is not necessary to turn printer power OFF prior to cleaning. If power is turned OFF, all label formats, images, and parameter settings stored in the printer’s formatting RAM will be lost. Permanent parameter settings stored in EEPROM will be retained. When power is turned back ON, it may be necessary to reload some items.

To clean the printhead and platen roller, open the media compartment door, refertoFigure6.1,andperformthefollowingsteps:

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 Corporationrecommended solvent and wipe the print elements from end to end. (The print elements form the gray/black strip just behind the chrome strip.SeeFigure6.1.)Allowafewsecondsforthesolventtoevaporate.

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.

Media, Ribbon, and Label Available Sensors

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 Figures6-1,7-2,and7-3.

Cutter Module

Periodically, the Cutter Module should be cleaned to remove paper dust and label residue. Cleaning the Cutter Module ensures that labels will be cut properly and not jam in the cutter mechanism. Refer to

Figure6.2.

Zebra S-Series User’s Guide 6-3

Clean the stationary cutter blade with a cotton swab moistened with isopropyl alcohol when it becomes gummed up with label adhesive or paper debris. If the cutter performs unsatisfactorily after it has been cleaned, refer to Volume 1 of the Maintenance Manual.

Figure 6.2 Cleaning the Cutter Blade

Lubrication

CAUTION: Some commercially available lubricants will damage the printer if used.

Lubrication of the Zebra S-Series Printer should be performed by a qualified service technician according to the directions provided in the Volume 1 of the Maintenance Manual (part # 38452L).

6-4 Zebra S-Series User’s Guide

Toggle Positioning

Note: The 105Se has one toggle, the 160S printer has two toggles.

The toggle(s) should be positioned to provide even pressure on the media. Toggles are positioned by sliding them left or right to the desired location. On the 105Se, the single toggle should normally be positioned over the center of the media. 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.

Printhead Pressure Adjustment

If printing is too light on one side, or if thick media is used, you may needtoadjusttheprintheadpressure.RefertoFigure7.1andfollow the procedure below.

1. Perform a PAUSE Key Self Test.

2. Lower the Darkness Setting until the printing is gray.

Adjustments

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.

Zebra S-Series User’s Guide 7-1

Figure 7.1 Printhead Pressure Adjustment (105Se shown)

Black Mark Media Sensor Position Adjustment

This sensor position requires no adjustment or calibration by the user.

Transmissive Media Sensor Position Adjustment

The transmissive media sensor senses either the “web” between labels or a hole or notch in the media to determine the length of the label or ticket. The factory-set position should be sufficient for any width label using media with a web. However, if position adjustments are needed, follow these procedures beginning with the upper sensor.

7-2 Zebra S-Series User’s Guide

Upper Transmissive Media Sensor Position Adjustment

To adjust the upper media sensor, refer to Figure 7.2 and follow these steps.

1. Remove the ribbon and locate the Upper Media Sensor.

2. Loosen the Phillips head screw.

3. Slide the upper sensor along the slot to the desired position. When using media that has a web between labels, position the media sensor anywhere along the web (except 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 7.2 Upper Media Sensor (105Se shown)

Zebra S-Series User’s Guide 7-3

Lower Transmissive Media Sensor Position Adjustment

To adjust the lower media sensor, follow these steps.

1. Locate the lower media sensor assembly (a spring clip holding a small printed circuit board) under the rear idler roller.

2. Position the sensor so that the two brass-colored infrared emitters are under the upper sensor by sliding it in its slot.

3. Gently pull wires out of the printer frame as required. (Wires should have a little slack.)

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 7.3 Lower Transmissive Media Sensor Locations

7-4 Zebra S-Series User’s Guide

Media and Ribbon Sensor Sensitivity Adjustment

Note: This adjustment is initially set by Zebra Technologies

Corporation during final printer calibration. Under normal circumstances, further adjustments should not be necessary. The exception to this might be the use of media with exceptionally thick or thin backing, which could require re-adjustment of the Sensor Sensitivity.

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 inches 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 will have the same effect as removing it.)

5. Close the printhead.

6. Hold the PAUSE, FEED, and CANCEL keys depressed while turning the printer ON. Once the printer is ON, release the keys.

7. The following two sets of lights will begin flickering, signifying that the adjustment has been made.

•

The PRINTHEAD and PAPER/RIBBON lights

•

The DARKEN and POSITION lights

Zebra S-Series User’s Guide 7-5

Note: If only one pair of lights is flickering, it indicates that the

adjustment was not successful. Go back to step 1 and start over.

8. Open the printhead.

9. Pull the media out of the printer until a label is positioned under the printhead. Move the ribbon back to its normal position.

Note: Be sure that label is positioned between the upper and lower

Media Sensors.

10. Close the printhead.

11. Press the MODE key to print a Media and Sensor Profile and save the new values (see Figure 7.4.).

12.PerformtheMediaCalibrationprocedurein“ConfigurationandCali-

bration.”

Figure 7.4 Media Sensor Profile Sample Printout

7-6 Zebra S-Series User’s Guide

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

All indicator lights never light. No AC Power applied to the

printer. Faulty AC power fuse. Refer to Installation for fuse replace-

Troubleshooting

Ensure that the AC power cable is con- nected to a working voltage source.

ment procedures.

Printer locks up when running Power-On Self Test.

POWER light ON, other lights all OFF or all ON and the printer locks up.

CALIBRATE light is OFF but all other lights are ON.

CALIBRATE light and POSITION light OFF but all other lights ON.

PRINTHEAD light is ON, printing continues.

Printer stops. PAUSE light and

PAPER/RIBBON light both

ON.

No voltage available from the internal power supply.

An improper configuration was set.

ROM CRC test has failed. Call a service technician.

Dynamic RAM failed. Call a service technician.

FONT ROM error. Call a service technician.

Printhead under-temperature condition.

Media incorrectly loaded or not loaded.

Misadjusted Media Sensor.

Media not calibrated.

Call a service technician.

Reload factory defaults. Then, set cor- rect parameters. See Operation.

Wait until printhead warms up. If con- dition persists and print quality is af- fected, move printer to a warmer environment. If print quality is accept- able, no action is required.

Load media correctly. See

ing

in Installation.

Check position and sensitivity of Media Sensor and/or calibrate media. See Adjustments and Configuration and Calibration.

Media Load-

Zebra S-Series User’s Guide 8-1

SYMPTOM DIAGNOSIS ACTION

Printer stops. PAUSE light ON and PAPER/ RIBBON light FLASHING.

Ribbon incorrectly loaded or not loaded.

Malfunctioning Ribbon Sensor. Call a service technician.

Load ribbon correctly. See

in Installation.

Ribbon

Printer stops. PAUSE light ON and PRINTHEAD light FLASHING.

Printer stops. PAUSE light and PRINTHEAD light both ON.

Dots missing in printed area of label.

Loss of printing registration on labels.

For Peel-Off Mode.

Excessive vertical drift in top- of-form registration.

Printhead is not fully closed. Close printhead completely. Printhead Open Sensor not de-

tecting its position flag. Printhead element is over-

heated (105Se or 160S).

Power supply is overheated (105Se or 160S).

Printhead element going bad. Call a service technician.

Possible media sensor or cali- bration problem.

Printer set for non-continuous media, but continuous media loaded.

Improperly adjusted Media Edge Guides.

Incorrect media loading. See

Call a service technician.

Printer resumes printing when the print- head element cools. If condition per- sists, move printer to a cooler environment.

Printer resumes printing when the power supply cools. If condition per- sists, move printer to a cooler environ- ment.

Adjust media sensor position or cali- brate media. Call a service technician if necessary.

Set printer for correct media. See In- stallation.

Refer to Installation.

Media Loading

in Installation.

Light vertical lines running through all labels.

Light printing or no printing on the left or right side of the label.

Short printed lines at 45° to la- bel edge on left or right side of label.

Fine gray lines on blank labels at angles.

Dirty head or ribbon rollers. See

Defective printhead elements. Call a service technician. Printhead needs balancing. Adjust toggle pressure and/or position.

Too much printhead pressure. Adjust toggle pressure and/or position.

Wrinkled ribbon. See

Printhead Cleaning

Maintenance.

Wrinkled Ribbon

in Preventive

in this table.

8-2 Zebra S-Series User’s Guide

SYMPTOM DIAGNOSIS ACTION

Truncated print, no print, or FEED button operates incor- rectly while using non- continuous media.

Media or ribbon improperly loaded.

See

Media Loading

ing

instructions in Installation.

and

Ribbon Load-

Long tracks of missing print on several labels.

In Peel-Off Mode, skewed or stuck labels.

Wrinkled ribbon. Ribbon fed through machine

Continued wrinkled ribbon. Strip plate needs adjusting. Call a service technician. Misregistration and misprint of

1 to 3 labels.

Wrinkled ribbon. See Print element damaged. Call a service technician. Glue material from back of la-

bels causing media movement problems.

Media and backing not prop- erly aligned in printer.

incorrectly. Incorrect Darkness setting. Set to the lowest value needed for good

Incorrect printhead position or pressure.

Media not feeding properly; it is walking from side to side.

Continuing symptoms. Call a service technician.

Media was pulled when motor was not moving.

Incorrect Media Sensor posi- tion.

Wrinkled Ribbon

Refer to Preventive Maintenance and perform maintenance and cleaning of the printer.

Refer to Installation.

See

Ribbon Loading

print quality. Adjust toggle pressure and/or position.

Make sure the media is snug by adjust- ing the media guides.

Enter Calibrate Mode and recalibrate.

See the media sensor position adjust- ments in Adjustments.

in this table.

in Installation.

Changes in parameter settings did not take effect.

Media or ribbon improperly loaded.

Incorrect Media Sensor position or sensitivity.

Parameters are set or saved in- correctly.

If problem continues, there may be a problem on the main logic board.

See

Media

and

Ribbon Loading

stallation. See Configuration and Calibration.

Reload the factory defaults. Refer to Operation and calibrate the printer. Then, cycle the power ON/OFF Switch.

Call a service technician.

in In-

Zebra S-Series User’s Guide 8-3

SYMPTOM DIAGNOSIS ACTION

ZPL II was sent to printer, but not recognized. The DATA light remains OFF.

Communications parameters or DIP switches are set incor- rectly.

See Operation and perform MODE Key Self Test. Check for format or overrun errors. Reset Communication parameters if needed.

Printer does not operate in the mode specified in ZPL II or by calibration

Printer does not feed media with black marks correctly.

In Cutter Mode, skewed or stuck labels.

The cutter is not cutting labels cleanly.

Prefix and delimiter characters set in printer configuration do not match the ones sent in the ZPL II label formats.

Bank 2 DIP switches set to override ZPL II and calibra- tion.

Printer not set up correctly. See Configuration and Calibration 

Sensor is broken. (No red light is visible when looking through the front of the printer with the printhead open.)

Cutter is dirty. Follow cutter module cleaning proce-

Cutter blades are dull. Replace the Cutter Module.

Set the characters in the printer to match ZPL II format. Check Configu- ration Label for correct characters. If problem continues, check the ZPL II format for changed

^CD

instructions.

Check Bank 2 DIP switch settings.

recalibrate printer. See Configuration and Calibration to

check Bank 2 DIP switch settings. Call a service technician.

dure in Preventive Maintenance.

^CC,^CT

, and

Labels jamming in cutter, or la- bels are being cut more than once.

Cutter is dirty. Follow cutter module cleaning proce-

dure in Preventive Maintenance.

Label length is too short. Increase label length.

8-4 Zebra S-Series User’s Guide

SYMPTOM DIAGNOSIS ACTION

For printers with the Cutter Option installed:

stops. PAPER/RIBBON, PAUSE, and CANCEL LEDs on.

Printing

Media jammed in Cutter. Remove media, clean Cutter Module. Connecting cable not con-

nected to Cutter Module. Cutter Module is dirty. Clean Cutter Module.

Plug cable into Cutter Module.

End of the media is not posi- tioned correctly on top of the platen.

Re-position media so that the end is on top of the platen.

Zebra S-Series User’s Guide 8-5

Peel-Off

Your printer may be equipped with the Peel-Off option. In the Peel-Off Mode, only the label backing rewinds onto the Rewind Spindle. The Peel/Tear Bar separates the label from the backing and the Label Available Sensor activates the PAUSE mode to allow the operator to remove a printed label before subsequent labels print.

This option cannot be added to a printer equipped with the optional Cutter.

Cutter Module

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.

Media Rewind

Your printer may be equipped with a Media Rewind Option. This option

supports both the Rewind and Peel-Off modes of operation.

Options

In Rewind mode, both labels and backing material rewind internally onto a user-supplied three-inch 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.

(SeePeel-OffOptionforPeel-Offmodeofoperation.)

Zebra S-Series User’s Guide 9-1

Fanfold Supply Bin

Your printer may be equipped with an optional internal Fanfold Supply Bin. It is used to load fanfold media within the media compartment, and it protects the media from environmental contaminants such as dust and dirt.

The Fanfold Media Supply Bin is fully adjustable. It accommodates media from 1.57" (40 mm) to 3.54" (90 mm) wide (7.17" [183 mm] wide for the 160S) and 3.5" (89 mm) to 8" (203mm) long. The maximum stack height for 8" long media is 4.5". Stack heights of 6.5" 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).

External ZebraNet™ (Ethernet) Interface

Allows you to connect your printer to your ethernet network. Available for both 10Base-2 and 10Base-T networks.

Black Mark (Reflective) Sensor (105Se Only)

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.

9-2 Zebra S-Series User’s Guide

Optional Printer Fonts

The S-Series Printer can be optioned with character fonts in addition to those which are standard in the unit.

Only one additional font can be installed in the printer at a time. This installation should be performed by a service technician. Once installed, this font can be used in addition to the standard fonts available in the printer. Refer to the ZPL II Programming Guide for further application information.

Once an optional font is installed in the printer, the Configuration printout from the CANCEL Key Self Test will indicate 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™, CG Palacio™, Futura™, Univers

The following Bitmap Smooth Fonts (supplied in bold style only) are presently available:

CG Triumvirate™ Bold, CG Triumvirate™ Bold Condensed, Futura™ Bold, Univers

Bold, CG Times™Bold and CG Palacio™ Bold (type sizes of 6 pt, 8 pt, 10 pt, 12 pt, 14 pt, 18 pt, 24 pt, 30 pt, 36 pt are available.)

Examples of these optional fonts can be found in “Appendix D.”

230 VAC Factory Setup

Your Zebra S-Series Printer will be 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 “Installation.”

Zebra S-Series User’s Guide 9-3

512 KB DRAM Memory Expansion (Not available for 105Se

300 dots/inch)

This option increases the printer’s dynamic memory capacity from 0.5 MB to 1 MB. This supports longer label lengths and provides more capacity for downloadable fonts and large graphic image files. Extra memory may be installed at the factory or in the field.

12-Dot/mm and 6-Dot/mm Printhead (105Se 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.

9-4 Zebra S-Series User’s Guide

Appendix A - 230 VAC Power Cord

230 VAC Power Cord

Depending on how the Zebra printer was ordered, a power cord may or may not be included when the printer is optioned for 230 VAC, 50/60 Hz operation.

If a power cord is not supplied, you will need to obtain one with the following specifications:

The overall length must be less than 3.8 meters.

•

It must be rated for at least 5 amps, 250 V.

•

The CHASSIS GROUND (EARTH) MUST BE CONNECTED to

•

assure safety and reduce electromagnetic interference. This is done by the third wire in the power cord.

The plug cap should bear the certification mark of a known interna-

•

tional safety organization (see Figure A.2).

Figure A.1 AC Power Cord

Figure A.2 International Safety Organizations

Zebra S-Series User’s Guide A-1

Appendix B - ASCII Code Chart

HEX CHAR HEX CHAR HEX CHAR HEX CHAR

00 NUL 20 space 40 @ 60  01 SOH 21 ! 41 A 61 a 02 STX 22  42 B 62 b 03 ETX 23 # 43 C 63 c 04 EOT 24 $ 44 D 64 d 05 ENQ 25 % 45 E 65 e 06 ACK 26 & 46 F 66 f 07 BEL 27  47 G 67 g 08 BS 28 ( 48 H 68 h

09 HT 29 ) 49 I 69 i 0A LF 2A * 4A J 6A j 0B VT 2B + 4B K 6B k 0C FF 2C , 4C L 6C l 0D CR 2D - 4D M 6D m 0E SO 2E . 4E N 6E n

0F SI 2F / 4F O 6F o

10 DLE 30 0 50 P 70 p

11 DC1 31 1 51 Q 71 q

12 DC2 32 2 52 R 72 r

13 DC3 33 3 53 S 73 s

14 DC4 34 4 54 T 74 t

15 NAK 35 5 55 U 75 u

16 SYN 36 6 56 V 76 v

17 ETB 37 7 57 W 77 w

18 CAN 38 8 58 X 78 x

19 EM 39 9 59 Y 79 y 1A SUB 3A : 5A Z 7A z 1B ESC 3B ; 5B 1C FS 3C < 5C \ 7C | 1D GS 3D = 5D 1E RS 3E > 5E ^ 7E ~

1F US 3F ? 5F

[

]

7B {

7D }

7F DEL

Shaded values are NOT recommended for Command Prefix, Format Prefix, or Delimiter characters.

Zebra S-Series User’s Guide B-1

Appendix C - Adjusting Bar Code Darkness

Adjusting Darkness For “In-Spec” Bar Codes

All direct thermal and thermal transfer materials do not use the same darkness setting. The best way to check for the proper darkness is to use a bar code verifier that actually measures bars/spaces and will calculate the Print Contrast Signal (PCS) ratio. Without the assistance of a verifier, your eyes and/or the scanner to be used in the system may be used for picking the optimum darkness setting. 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 in “Installation.” Ensure that the proper print method has been selected.

2. With power off, press and hold the FEED key.

3. Turn the printer power on, then release the FEED key. The printer begins printing test labels.

4. Print a label, then press the PAUSE key. The label will contain 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.ComparethetestlabelprintedtothebarcodesinFigureC.1.Ifthetest 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.

Zebra S-Series User’s Guide C-1

Too Dark - Dark labels are fairly obvious. The normal bar code bars

increase in size, and the openings in small alphanumeric characters may fill in with ink. It may be readable but not “in-spec”. Rotated bar code bars and spaces will run together.

Slightly Dark

code will be “in-spec”. Small character alphanumerics will be 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 dark for “in-spec” bar codes. Both normal and rotated bar codes will be “in-spec”, but small alphanumeric characters may not be complete.

Too Light

codes have incomplete bars and spaces. Small alphanumeric characters are unreadable.

In-Spec

but it should exhibit some very visible characteristics. The normal bar code will have complete, even bars and clear, distinct spaces. The rotated bar code will also have complete bars and clear distinct spaces. Although it may not look as good as a slightly dark bar code, it will be “in-spec”. In both normal and rotated styles, small alphanumeric characters will look complete.

- Slightly dark labels are not as obvious. The normal bar

- Slightly light labels are, in some cases, preferred to

- Light labels are obvious. Both normal and rotated bar

- The “in-spec” bar code can only be confirmed by a verifier,

C-2 Zebra S-Series User’s Guide

Figure C.1 Bar Code Examples

Zebra S-Series User’s Guide C-3

Appendix D - Optional Printer Fonts

Your printer can be optioned with character fonts in addition to those that are standard in the unit. The following pages illustrate the Optional Fonts in each of the available styles. From time to time, additions may be made to the list of available fonts. Contact Zebra Technologies Corporation or your sales representative for further information.

Once an optional font is installed in the printer, the configuration label printed during the CANCEL Key Self Test will indicate the font type as the “Socket 2 ID”.

Optional Printer Fonts Currently Available

Scalable Smooth Fonts (each is supplied as a complete set of Normal, Bold, Italic, and Bold Italic styles)

Bitmap Smooth Fonts (supplied only in Bold). Type sizes: 6 pt, 8 pt, 10 pt, 12 pt, 14 pt, 18 pt, 24 pt.

CG Triumvirate CG Triumvirate - CG Triumvirate Condensed* CG Times CG Times CG Palacio CG Palacio Futura Futura Univers

*When equipped with the Bitmap CG Triumvirate™ Bold Condensed font, the 105Se and

160S have the same font styles as the Stripe

Univers

S-300 printer.

Zebra S-Series User’s Guide D-1

CG Triumvirate™ - Normal 0123456789.,?!AaBbCc

CG Triumvirate™ - Bold 0123456789.,?!AaBbCcDd

CG Triumvirate™ - Italic 0123456789.,?!AaBbCcDdEe

CG Triumvirate™ - Bold Italic 0123456789.,?!AaBb

CG Times™ - Normal 0123456789.,?!AaBbCcDdEeFfGg

CG Times™ - Bold 0123456789.,?!AaBbCcDdEeFfGgHh

CG Times™ - Italic 0123456789.,?!AaBbCcDdEeFfGgHhIi

CG Times™ - Bold Italic 0123456789.,?!AaBbCcDdEeFf

CG Palacio™ - Normal 0123456789.,?!AaBbCcDdEeFf

CG Palacio™ - Bold 0123456789.,?!AaBbCcDdEeFfGg

CG Palacio™ - Italic 0123456789.,?!AaBbCcDdEeFfGg

CG Palacio™ - Bold Italic 0123456789.,?!AaBbCcDdEe

CG Futura - Normal 0123456789.,?!AaBbCcDd

CG Futura - Bold 0123456789.,?!AaBbCcDdEe

CG Futura - Italic 0123456789.,?!AaBbCcDdEeFf

CG Futura - Bold Italic 0123456789.,?!AaBbCc

Univers® - Normal 0123456789.,?!AaBbCcDdEeFf

Univers® - Bold 0123456789.,?!AaBbCcDdEeFfGgHh

Univers® - Italic 0123456789.,?!AaBbCcDdEeFfGgHh

Figure D.1 Scalable Smooth Fonts (Optional)

CG Triumvirate™ - Bold 0123456789.,?!AaBbCcDd

CG Triumvirate™ Condensed - Bold 0123456789.,?!AaBb

CG Futura - Bold 0123456789.,?!AaBbCcDdEe

Univers® - Bold 0123456789.,?!AaBbCcDdEeFfGgHh

CG Times™ - Bold 0123456789.,?!AaBbCcDdEeFfGgHh

CG Palacio™ - Bold 0123456789.,?!AaBbCcDdEeFfGg

Figure D.2 Bitmap Smooth Fonts (Optional)

D-2 Zebra S-Series User’s Guide

Figure D.3 Point Size Examples

Zebra S-Series User’s Guide D-3

Glossary

alphanumeric Indicating letters, numerals, and characters such as punctuation marks.

backfeed The printer pulls the media and ribbon (if used) backward into the printer so that the

beginning of the label to be printed is properly positioned behind the printhead. Backfeed occurs when you’re operating the printer in tear-off or peel-off mode.

bar code A code by which alphanumeric characters can be represented by a series of adjacent

stripes of different widths. Many different code schemes exist, such as the universal product code (UPC) or Code 39.

black mark sensing See “reflective media sensor”.

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 will be 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, but 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.

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. In-

stead, 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 (ex: 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.

Zebra S-Series User’s Guide Glossary - 1

label An adhesive-backed piece of paper, plastic, or other material on which information is

printed.

label available sensor For printers equipped with the Peel-Off Option, this sensor detects a

printed label waiting to be taken or “picked” by the operator. While it detects this label, the printer will not print additional labels. Once the label has been taken, printing resumes. Also called “take-label sensor”.

label backing (label liner) The material on which labels are affixed during manufacture and

which 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”.

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.

print speed The speed at which printing occurs. For thermal transfer printers, this speed is ex-

pressed 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.

Glossary - 2 Zebra S-Series User’s Guide

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.

tag A type of media having no adhesive backing but featuring a hole or notch by which the tag

can be hung on something. Usually tags are made of cardboard or other durable material.

take label sensor See “label available sensor”.

thermal direct printing See “direct thermal printing”.

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”.

transmissive media sensor This sensor is located behind the printhead to detect 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, it did not

occur. A void can cause a bar code symbol to be read incorrectly or not be read at all.

Zebra S-Series User’s Guide Glossary - 3

Zebra 105Se User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual