Zebra 105sl User Guide

Zebra 105

User Guide

SL

™

Customer order # 11342L Rev. 4
Manufacturer part # 11342LB Rev. 7

Proprietary Statement

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

Product Improvements

Continuous improvement of products is a policy of Zebra Technologies. 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 B digital device, pursuant to
Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a
residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions, may cause harmful interference to radio communications. However, there is
no guarantee that the interference will not occur in a particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and the receiver.

• Connect the equipment into an outlet on a circuit different than that to which the receiver is connected.

• Consult the dealer or an experienced Radio/TV technician for help.

NOTE: This unit was tested with shielded cables on the peripheral devices. Shielded cables must be used with the unit
to ensure compliance.

“The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies 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.

CE Compliance

If the accompanying printer displays the CE mark, it also meets EMC directive 89/336/EEC, with amendments
effective at the time of manufacture.

Liability Disclaimer

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

No Liability for Consequential Damage

In no event shall Zebra Technologies 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 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

This copyrighted manual and the label printers described herein are owned by ZIH Corp. All rights are reserved.
Unauthorized reproduction of this manual or the software in the label printer may result in imprisonment of up to one
year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability.

All products and brand names are trademarks of their respective companies. All rights reserved.

© 2003 ZIH Corp. All rights reserved.

ii Zebra 105SL User Guide

Zebra 105SL User Guide iii

iv Zebra 105SL User Guide

Table of Contents

List of Figures ...................................................... ix

Introduction ............................................................1

Hello! ......................................................................................................................1

Unpacking and Inspection .......................................................................................2

Reporting Damage .............................................................................................2

Storage ...............................................................................................................2

Media and Ribbon Requirements ............................................................................3

Power Cord .............................................................................................................3

Printer Anatomy 101 ...............................................................................................4

Calibrating the Printer ...........................................5

Purpose ....................................................................................................................5

Types of Media .......................................................................................................6

Non-Continuous Web Media .............................................................................6

Non-Continuous Black Mark Media .................................................................7

Continuous Media ..............................................................................................7

Choosing the Print Mode ........................................................................................8

Loading the Media ..................................................................................................9

Positioning the Media Sensors ..............................................................................10

Transmissive Sensor ........................................................................................10

Black Mark Sensor ..........................................................................................12

Loading the Ribbon ...............................................................................................13

Operator Controls ..................................................................................................14

POWER Switch ...............................................................................................14

Front Panel .......................................................................................................14

Configuring the Printer .........................................................................................15

Configuring the Software or Printer Driver ..........................................................16

Media and Ribbon Calibration ..............................................................................17

Printing a Test Label .............................................................................................19

Zebra 105SL User Guide v

Establishing Communication ..............................21

System Considerations ......................................................................................... 21

Interfaces ......................................................................................................... 21

Data Specifications .......................................................................................... 21

Cabling Requirements .......................................................................................... 23

Printer Basics ........................................................25

Operator Controls ................................................................................................. 25

POWER Switch ............................................................................................... 25

Front Panel Display ......................................................................................... 26

Front Panel Keys ............................................................................................. 27

Front Panel Lights ........................................................................................... 28

Roll Media Loading .............................................................................................. 29

Tear-Off Mode ................................................................................................ 29

Peel-Off Mode ................................................................................................. 31

Rewind Mode .................................................................................................. 33

Cutter Mode ..................................................................................................... 35

Peel-Only Mode .............................................................................................. 36

Removing the Label Liner .................................................................................... 38

Fanfold Media Loading ........................................................................................ 39

Ribbon Loading .................................................................................................... 41

Ribbon Removal ................................................................................................... 43

Configuration .......................................................45

Entering Setup Mode ............................................................................................ 45

Changing Password-Protected Parameters ........................................................... 46

Leaving Setup Mode ............................................................................................. 47

Configuration and Calibration Sequence .............................................................. 48

Routine Care and Adjustment ..............................65

Cleaning ................................................................................................................ 65

Cleaning the Exterior ...................................................................................... 66

Cleaning the Interior ........................................................................................ 66

Cleaning the Printhead and Platen Roller ....................................................... 66

Cleaning the Sensors ....................................................................................... 68

Cleaning the Snap Plate ................................................................................... 68

Cleaning the Cutter Module ............................................................................ 70

Lubrication ........................................................................................................... 70

vi Zebra 105SL User Guide

Fuse Replacement .................................................................................................71

Adjustments ..........................................................................................................72

Toggle Positioning ...........................................................................................72

Printhead Pressure Adjustment ........................................................................73

Media Sensor Position Adjustment .................................................................73

Troubleshooting ....................................................75

LED Error Conditions and Warnings ...................................................................75

Print Quality Problems ..........................................................................................77

Wrinkled Ribbon ...................................................................................................79

Communications ...................................................................................................79

Printer Diagnostics ................................................................................................81

Power-On Self Test ..........................................................................................81

Additional Printer Self Tests ...........................................................................81

Specifications ........................................................87

Media Handling ....................................................................................................87

Options ..................................................................................................................87

ZPL Programming Language (ZPL II) .................................................................88

Bar Codes ..............................................................................................................88

General Specifications ..........................................................................................89

Printing Specifications ..........................................................................................90

Ribbon Specifications ...........................................................................................90

Font Specifications ..........................................................................................91

Media Specifications .............................................................................................92

Power Cord Specifications ....................................................................................93

Appendix A: DB-25 Connectors ............................95

Printer Interface Technical Information ................................................................95

RS-232/RS-422/RS-485 Serial Data Port ........................................................95

Parallel Data Port .............................................................................................99

Appendix B: DB-9 Connectors ...........................101

Printer Interface Technical Information ..............................................................101

RS-232 Serial Data Port .................................................................................101

Parallel Data Port ...........................................................................................106

Zebra 105SL User Guide vii

Appendix C: PCMCIA................................ Card 107

PCMCIA Card Installation ................................................................................. 107

Appendix D: Save-a-Printhead Cleaning Film ..109

Extend the Life of Your Printhead with ............................................................. 109

Save-a-Printhead Cleaning Film ......................................................................... 109

Recommended for all Zebra printers—especially 600 dpi printers .............. 109

Index ....................................................................115

Printer Software and Firmware License Agreement

Warranty Information

viii Zebra 105SL User Guide

List of Figures

Figure 1. Printer Overview ...............................................................................4

Figure 2. Non-Continuous Web Media .............................................................6

Figure 3. Non-Continuous Black Mark Media .................................................7

Figure 4. Continuous Media .............................................................................7

Figure 5. Media Loading ..................................................................................9

Figure 6. Upper Media Sensor Adjustment ....................................................11

Figure 7. Lower Media Sensor Adjustment ....................................................12

Figure 8. Ribbon Loading ...............................................................................13

Figure 9. Front Panel ......................................................................................14

Figure 10. Media and Ribbon Calibration ......................................................17

Figure 11. Test Label ......................................................................................19

Figure 12. DB-25 Serial Interface ...................................................................22

Figure 13. DB-9 Serial Interface .....................................................................22

Figure 14. Parallel Interface ............................................................................23

Figure 15. Front Panel ....................................................................................26

Figure 16. Tear-Off Mode Loading ................................................................30

Figure 17. Peel-Off Mode Loading .................................................................32

Figure 18. Rewind Mode Loading ..................................................................34

Figure 19. Cutter Mode Loading ....................................................................35

Figure 20. Peel-Only Mode Loading ..............................................................37

Figure 21. Fanfold Media Loading—Bottom Supply .....................................40

Figure 22. Fanfold Media Loading—Rear Supply .........................................40

Figure 23. Ribbon Loading .............................................................................42

Figure 24. Ribbon Hook Placement ................................................................42

Figure 25. Ribbon Removal ............................................................................43

Figure 26. Media Sensor Profile .....................................................................52

Figure 27. Head Resistance Value ..................................................................60

Figure 28. Printhead and Platen Roller Cleaning ...........................................67

Figure 29. Snap Plate Removal and Cleaning ................................................68

Zebra 105SL User Guide ix

Figure 30. Snap Plate Reinstallation ...............................................................69

Figure 31. Fuse Replacement ..........................................................................71

Figure 32. Toggle Adjustment ........................................................................72

Figure 33. Test Label ......................................................................................82

Figure 34. PAUSE Key Test Label .................................................................83

Figure 35. FEED Key Test Label ...................................................................84

Figure 36. Communications Test Label ..........................................................85

Figure 37. Power Cord ....................................................................................93

Figure 38. International Safety Organization Symbols ...................................93

Figure 39. RS-232 Connections ......................................................................96

Figure 40. 9-Pin Serial Port Connections .......................................................97

Figure 41. RS-232 Cable Connections ...........................................................97

Figure 42. DB-25 RS-422/RS-485 Connections .............................................98

Figure 43. RS-422/RS-485 Connections ........................................................98

Figure 44. RS-232 Connections ....................................................................102

Figure 45. RS-232 Cable Connections .........................................................103

Figure 46. DB-9 to DB-25 Connections .......................................................104

Figure 47. DB-25 Adapter Connections .......................................................105

Figure 48. PCMCIA Card Installation ..........................................................108

xZebra 105SL User Guide

Hello!

Introduction

Thank you for purchasing this high-quality Zebra 105SL™ printer,
manufactured by the industry leader in quality, service, and value—
Zebra Technologies. For over 30 years, Zebra has provided customers the
highest caliber of products and support.

• This manual provides all of the information you need to operate your
printer.

•The ZPL II
and II (part number 45540L) show you how to create the perfect label
format for your application. The guide also explains how ZBI™ extends
the power of ZPL II by allowing custom programs to be written that
operate within the printer, directly interfacing with, for example, bar
code scanners and keyboard display devices. The guide also contains
information about the enhanced operating system features of your
printer. There are three ways to obtain these books: on the accessory
CD-ROM (supplied with the printer), on our Web site
(www.zebra.com

• The ZebraNet
Guide (part number 45537L) explains how you can quickly set up your
printer on an IP network and experience ZebraLink™, our revolutionary
real-time connectivity and control solution for Zebra printers (optional
ZebraNet

®

Programming Reference Volumes I (part number 5541L)

), or by ordering printed manuals from your distributor.

®

Networking: PrintServer II™ User and Reference

PrintServer II required).

• The maintenance manual for your printer (part number 32056L)
contains the information you need to maintain your printer.

Zebra 105SL User Guide 1

Introduction

Unpacking and Inspection

Carefully unpack and inspect the printer for damage:

• Check all exterior surfaces.

• Raise the media access door and inspect the media compartment.

Save the carton and all packing material in case the printer needs to be
shipped. Contact your authorized Zebra reseller for instructions.

Reporting Damage

If you discover shipping damage:

• Immediately notify the shipping company and file a report with them.

Zebra Technologies is not responsible for any damage incurred during
shipment of the equipment and will not repair this damage under
warranty.

• Keep the carton and all packing material for inspection.

• Notify your authorized Zebra reseller.

Storage

If you are not placing the printer into operation immediately, repackage it
using the original packing materials. The printer may be stored under the
following conditions:

• Temperature: –40° to +140° F (–40° to +60° C)

• Relative humidity: 5% to 85% non-condensing

2Zebra 105SL User Guide

Media and Ribbon Requirements

Since print quality is affected by media and ribbon, printing speeds, and
printer operating modes, it is very important to run tests for your
applications.

We strongly recommend using Zebra Technologies-brand supplies for
continuous high-quality printing. A wide range of paper, polypropylene,
polyester, and vinyl stock has been specifically engineered to enhance the
printing capabilities of the printer and to ensure against premature
printhead wear.

• Continuous roll media, fanfold media, or card stock with optional
perforations and registration holes may be used.

• Printhead life may be reduced by the abrasion of exposed paper fibers
when using perforated media.

• The ribbon must be as wide as or wider than the media being used. If
the ribbon is narrower than the media, areas of the printhead are
unprotected and subject to premature wear. (When printing in direct
thermal mode, ribbon is not used and should not be loaded in the
printer.)

Introduction

Power Cord

CAUTION: For personnel and equipment safety, always
use a three-prong plug with a ground (earth) connection.

NOTE: Depending on how your printer was ordered, a
power cord may or may not be included. If one is not
included, or if the one included is not suitable for your
requirements, refer to “Power Cord Specifications” on

page 93.

The power cord connector must be plugged into the mating connector on
the rear of the printer. Make sure that the POWER on/off switch (located at
the back of the printer) is in the “off” (O) position before connecting the
power cable to an electrical outlet.

Zebra 105SL User Guide 3

Introduction

Printer Anatomy 101

Figure 1 outlines the basic components of your printer. Depending on the

installed options, your printer may look slightly different.

Figure 1. Printer Overview

4Zebra 105SL User Guide

Purpose

• To calibrate the printer.

• To verify that the printer is properly set up by printing a test label.

To calibrate the printer, you must perform the following procedures:

• Determine the type of media (labels) being used.

• Choose the print method.

• Position the media sensors (if necessary).

• Configure the printer and software or driver based on the label being

• Perform a media and ribbon calibration.

•Print a test label.

Calibrating the Printer

NOTE: This procedure must be performed when the printer is first
installed or if it cannot properly detect the top of the label.

used.

Zebra 105SL User Guide 5

Calibrating the Printer

Types of Media

Non-Continuous Web Media

Non-continuous web media (refer to Figure 2) refers to individual labels
that are separated by a gap, notch, or hole. When you look at the media,
you can tell where one label ends and the next one begins.

Figure 2. Non-Continuous Web Media

6 Zebra 105SL User Guide

Non-Continuous Black Mark Media

Non-continuous black mark media has black marks printed on the back of
the liner material that indicate the start and end of each label (refer to

Figure 3).

Figure 3. Non-Continuous Black Mark Media

Continuous Media

Continuous media (refer to Figure 4) is one uninterrupted roll of material
that allows the image to be printed anywhere on the label.

Calibrating the Printer

Figure 4. Continuous Media

Zebra 105SL User Guide 7

Calibrating the Printer

Choosing the Print Mode

•In Tear-Off Mode, each label (or a strip of labels) can be torn off after it
is printed.

•In Peel-Off Mode, backing material is peeled away from the label as it
is printed. After this label is removed from the printer, the next one is
printed.

•In Cutter Mode, the printer automatically cuts the label after a specified
length has been printed.

•In Rewind Mode, the media and liner are rewound onto a core as the
labels are printed.

8 Zebra 105SL User Guide

Loading the Media

Figure 5 illustrates one method of media loading. For more detailed

instructions, as well as information about how to load the different types of
media and the various printing modes, refer to the instructions that begin
on page 29.

Calibrating the Printer

Figure 5. Media Loading

Zebra 105SL User Guide 9

Calibrating the Printer

Positioning the Media Sensors

The correct positioning of the media sensors is important—it can make the
difference between a perfect label and a call to Technical Support!

Transmissive Sensor

The web or gap sensor, also known as the “transmissive sensor,” detects
the gap between labels.

The transmissive sensor actually consists of two sections: a light source
(the lower media sensor) and a light sensor (the upper media sensor). The
media passes between the two.

The upper media sensor must be positioned:

• Directly over the hole or notch, or

• Anywhere along the width of the media if there is a gap between labels.

NOTE: If you are using continuous media, position the upper
media sensor over the media with the lower media sensor directly
below it so that the printer can detect an out-of-paper condition.

10 Zebra 105SL User Guide

Adjusting the Upper Media Sensor

Refer to Figure 6. (For clarity, not all printer parts are shown.)

1. Remove the ribbon (if it is installed). Refer to page 43 for details.

2. Locate the upper media sensor. The upper media sensor “eye” is
directly below the adjustment screw head.

3. Slightly loosen the upper media sensor adjustment screw (use a
Phillips-head screwdriver).

4. Using the tip of the screwdriver, slide the upper sensor along the slot
to the desired position.

5. Tighten the upper media sensor adjustment screw.

Calibrating the Printer

Figure 6. Upper Media Sensor Adjustment

Zebra 105SL User Guide 11

Calibrating the Printer

Adjusting the Lower Media Sensor

Refer to Figure 7. Position the lower media sensor by sliding it in its slot
until the lower media sensor (light source) is positioned directly below the
upper media sensor.

Figure 7. Lower Media Sensor Adjustment

Black Mark Sensor

The optional black mark sensor is in a fixed position and enabled via the
front panel (refer to “Configuring the Printer” on page 15 for details).

12 Zebra 105SL User Guide

Loading the Ribbon

Figure 8 illustrates the ribbon path. For more detailed information, refer to

the instructions that begin on page 41.

Calibrating the Printer

Figure 8. Ribbon Loading

Zebra 105SL User Guide 13

Calibrating the Printer

Operator Controls

POWER Switch

The POWER switch is located at the back of the printer above the power
cord connector. Turn on the printer (l).

Front Panel

The step-by-step instructions in this section
tell you which keys to press and what
appears on the liquid crystal display (LCD)
during the calibration procedure.

For a more detailed explanation of the front
panel keys and lights (shown in Figure 9),
refer to the instructions that begin on

page 26.

Figure 9. Front Panel

14 Zebra 105SL User Guide

Configuring the Printer

The configuration procedure in the following table contains the
information you need to get your printer up and running, but it is not
comprehensive. Refer to page 48 for more information.

• Enter Setup Mode by pressing SETUP/EXIT at the “PRINTER

READY” display.

NOTE: You need to press NEXT/SAVE more than once to
advance to or skip some of the displays.

• To increase the value, answer “yes,” indicate “on,” or move to

the next selection, use the (+) key.

• To decrease the value, answer “no,” indicate “off,” or return to

the previous selection, use the (–) key.

NOTE: When changing parameters, an asterisk (*) in the upper
left-hand corner of the LCD indicates that you have changed this
setting from the one that is stored currently in memory.

Calibrating the Printer

Zebra 105SL User Guide 15

Calibrating the Printer

Press LCD Shows Action/Explanation

— PRINTER READY Normal printer operation.

DARKNESS

PRINT MODE

MEDIA TYPE

SENSOR TYPE

PRINT METHOD

MAXIMUM
LENGTH

SAVE CHANGES

Press the (+) or (–) keys to increase or decrease the print
darkness setting. (You may need to change this setting when
you print your label.)

Press the (+) or (–) keys to select Tear-Off, Peel-Off, Cutter, or
Rewind Mode.

Press the (+) or (–) keys to select continuous or non-continuous
media type. (If you choose continuous media, you must also
include a label length instruction in your label format.)

Press the (+) or (–) keys to select transmissive or black mark
sensing mode. Unless your media has black marks on the back,
leave your printer at the default setting (web).

Press the (+) or (–) keys to select thermal transfer (if you are
using ribbon) or direct thermal (no ribbon).

Press the (+) or (–) keys to set the value that is closest to, but
not less than, the length of the label you are using.

Press the (+) or (–) keys to select:
PERMANENT—keeps changes saved to memory after the
power is turned off.
Press NEXT/SAVE to accept the selection.

— PRINTER READY You have exited Setup Mode and are ready to calibrate the

printer.

Configuring the Software or Printer Driver

Many printer settings may also be controlled by your printer’s driver or
label preparation software, which may override any settings you have
made manually through the front panel. Please refer to the driver or
software documentation for more information.

16 Zebra 105SL User Guide

Media and Ribbon Calibration

Initially, you may want to try autocalibrating the printer rather than
proceeding with the full calibration procedure described below. To
autocalibrate the printer:

1. Load the media and ribbon.

2. Close the printhead. The printer autocalibrates.

If the media fails to load or an error occurs, then perform the steps listed
below.

NOTE: All steps must be performed in the following procedure,
even if only one sensor needs to be adjusted.

1. Press SETUP/EXIT.

2. Press NEXT/SAVE until “MEDIA AND RIBBON CALIBRATE”
displays.

3. Press the (+) key to start the calibration sequence. “LOAD BACKING
CANCEL CONTINUE” displays.

Calibrating the Printer

4. Open the printhead. Remove approximately 8 in. (200 mm) of labels
from the media roll, enough so that only the liner is threaded between
the media sensors when the media is loaded
(refer to Figure 10).

Figure 10. Media and Ribbon Calibration

Zebra 105SL User Guide 17

Calibrating the Printer

5. Press the (+) key. The LCD shows “REMOVE RIBBON CANCEL
CONTINUE.”

6. Slide the ribbon as far from the printer frame as possible.

7. Close the printhead, trapping the ribbon in this position.

8. Press the (+) key. The LCD shows “CALIBRATING PLEASE WAIT.”

9. When this part of the calibration process is completed, the LCD reads
“RELOAD ALL CONTINUE.”

10. Open the printhead. Pull the liner until a label is positioned between
the media sensors.

11. Return the ribbon to its proper position.

12. Close the printhead. Press the (+) key to perform the next part of the
calibration sequence. “MEDIA AND RIBBON CALIBRATE”
displays. The printer is calibrated when the media stops feeding.

13. Press SETUP/EXIT to leave Setup Mode. Choose “permanent” when
SAVE CHANGES displays.

14. Press NEXT/SAVE to save the changes.

18 Zebra 105SL User Guide

Printing a Test Label

To print a test label:

1. Turn off the printer (O).

2. Press and hold CANCEL while

turning on the printer.

A configuration label prints showing
the printer’s currently stored
parameters (similar to the one shown
in Figure 11).

If you encounter any problems while
you are configuring or calibrating the
printer or printing a test label, refer to
“LED Error Conditions and

Warn in gs” beginning on page 75.

Otherwise, refer to “Establishing

Communication” beginning on
page 21 to set up the communication

parameters.

Calibrating the Printer

Figure 11. Test Label

Zebra 105SL User Guide 19

Calibrating the Printer

20 Zebra 105SL User Guide

Establishing Communication

System Considerations

NOTE: Depending on the date of manufacture, your Zebra 105SL
printer may be equipped with either a DB-25 serial connector or a
DB-9 serial connector.

Interfaces

The method of interfacing this printer to a data source depends on the
communication options installed in the printer. Following are the standard
interfaces for a DB-25 and a DB-9 serial interface connector:

Serial Connector Standard Interfaces

DB-25 • RS-232/RS-422/RS-485 serial data port

• Bidirectional parallel port

DB-9 • RS-232 serial data port

• Bidirectional parallel port

The optional ZebraNet PrintServer II enables printers to be connected to
10Base-T Ethernet networks. In addition, the IBM
option is available for those applications that require them.

NOTE: If you have the DB-9 serial interface connector, RS-422
and RS-485 serial data ports are available through an adapter.
Contact your Zebra distributor for details.

®

Twinax or IBM Coax

Data Specifications

When communicating via an asynchronous serial data port (refer to

Figure 12 for a DB-25 serial interface connector and Figure 13 for a DB-9

serial interface connector), the baud rate, number of data and stop bits,
parity, and handshaking are user selectable. Parity applies only to data
transmitted by the printer since the parity of received data is ignored.

Zebra 105SL User Guide 21

Establishing Communication

Figure 12. DB-25 Serial Interface

Figure 13. DB-9 Serial Interface

22 Zebra 105SL User Guide

Establishing Communication

When communicating via the
parallel port (refer to

Figure 14), the previously

mentioned parameters are not
considered. Refer to page 54 to
configure the communication
parameters for the printer. The
values selected must be the
same as those used by the host
equipment connected to the
printer.

For serial and parallel pinout
and technical information, refer
to “Appendix A: DB-25

Connectors” on page 95 or
“Appendix B: DB-9
Connectors” on page 101.

Figure 14. Parallel Interface

Cabling Requirements

Data cables must be fully shielded and fitted with metal or metallized
connector shells. Shielded cables and connectors are required to prevent
radiation and reception of electrical noise.

To minimize electrical noise pickup in the cable:

• Keep data cables as short as possible.

• Do not bundle the data cables tightly with the power cords.

• Do not tie the data cables to power wire conduits.

NOTE: Zebra printers comply with FCC “Rules and Regulations,”
Part 15, Subpart J, for Class B Equipment, using fully shielded
6 ft. (1.8 m) data cables. Use of longer cables or unshielded cables
may increase radiated emissions above the Class B limits.
RS-422 and RS-485 applications should use twisted shielded pairs

as recommended in the Appendix of the TIA/EIA RS-485
Specification.

Zebra 105SL User Guide 23

Establishing Communication

24 Zebra 105SL User Guide

Operator Controls

This section discusses the functions of the controls and indicators on the
printer. Become familiar with each of these functions before operating
your 105SL printer.

POWER Switch

This switch is located at the back of the printer above the power cord. The
POWER switch should be turned off (O) before connecting or
disconnecting any cables.

External influences, such as lightning storms or noise on the power or data
cables, may cause erratic printer behavior. Turning the printer’s power off
and then back on may re-establish proper printer operation.

Printer Basics

Zebra 105SL User Guide 25

Printer Basics

Front Panel Display

The front panel display (shown in Figure 15) communicates operational
status and setup modes and parameters.

Figure 15. Front Panel

26 Zebra 105SL User Guide

Printer Basics

Front Panel Keys

Key Function

Starts and stops the printing process.

• If the printer is not printing: no printing can occur.

• If the printer is printing: printing stops once the current label is complete.
Press to remove error messages from the LCD.
NOTE: Pause Mode can also be activated via ZPL II (~PP, ^PP).

Forces the printer to feed one blank label each time the key is pressed.

• Printer not printing: one blank label immediately feeds.

• Printing: one blank label feeds after the current batch of labels is complete.
NOTE: Equivalent to the Slew to Home Position (~PH, ^PH) ZPL II instruction.

When in Pause Mode, this key cancels print jobs.

• Print job in queue: press once for each print job to be deleted.

• Press and hold for several seconds to cancel all print jobs in the printer ’s memory.
The DATA light turns off.

NOTE: The keys below are used only when configuring the printer. Specific uses of these keys

are explained in “Configuration,” beginning on page 45.

• Scrolls back to the previous parameter.

•Press and hold to go backward quickly through parameter sets.

• Scrolls forward to the next parameter. (Saves any changes you have made in the
configuration and calibration sequence.)

•Press and hold to advance quickly through parameter sets.

Enters and exits Setup Mode.

These keys change the parameter values. They are used in different ways
depending on the parameter displayed. Common uses are: to increase/decrease a
value; answer “yes” or “no;” indicate “on” or “off;” scroll through several choices;
input the password; or set up the printer for a firmware download.

Zebra 105SL User Guide 27

Printer Basics

Front Panel Lights

NOTE: If two operating conditions occur simultaneously
(for example, one that causes a light to be on constantly and
one that causes the same light to flash), the light flashes.

Light Status Indication

POWER

Off The printer is off or power is not applied.

On The printer is on.

TAKE LABEL

ERROR

CHECK RIBBON

PAPER OUT

PAU SE

DATA

Off Normal operation.

Flashing (Peel-Off Mode only.) The label is available. Printing is paused until

the label is removed.

Off Normal operation—no printer errors.

Flashing A printer error exists. Check the LCD for more information.

Off Normal operation—ribbon (if used) is properly loaded.

On Printing is paused, the LCD displays a warning message, and the

PAUSE light is on.

• If the printer is in Direct Thermal Mode: ribbon is loaded.

• If the printer is in Thermal Transfer Mode: no ribbon is loaded.

Off Normal operation—media is properly loaded.

On No media is under the media sensor. Printing is paused, the LCD

shows an error message, and the PAUSE light is on.

Off Normal operation.

On The printer has stopped all printing operations. Either PAUSE was

pressed, a pause command was included in the label format, the
online verifier detected an error, or a printer error was detected.
Refer to the LCD for more information.

Off Normal operation. No data being received or processed.

On Data processing or printing is taking place. No data is being

received.

Flashing The printer is receiving data from or sending status information to

the host computer. Flashing slows when the printer cannot accept
more data, but returns to normal once data is again being received.

28 Zebra 105SL User Guide

Roll Media Loading

NOTE: A calibration must be performed with all loading
modes during the following circumstances if the printer is
set to Feed or No Motion at power up or head close:

• When media and ribbon (if used) are first installed
in the printer.

• When media or ribbon is changed to a different
type.

Tear-Off Mode

Refer to Figure 16.

1. Open the printhead.

2. Slide the media guide and media supply guide as far from the printer
frame as possible.

3. Load media as shown.

Printer Basics

4. Slide in the media guide and media supply guide so they just touch,
but do not restrict, the edge of the roll.

5. Close the printhead.

Zebra 105SL User Guide 29

Printer Basics

Figure 16. Tear-Off Mode Loading

30 Zebra 105SL User Guide

Peel-Off Mode

Refer to Figure 17.

1. Remove the rewind plate from the front of the printer (if installed).
Store it upside down on the two mounting screws on the inside of the
front panel.

2. Open the printhead.

3. Slide the media guide and media supply guide as far from the printer
frame as possible.

4. Load media as shown.

5. When loading media, allow approximately 36 in. (915 mm) of media
to extend past the tear-off bar. Remove all labels from this portion to
create a leader.

6. Remove the hook from the rewind spindle. If you are using a core,
slide it onto the rewind spindle until it is flush against the guide plate.

Printer Basics

NOTE: The following instructions pertain to printers with
the rewind option only.

7. Wind the label liner around either the 3 in. (76.2 mm) core or the
rewind spindle and reinstall the hook.

8. Slide in the media guide and media supply guide so they just touch,
but do not restrict, the edge of the roll.

NOTE: Before closing the printhead, make sure:

• the media is positioned against the inside guides.

• the media is taut and parallel with itself and the
pathway when wound onto the rewind spindle/
core.

9. Close the printhead.

10. To discard the label liner from the rewind spindle, refer to “Removing

the Label Liner” on page 38.

Zebra 105SL User Guide 31

Printer Basics

Label

Printhead Lever

Open

Label

Liner

Closed

Tear-off

Rewind

Plate

Bar

Hook

Media
Guide

Figure 17. Peel-Off Mode Loading

Guide

Plate

Rewind
Spindle

Media

Supply

Guide

Media

32 Zebra 105SL User Guide

Rewind Mode

Refer to Figure 18.

1. Remove the rewind plate from its storage location in front of the print

2. Invert the rewind plate so that the lip on the attached hook plate points

3. Insert the hook plate lip a short distance (½ in. or 13 mm) into the

4. Align the upper end of the rewind plate with the corresponding

5. Open the printhead.

6. Slide the media guide and media supply guide as far from the printer

Printer Basics

NOTE: The following instructions pertain to printers with
the rewind option only.

mechanism inside the media compartment.

down.

lower opening in the side plate.

opening in the side plate. Slide in the rewind plate so that it stops
against the printer’s main frame.

frame as possible.

7. Load media as shown.

8. When loading media, allow approximately 36 in. (915 mm) of media
to extend past the printhead. Remove all labels from this portion to
create a leader.

9. Remove the hook from the rewind spindle. If you are using a core,
slide it onto the rewind spindle until it is flush against the guide plate.

10. Wind the label liner around either the 3 in. (76.2 mm) core or the
rewind spindle and reinstall the hook.

11. Slide in the media guide and media supply guide so they just touch,
but do not restrict, the edge of the roll.

Zebra 105SL User Guide 33

Printer Basics

NOTE: Before closing the printhead, make sure:

• The media is positioned against the inside guides.

• The media is taut and parallel with itself and the
pathway when wound onto the rewind spindle or
core.

12. Close the printhead.

Figure 18. Rewind Mode Loading

34 Zebra 105SL User Guide

Cutter Mode

Refer to Figure 19.

1. Open the printhead.

2. Slide the media guide and media supply guide as far from the printer

3. Load media as shown.

4. Slide in the media guide and media supply guide so they just touch,

5. Close the printhead.

6. The printer automatically feeds out and cuts one label when the printer

Printer Basics

NOTE: The following instructions pertain to printers with
the cutter option only.

frame as possible.

but do not restrict, the edge of the roll.

is turned on.

Figure 19. Cutter Mode Loading

Zebra 105SL User Guide 35

Printer Basics

Peel-Only Mode

Refer to Figure 20.

1. Press the printhead open lever. The printhead assembly springs up.

2. Slide out the media supply guide as far from the printer frame as
possible.

3. Place the roll of media on the media supply hanger and orient the
media properly.

4. Slide in the media supply guide so that it just touches, but does not
restrict, the edge of the roll.

5. Feed the media under the inner media guide in the print mechanism.

6. Pull approximately 36 in. (915 mm) of media through the front of the
printer.

NOTE: The following instructions pertain to printers with
the peel option only.

7. Ensure that the media is against the inner media guide. Slide in the
outer media guide so that it just touches, but does not restrict, the edge
of the media.

8. Close the printhead assembly.

NOTE: If your printer has a peel with a rewind option,
remove the rewind plate and store it upside down on the
mounting screw on the inside of the front panel before
proceeding to step 9.

9. Remove the hook from the take-up spindle shaft.

10. Remove several labels from the media liner and then wind the liner
1–2 times around the media take-up spindle and reinstall the hook.

36 Zebra 105SL User Guide

Figure 20. Peel-Only Mode Loading

Printer Basics

Zebra 105SL User Guide 37

Printer Basics

Removing the Label Liner

NOTE: Since the rewind spindle holds the liner from a
standard-size media roll, we recommend that you perform
this procedure whenever you change the media.

To remove the liner from the rewind spindle, follow these steps (you do
not need to turn off the printer for this procedure):

1. Unwind approximately 36 in. (915 mm) of liner from the rewind
spindle. Cut it off at the spindle.

2. Pull out the hook. Slide the liner off of the rewind spindle and discard.

3. Wind the media around the rewind spindle once or twice and reinstall
the hook. Continue winding to remove any slack in the media.

38 Zebra 105SL User Guide

Fanfold Media Loading

NOTE: A calibration must be performed when media and
ribbon (if used) are first installed in the printer, or when a
different type of media or ribbon is being used.

Fanfold media feeds through either the bottom or rear access slot from
outside the printer.

Refer to Figure 21 and Figure 22.

1. Open the printhead.

2. Slide the media guide as far from the printer frame as possible.

3. Load media as shown. If the printer is in Cutter Mode, route the media

through the cutter.

4. Slide in the media guide so it just touches, but does not restrict, the

edge of the roll.

5. Close the printhead.

Printer Basics

Zebra 105SL User Guide 39

Printer Basics

Figure 21. Fanfold Media Loading—Bottom Supply

Figure 22. Fanfold Media Loading—Rear Supply

40 Zebra 105SL User Guide

Ribbon Loading

To load ribbon, refer to Figure 23 and follow the procedure below.

NOTE: Always use ribbon that is at least as wide as the
media. The smooth liner of the ribbon protects the
printhead from wear and premature failure due to excessive
abrasion. (For direct thermal print mode, ribbon is not used
and should not be loaded in the printer.)

1. Align the segments of the ribbon supply spindle.

2. Place the ribbon roll on the ribbon supply spindle.

NOTE: 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 printhead entirely on the inside,
exposing print elements to potentially damaging contact
with the media

Printer Basics

3. To make ribbon loading and unloading easier, make a leader for your

ribbon roll if one is not present.

4. Tear off a strip of media (labels and

liner) about 6–12 in. (150–305 mm)
long from the roll. Peel off a label from
this strip. 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. Open the printhead and thread the leader and attached ribbon through

the print mechanism, under the upper roller, and past the platen roller
as shown.

6. Before wrapping the ribbon around the ribbon take-up spindle, ensure

the ribbon hook is placed correctly. The ribbon hook fits snugly in the
notch (see Figure 24).

Zebra 105SL User Guide 41

Printer Basics

7. Place the ribbon with leader around the ribbon take-up spindle and
wind counterclockwise for several turns (see Figure 23).

8. Close the printhead.

Figure 23. Ribbon Loading

Figure 24. Ribbon Hook Placement

42 Zebra 105SL User Guide

Ribbon Removal

Refer to Figure 25.

1. If the ribbon is not exhausted, cut or break it as close to the ribbon

take-up spindle as possible.

2. Push the hook either forward or backward with your thumb until it

slips out of the groove (1). Slide the hook to the side (2), then rotate it
back and forth several times to loosen it (3).

3. Remove the loosened hook from the spindle (4).

4. Lightly tap the top of the used ribbon to loosen it; grasp the used

ribbon and remove it from the ribbon take-up spindle.

5. Remove the core from the ribbon supply spindle.

6. Follow the ribbon loading procedure on page 41 to load the new

ribbon.

Printer Basics

Figure 25. Ribbon Removal

Zebra 105SL User Guide 43

Printer Basics

44 Zebra 105SL User Guide

Configuration

After you have installed the media and ribbon and the Power-On Self Test
(POST) is complete, the LCD shows “PRINTER READY.” (If the printer
fails its POST, refer to page 81.) Using the front panel display and the five
keys directly below it, set the printer parameters for your application.

NOTE: Printers that are operating on an IP network can be
quickly configured using ZebraNet WebView (optional
ZebraNet PrintServer II required). For information, refer to
PrintServer II ™ Installation and Users Guide (part
number 48152L).

If it becomes necessary to restore the initial printer
defaults, see “FEED Key and PAUSE Key Self Test”
on page 85.

Unless otherwise noted, all parameters are listed in the
order they are displayed, starting with “DARKNESS.”

Entering Setup Mode

To enter Setup Mode, press SETUP/EXIT. Press either NEXT/SAVE or
PREVIOUS to scroll to the parameter you wish to set.

NOTE: You may also press and hold NEXT/SAVE and
PREVIOUS to advance quickly through the configuration

parameters.

Parameters in this section are shown in the order displayed when pressing
NEXT/SAVE. Throughout this process, press NEXT/SAVE to continue to
the next parameter, or press PREVIOUS to return to the previous
parameter in the cycle.

An asterisk (*) in the upper left-hand corner of the LCD indicates that the
value displayed is different from the currently stored value.

Zebra 105SL User Guide 45

Configuration

Changing Password-Protected Parameters

Certain parameters are password-protected by factory default.

CAUTION: Beginners should not attempt to change
password-protected parameters. This activity should be
performed by trained individuals only—parameters set
incorrectly could cause the printer to function unpredictably.

The first attempt to change one of these parameters (pressing either the (+)
or (–) key) requires you to enter a four-digit password at the “ENTER
PASSWORD” display. The (–) key changes the selected digit position; the
(+) key increases the selected digit value. After entering the password,
press NEXT/SAVE. The parameter you wish to change is displayed. If the
password was entered correctly, you can now change the value.

The default password value is 1234. The password can be changed using
the ^KP (Define Password) ZPL II instruction or through ZebraNet
WebView (optional ZebraNet PrintServer II required).

NOTE: Once the password has been entered correctly, it
does not have to be entered again unless you leave and re­enter Setup Mode using SETUP/EXIT.

You can disable the password-protection feature so
that it no longer prompts you for a password by setting
the password to ØØØØ via the ^KPØ ZPL/ZPL II
command. To re-enable the password-protection fea­ture, send the ZPL/ZPL II command ^KPx, where “x”
can be any number, one to four digits in length,
except Ø.

46 Zebra 105SL User Guide

Leaving Setup Mode

You can leave Setup Mode at any time by pressing SETUP/EXIT. The
“SAVE CHANGES” display appears. There are five choices, as described
below. Pressing the (
NEXT/SAVE selects the displayed choice.

• PERMANENT—Permanently saves the changes. Values are stored in

the printer even when power is turned off.

• TEMPORARY—Saves the changes until you change them again or

until power is turned off.

• CANCEL—Cancels all changes from the time you pressed

SETUP/EXIT except the darkness and tear-off settings (if they were
changed).

• LOAD DEFAULTS—Loads factory defaults. The factory defaults are

shown on the following pages.

NOTE: Loading factory defaults requires printer
calibration.

–) or (+) key displays other choices and pressing

Configuration

• LOAD LAST SAVE—Loads values from the last permanent save.

Zebra 105SL User Guide 47

Configuration

Configuration and Calibration Sequence

Press LCD Shows Action/Explanation

— PRINTER READY Normal printer operation.

Setting Print Parameters

Adjusting Print Darkness: Press the (+) key to increase

darkness; press the (–) key to decrease darkness.

Default: +10
Range: 0 to +30

Darkness settings are dependent on a variety of factors,
including ribbon type, media, and the condition of the printhead.
You may adjust the darkness for consistent high-quality
printing.
If printing is too light, or if there are voids in printed areas,

DARKNESS

increase the darkness. If printing is too dark, or if there is
spreading or bleeding of printed areas, decrease the darkness.
The FEED Key Self Test on page 84 can also be used to
determine the best darkness setting. Since the darkness setting
takes effect immediately, you can see the results on labels that
are currently printing.
CAUTION: Set the darkness to the lowest setting that provides

good print quality. Darkness set too high may
cause ink smearing and/or it may burn through the

ribbon.
Darkness settings also may be changed by the driver or
software settings.

Adjusting the Tear-Off Position: Press the (+) key to increase
the value; press the (–) key to decrease the value. Each press
of the key adjusts the tear-off position by four dot rows.

TEAR OFF

PRINT MODE

Default: +0
Range: –120 to +120

This parameter establishes the position of the media over the
tear-off bar after printing. The label and liner can be torn off or
cut between labels.

Selecting Print Mode: Press the (+) or (–) key to display other
choices.

Default: Tear-Off
Selections: Tear-Off, Peel-Off, Cutter, Rewind

Print Mode settings tell the printer the method of media delivery
that you wish to use. Select a Print Mode that your hardware
configuration supports since some selections displayed are for
optional printer features.

48 Zebra 105SL User Guide

Configuration

Press LCD Shows Action/Explanation

Setting Media Type: Press the (+) or (–) key to display other

choices.

Default: Non-Continuous
Selections: Continuous, non-continuous

This parameter tells the printer the type of media you are using.

MEDIA TYPE

SENSOR TYPE

Selecting continuous media requires that you include a label
length instruction in your label format (^LLxxxx if you are using
ZPL or ZPL II).
When non-continuous media is selected, the printer feeds
media to calculate label length (the distance between two
detections of the inter-label gap, webbing, or alignment notch or
hole).

Setting the Sensor Type: Press the (+) or (–) key to display
other choices.

Default: Web
Selections: Web, mark

This parameter tells the printer whether you are using media
with a web (gap/space between labels, notch, or hole) to
indicate the separations between labels or if you are using
media with a black mark printed on the back. If your media does
not have black marks on the back, leave your printer at the
default (web).

Selecting Print Method: Press the (+) key for the next value;
press the (–) key for the previous value.

Default: Thermal transfer
Selections: Thermal transfer, direct thermal

PRINT METHOD

The print method parameter tells the printer the method of
printing you wish to use: direct thermal (no ribbon) or thermal
transfer (using thermal transfer media and ribbon).
NOTE: Selecting direct thermal when using thermal transfer

media and ribbon creates a warning condition, but
printing continues.

Zebra 105SL User Guide 49

Configuration

Press LCD Shows Action/Explanation

Setting Print Width: Press the (+) key to increase the value,

press the (–) key to toggle to a different digit. To change the unit
of measurement, press the (–) key until the unit of
measurement is active, then press the (+) key to toggle to a
different unit of measure (inches, mm, or dots).

PRINT WIDTH

MAXIMUM LENGTH

Default; Range: The default and range of acceptable values

vary depending on which printer you have.
Refer to “Printing Specifications” on page 90
for further information about the ranges

available for your model.
Print width determines the printable area across the width of the
label.

Setting Maximum Length: Press the (–) key to decrease the
value, press the (+) key to increase the value.
Default; Range: The default and range of acceptable values

vary depending on your printer’s

configuration. Values are adjustable in 1 in.

(25.4 mm) increments.
Maximum length is used in conjunction with the calibration
procedure. The value of this setting determines the maximum
label length used during the media portion of the calibration
process. Only a few labels are needed to set media sensors.
Always set the value that is closest to, but not lower than, the
length of the label you are using. For example, if the length of
the label is 14.5 in. (368 mm), set the parameter for 15.0 in.
(381 mm).

50 Zebra 105SL User Guide

Listing Printer Information

Press LCD Shows Action/Explanation

List Fonts: Press the (+) key to print a label listing all available

fonts.

LIST FONTS

This selection is used to print a label listing all fonts available in
the printer, including standard printer fonts plus any optional
fonts. Fonts may be stored in RAM, Flash memory, font
EPROMs, or font cards.

Configuration

LIST BAR CODES

LIST IMAGES

LIST FORMATS

LIST SETUP

LIST ALL

List Bar Codes: Press the (+) key to print a label listing all
available bar codes.
This selection is used to print a label listing all bar codes
available in the printer.

List Images: Press the (+) key to print a label listing all
available images.
This selection is used to print a label listing all images stored in
the printer’s RAM, Flash memory, optional EPROM, or optional
memory card.

List Formats: Press the (+) key to print a label listing all
available formats.
This selection is used to print a label listing all formats stored in
the printer’s RAM, Flash memory, optional EPROM, or optional
memory card.

List Setup: Press the (+) key to print a label listing the current
printer configuration.
This selection is used to print a label that lists the current printer
configuration information. (Same as CANCEL Key Self Test.)

List All: Press the (+) key to print a label listing all available
fonts, bar codes, images, formats, and the current printer
configuration.
This selection is used to print a label that lists the five previous
selections, as described.

Zebra 105SL User Guide 51

Configuration

Media and Ribbon Sensor Calibration

NOTE: Before you begin this procedure, make sure that the maximum length is set to a value equal to or

greater than the length of the labels you are using. If the maximum length is set to a lower value,
the calibration process assumes that continuous media is in the printer. See page 50 for more
information.

There are two different types of calibration that can be performed by the printer:

1) Auto Calibration. When the printer is turned on after the printhead has been closed, the printer feeds
media and automatically sets the value it detects for media, media liner (the spaces between labels), and
media out. This type of calibration also occurs as part of the sensor profile and media and ribbon
calibration procedures.

2) Media and Ribbon Sensor Sensitivity Calibration. Performing the media and ribbon calibration
procedure first resets the sensitivity of the sensors to better detect the media and ribbon you are using.
With the sensors at their new sensitivity, the printer then performs the auto calibration described above.
Changing the type of ribbon and/or media may require resetting the sensitivity of the media and ribbon
sensors. Indications that the sensitivity may need to be reset include an illuminated CHECK RIBBON light
with the ribbon properly installed or non-continuous media being treated as continuous media.

Press LCD Shows Action/Explanation

Sensor Profile: Press NEXT/SAVE to skip this standard

calibration procedure and continue with the media and ribbon
calibration parameter on the next page. Press the (+) key to
initiate this standard calibration procedure and print a media

SENSOR PROFILE

sensor profile.
See Figure 26. The media sensor profile may be used to
troubleshoot registration problems that may be caused when the
media sensor detects preprinted areas on the media or
experiences difficulty in determining web location. If the sensitivity
of the media and/or ribbon sensors must be adjusted, use the
media and ribbon sensor sensitivity procedure.

Figure 26. Media Sensor Profile

52 Zebra 105SL User Guide

Press LCD Shows Action/Explanation

Media and Ribbon Sensor Sensitivity: Press NEXT/SAVE to

skip the calibration procedure and continue with the host port

selection parameters that follow. Press the (+) key to start the
MEDIA AND
RIBBON
CALIBRATE

Media and Ribbon Calibration Procedure

LOAD BACKING

REMOVE RIBBON

calibration procedure.

This procedure is used to adjust the sensitivity of the media and

ribbon sensors.

NOTE: The procedure must be followed exactly as presented.

All steps must be performed even if only one of the
sensors requires adjustment.

1) Open the printhead.

2) Remove approximately 8 in. (200 mm) of labels from the
media roll, enough so that only the liner material is threaded
between the media sensors when the media is loaded.

3) Close the printhead.

NOTE: To cancel the operation, press the (–) key.

1) Open the printhead.

2) Remove the ribbon (sliding it as far to the right as possible
has the same effect as removing it).

3) Close the printhead.

NOTE: To cancel the operation, press the (–) key.

Configuration

The printer automatically adjusts the scale (gain) of the signals
CALIBRATING
PLEASE WAIT

— RELOAD ALL

MEDIA AND
RIBBON
CALIBRATE

it receives from the media and ribbon sensors based on the

specific media and ribbon combination you are using. On the

sensor profile, this corresponds to moving the graph up or down

to optimize the readings for your application.

When “RELOAD ALL” is displayed:

1) Open the printhead and pull the media forward until a label is
positioned under the media sensor.

2) Move the ribbon back to its proper position.

3) Close the printhead.

Now that the scale has changed, the printer performs another
calibration. During this process, the printer checks the readings
for the media and ribbon based on the new scale you have
established, determines the label length, and determines
whether you are in Direct Thermal or Thermal Transfer Print
Mode. The process is now complete! To see the new readings
on the new scale, print a sensor profile.

Zebra 105SL User Guide 53

Configuration

Setting Communication Parameters

Communication parameters must be set correctly for the printer to communicate with the host computer.
These parameters ensure that the printer and host computer are “speaking the same language.” All
communications parameters are password protected.

Press LCD Shows Action/Explanation

Setting Serial Communications: Press the (+) or (–) key to

display other choices.

SERIAL COMM

PARALLEL COMM

BAUD

Default: RS-232
Selections: RS-232, RS-422/485, RS-485 multidrop

Select the communications port that matches the one being
used by the host computer.

Setting Parallel Communications: Press the (+) or (–) key to
display other choices.

Default: Parallel
Selections: Parallel, twinax/coax

Select the communications port that matches the one being
used by the host computer.

Setting Baud: Press the (+) or (–) key to display other choices.
Default: 9600
Selections: 110, 300, 600, 1200, 2400, 4800, 9600, 14400,

19200, 28800, 38400, 57600, 115200
The baud setting of the printer must match the baud setting of
the host computer for accurate communications to take place.
Select the value that matches the one being used by the host
computer.

Setting Data Bits: Press the (+) or (–) key to display other
choices.
Default: 7bits

DATA BITS

Selections: 7bits, 8 bits
The data bits of the printer must match the data bits of the host
computer for accurate communications to take place. Set the
data bits to match the setting being used by the host computer

This setting must be set to 8 data bits to use

NOTE:

Code Page 850.

.

54 Zebra 105SL User Guide

Configuration

Press LCD Shows Action/Explanation

Setting Parity: Press the (+) or (–) key to display other

choices.

PAR ITY

STOP BITS

HOST HANDSHAKE

Default: Even
Selections: Even, odd, none

The parity of the printer must match the parity of the host
computer for accurate communications to take place. Select the
parity that matches the one being used by the host computer.

NOTE: Depending on the model you have, this menu

item may not be available.
Setting Stop Bits: Press the (+) or (–) key to display other
choices.

Default: 1 stop bit
Selections: 1 stop bit, 2 stop bits

The stop bits of the printer must match the stop bits of the host
computer for accurate communications to take place. Select the
stop bits that match the one being used by the host computer.

Setting Host Handshake: Press the (+) or (–) key to display
other choices.

Default: XON/XOFF
Selections: XON/XOFF, DTR/DSR, RTS/CTS

The handshake protocol of the printer must match the
handshake protocol of the host computer for communications to
take place. Select the handshake protocol that matches the
one being used by the host computer.

Setting Protocol: Press the (+) or (–) key to display other
choices.

Default: None
Selections: None, Zebra, ACK/NACK

Protocol is a type of error-checking system. Depending on the

PROTOCOL

selection, an indicator may be sent from the printer to the host
computer signifying that data has been received. Select the
protocol that is requested by the host computer. Further details
on protocol can be found in the ZPL II Programming Guide
Volume I.

NOTES:

Zebra is the same as ACK/NACK, except that Zebra

response messages are in packets.

If Zebra is selected, printer must use either “DTR/

DSR” or “RTS/CTS” host handshake protocol.

Protocol error works in Serial Mode only.

Zebra 105SL User Guide 55

Configuration

NETWORK ID

COMMUNICATIONS

Setting Network ID: Press the (–) key to move to the next digit
position; press the (+) key to increase the value of the digit.

Default: 000
Range: 000–999

Network ID is used to assign a unique number to a printer used
in an RS-422/RS-485 network. This gives the host computer
the means to address a specific printer. If the printer is used in a
network, you must select a network ID number. This does not
affect TCP/IP or IPX networks.

Setting Communications Mode: Press the (+) or (–) key to
display other choices.

Default: Normal mode
Selections: Normal mode, diagnostics

The Communication Diagnostics Mode is a troubleshooting tool
for checking the interconnection between the printer and the
host computer. When “diagnostics” is selected, all data sent
from the host computer to the printer is printed as straight ASCII
hex characters. The printer prints all characters received,
including control codes, such as CR (carriage return). A sample
printout is shown in Figure 36 on page 85.
NOTES on diagnostic printouts:

• FE indicates a framing error.

• OE indicates an overrun error.

• PE indicates a parity error.

• NE indicates noise.
For any errors, check that your communication parameters are
correct. Set the print width equal to or less than the label width
used for the test. See page 50 for more information.

56 Zebra 105SL User Guide

Configuration

Press LCD Shows Action/Explanation

Selecting Prefix and Delimiter Characters

Prefix and delimiter characters are 2-digit hex values used within the ZPL/ZPL II formats sent to the
printer. The printer uses the last prefix and delimiter characters sent to it, whether from a ZPL II
instruction or from the front panel.
NOTE: Do not use the same hex value for the control, format, and delimiter character. The printer

needs to see different characters to function properly.

Control Prefix Character: Press the (–) key to move to the
next digit position; press the (+) key to increase the value of
the digit.

CONTROL PREFIX

FORMAT PREFIX

Default: 7E (tilde—displayed as a black square)
Range: 00–FF

The printer looks for this 2-digit hex character to indicate the
start of a ZPL/ZPL II control instruction.

Format Prefix Character: Press the (–) key to move to the
next digit position; press the (+) key to increase the value of
the digit.

Default: 5E (caret)
Range: 00–FF

The printer looks for this 2-digit hex character to indicate the
start of a ZPL/ZPL II format instruction.

Delimiter Character: Press the (–) key to move to the next
digit position; press the (+) key to increase the value of the
digit.
Default: 2C (comma)

DELIMITER CHAR

Range: 00–FF
The delimiter character is a 2-digit hex value used as a
parameter place marker in ZPL/ZPL II format instructions.
Refer to the ZPL II Programming Guide Volume I for more
information.

Zebra 105SL User Guide 57

Configuration

Selecting ZPL Mode

Press LCD Shows Action/Explanation

Selecting ZPL Mode: Press the (+) or (–) key to display other

choices.

Default: ZPL II
Selections: ZPL II, ZPL

ZPL MODE

Power-Up and Head Close Parameters

MEDIA POWER UP

The printer remains in the selected mode until it is changed by
this front panel instruction or by using a ZPL/ZPL II command.
The printer accepts label formats written in either ZPL or ZPL II.
This eliminates the need to rewrite any ZPL formats you
already have. Refer to the ZPL II Programming Guide Volume II
for more information on the differences between ZPL and ZPL
II.

Media Power-Up: Press the (+) or (–) key to display other
choices.

Default: Calibration
Selections: Feed, calibration, length, and no motion

This parameter establishes the action of the media when the
printer is turned on.

• Calibration: Recalibrates the media sensors.

• Feed: Feeds the label to the first web.

• Length: Determines the length of the label.

• No Motion: Media does not move.

Head Close: Press the (+) or (–) key to display other choices.
Default: Calibration
Selections: Feed, calibration, length, no motion

Determines the action of the media after the printhead has

HEAD CLOSE

been opened and then closed.

• Calibration: Recalibrates the media sensors.

• Feed: Feeds the label to the first web.

• Length: Determines the length of the label.

• No Motion: Media does not move.

58 Zebra 105SL User Guide

Label Positioning Parameters

Press LCD Shows Action/Explanation

Backfeed Sequence: Press the (+) or (–) key to display other

choices.

Default: Default (90%)
Selections: Default, after, before, 10%, 20%, 30%, 40%, 50%,

60%, 70%, 80%, off

establishes how much backfeed occurs before the next

label is printed. For example, a value of 40 means that

40% of the backfeed takes place after the label is

removed or cut. The remaining 60% takes place before

the next label is printed. A value of “before” means that

all backfeed takes place before the next label is printed.

BACKFEED

LABEL TOP

This parameter establishes when and how much label backfeed
occurs after a label is removed or cut in Peel-Off, Cutter, and
Applicator Modes. It has no effect in Rewind or Tear-Off Modes.
This parameter setting can be superseded by the ~JS
instruction when received as part of a label format (refer to the
ZPL II Programming Guide Volume I).

NOTE: The difference between the value entered and 100%

Adjusting Label Top Position: Press the (+) key to increase

the value; press the (–) key to decrease the value. The
displayed value represents dots.

Default: +0
Range: –120 to +120 dot rows

The label top position adjusts the print position vertically on the
label. Positive numbers adjust the label top position further
down the label (away from the printhead), negative numbers
adjust the position up the label (toward the printhead).

Configuration

Adjusting Left Position: Press the (–) key to move to the next
position, press the (+) key to change between + and to increase
the value of the digit. The displayed value represents dots.

Default: 0000
Range: –9999 to +9999
NOTE: For a negative value, enter the value before changing

LEFT POSITION

to the minus sign.
This parameter establishes how far from the left edge of a label
the format begins to print by adjusting horizontal positioning on
the label. Positive numbers adjust the printing to the left by the
number of dots selected; negative numbers shift printing to the
right.

Zebra 105SL User Guide 59

Configuration

HEAD RESISTOR

NOTE: Depending on the model you have, this menu item may

not be available. Newer printer models automatically
set the head resistor value after the printhead has been
replaced. For printers with model numbers 10500­2XXX-XXXX and 10500-3XXX-XXXX, the head resistor

value is set automatically.
Setting the Head Resistor Value: Press the (–) key to move to
the next digit position; press the (+) key to increase the value of
the digit.

CAUTION: This parameter should be changed only by

Initial Value:

Default Value: 0500
Range: 0500 to 1175

This value has been preset at the factory to match the
resistance value of the printhead. It does not need to be
changed unless the printhead is replaced.
CAUTION: Do not set the value higher than that shown on the

Before replacing the printhead, look for the label that shows the
resistance value (ohm value) of the new printhead and note it
for the setting.

qualified personnel!

Factory-set to match the printhead shipped with

your printer.

printhead. Setting a higher value may damage the
printhead!

Figure 27. Head Resistance Value

60 Zebra 105SL User Guide

Press LCD Shows Action/Explanation

WEB S.

MEDIA S.

RIBBON S.

Configuration

MARK S.

MARK MED S.

RIBBON LED

MARK LED

LCD ADJUST

FORMAT
CONVERT

CAUTION: These parameters are automatically set during

the calibration procedure. They should be
changed only by a qualified service technician.
Refer to the maintenance manual for more
information on these parameters.

Press NEXT/SAVE repeatedly to skip these parameters.

LCD Display Adjustment: Press the (–) key to decrease the
value (reduce brightness); press the (+) key to increase the
value (increase brightness).
Range: 00 to 19
This parameter allows you to adjust the brightness of your
LCD if it is difficult to read.

Format Convert: Press the (+) or (–) key to display other
choices.

Default: None
Selections: None, 150 → 300, 150 → 600, 200 → 600,

300 → 600
Selects the bitmap scaling factor. The first number is the
original dots per inch (dpi) value; the second, the dpi to which
you would like to scale.

Zebra 105SL User Guide 61

Configuration

Press LCD Shows Action/Explanation

IP Resolution: Press the (+) or (–) key to display other choices.
Default: Dynamic
Selections: Dynamic, permanent

IP RESOLUTION*

IP PROTOCOLS*

IP ADDRESS*

Depending on the selection, allows either the user (“permanent”)
or the server (“dynamic”) to select the IP address. For more
information, refer to ZebraNet Networking: PrintServer II User

and Reference Guide.

IP Protocols: Press the (+) or (–) key to display other choices.
Default: All
Selections: All, gleaning only, RARP, BOOTP, DHCP,

DHCP/BOOTP
If “dynamic” was chosen in the previous parameter, this selection
determines the method(s) by which the PrintServer II receives the
IP address from the server. For more information, refer to

ZebraNet Networking: PrintServer II User and Reference Guide.

IP Address: Press the (–) key to move to the next digit position;
press the (+) key to increase the value of the digit.
This parameter allows you to select the IP address if “permanent”
was chosen in “IP RESOLUTION.” If “dynamic” was chosen, the
user cannot select the address. For more information, refer to

ZebraNet Networking: PrintServer II User and Reference Guide.

Subnet Mask: Press the (+) or (–) key to display other choices.
Default: Permanent (user must set)

SUBNET MASK*

DEFAULT
GATEWAY*

Selections: Dynamic (user may set, but server can assign),

This parameter selects the part of the IP address that is
considered to be part of the local network. It can be reached
without going through the default gateway.

Default Gateway: Press the (–) key to move to the next digit
position; press the (+) key to increase the value of the digit.
This parameter allows you to select the IP address that the
network traffic is routed through if the destination address is not
part of the local network.

permanent

* ZebraNet PrintServer II option required

62 Zebra 105SL User Guide

Configuration

Press LCD Shows Action/Explanation

Selecting the Display Language: Press the (+) or (–) key to

display other choices.
Default: English

LANGUAGE

You have completed the entire configuration and calibration sequence. You may press either
NEXT/SAVE or SETUP/EXIT.

Selections: English, Spanish, French, German, Italian,

Norwegian, Portuguese, Swedish, Danish, Dutch,

Finnish, and Japanese
This parameter allows you to change the language displayed on
the LCD.

You are now back at the first parameter in the configuration
sequence.

DARKNESS

SAVE CHANGES

PRINTER READY

NOTE: If you pressed NEXT/SAVE but are through

programming the printer configuration, you may press
SETUP/EXIT and continue with the “SAVE
SETTINGS” function.

Save Changes: Press the (+) or (–) key to display other choices.
Default: Permanent
Selections: Permanent, temporary, cancel, load defaults, load

last save.
This display appears when you attempt to exit Setup Mode.

• Permanent: Permanently saves the changes, even when

printer power is turned off.

• Temporary: Saves the changes until changed again or until

power is turned off.

• Cancel: Cancels all changes since you entered Setup Mode

except for darkness and tear-off position (if they were
changed).

• Load defaults: Loads factory defaults.
NOTE: Loading factory defaults requires calibration.

• Load last save: Loads the values from the last permanent

save.

Press NEXT/SAVE to activate the displayed choice.
You have exited the configuration and calibration sequence and
are ready for normal printer operation.

Zebra 105SL User Guide 63

Configuration

64 Zebra 105SL User Guide

Routine Care and Adjustment

Cleaning

The table below provides a brief cleaning schedule. Specific cleaning
procedures are provided on the following pages.

Area Method Interval

Printhead Solvent* Direct Thermal Print Mode:

Platen roller Solvent*

Transmissive sensor Air blow

Black mark sensor Air blow

Media path Solvent*

Ribbon sensor Air blow

Label available sensors Air blow Monthly

After every roll of media
(500 ft. or 50 m of media).

Thermal Transfer Print Mode:
After every roll (1500 ft. or 450m) of
ribbon.

Tear-off bar Solvent*

Snap plate Solvent*

Cutter Solvent*

* Zebra recommends using a solvent of 90% isopropyl alcohol.

As needed

CAUTION: Use only the cleaning agents indicated.
Zebra Technologies is not responsible for any other fluids
used on this printer.

Zebra 105SL User Guide 65

Routine Care and Adjustment

Cleaning the Exterior

The exterior surfaces of the printer may be cleaned with 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.

Cleaning the Interior

Inspect this area after every four rolls of media. Remove any dirt and lint
from the interior of the printer using a soft bristle brush and/or vacuum
cleaner.

Cleaning the Printhead and Platen Roller

Inconsistent print quality, such as voids in the bar code or graphics, may
indicate a dirty printhead. For best results, perform the following cleaning
procedure after every roll of ribbon.

NOTE: You do not need to turn off the printer before
cleaning the printhead. If power is turned off, all label
formats and images, as well as any temporarily saved
parameter settings stored in the printer’s internal memory,
are lost. When power is turned back on, you need to reload
these items.

To clean the printhead, refer to Figure 28 and follow these steps:

1. Open the printhead.

2. Remove the media and ribbon (if loaded).

3. Moisten an applicator tip with a solvent containing 90% isopropyl
alcohol, and wipe along the print elements from end to end. (The print
elements are on the brown strip just behind the chrome strip on the
printhead.) Allow a few seconds for the solvent to evaporate.

66 Zebra 105SL User Guide

Routine Care and Adjustment

4. Rotate the platen roller and clean thoroughly with solvent and an

applicator.

5. Brush/vacuum any accumulated paper lint and dust away from the

rollers.

6. Reload ribbon and/or media, and close the printhead.

NOTE: If print quality has not improved after performing
this procedure, try cleaning the printhead with Save-a-
Printhead cleaning film. This specially-coated material
removes contamination buildup without damaging the
printhead. Please see Appendix D or call your authorized
Zebra reseller or distributor for more information.

Figure 28. Printhead and Platen Roller Cleaning

Zebra 105SL User Guide 67

Routine Care and Adjustment

Cleaning the Sensors

The media, ribbon, and label available sensors should be cleaned on a
regular basis to ensure proper operation of the printer. To locate these
sensors, refer to Figure 28 on page 67, Figure 6 on page 11, and Figure 7
on page 12. Brush or vacuum any accumulated paper lint and dust off of
these sensors.

Cleaning the Snap Plate

Clean the snap plate to remove label adhesive or a label that has adhered to
the underside of the snap plate.

Refer to Figure 29.

1. Insert a small-blade screwdriver or similar tool into the loop on the left
side of the snap plate. Lift the snap plate.

CAUTION: Do not bend, twist, or otherwise deform the
loops! If the snap plate is damaged in any way, a new plate
may be required for proper ribbon sensing.

2. Repeat step 1 on the right side of the snap plate.

3. Remove the snap plate from the printer.

4. Clean the snap plate with cleaning solvent and a soft cloth.

Figure 29. Snap Plate Removal and Cleaning

68 Zebra 105SL User Guide

Routine Care and Adjustment

Refer to Figure 30.

Figure 30. Snap Plate Reinstallation

5. To reinstall the snap plate, insert the two tabs on the bottom of the snap

plate into the two slots of the media pathway.

6. Slide the snap plate toward you.

7. Press down on the loops to lock the snap plate into place.

Zebra 105SL User Guide 69

Routine Care and Adjustment

Cleaning the Cutter Module

(For printers equipped with the optional cutter.)

If labels are not being cut properly or if the cutter jams with labels, turn off
the printer power (O) and unplug the printer. Then, clean the stationary
cutter blade with cleaning solvent. This removes label adhesive and/or
paper debris. If further cutter cleaning is necessary, or if the cutter
continues to perform unsatisfactorily, contact an authorized service
technician.

NOTE: Turning off the printer results in the loss of label
formats, images, and any temporarily saved parameter
settings stored in the printer’s internal memory. Perform
this procedure after your printing job is complete.

Lubrication

CAUTION: No lubricating agents other than Zebra­supplied, silicon-only lubricants should be used on the
spindle felt clutches of this printer. Other commercially
available lubricants damage the finish and mechanical
parts.

70 Zebra 105SL User Guide

Routine Care and Adjustment

Fuse Replacement

The printer uses a metric-style fuse (5 × 20 mm IEC) rated at F5A, 250V.
The end caps of the fuse must bear the certification mark of a known
international safety organization (see Figure 38 on page 93).

Depending on the model you have, the fuse may not be user-replaceable
(see Figure 31) and may need to be replaced by a qualified service
technician. Please see the maintenance manual (part number 32056L) for
details.

Figure 31. Fuse Replacement

NOTE: Models with a user-replaceable fuse have a

warning label next to the fuse for easy identification.

Zebra 105SL User Guide 71

Routine Care and Adjustment

Adjustments

Toggle Positioning

See Figure 32.

The toggle should be positioned so that it provides even pressure on the
media. Position the toggle by sliding it to the desired location.

Figure 32. Toggle Adjustment

72 Zebra 105SL User Guide

Routine Care and Adjustment

Printhead Pressure Adjustment

This adjustment may be necessary if printing is too light on one side or if
thick media is used. Refer to Figure 32.

1. Perform the toggle positioning procedure. If the problem is solved,

you may stop here; otherwise, continue with the rest of this procedure.

2. Print some labels at speed A by running the PAUSE Key Self Test (see

page 83).

3. While printing labels, lower the darkness setting until you see a gray

level of printing.

4. Loosen the knurled (upper) locking nuts at the top of the toggle

assembly/assemblies.

5. Increase or decrease spring pressure using the knurled (lower)

adjusting nuts on the shafts of the toggle until the left and right edges
of the printed area are equally dark.

NOTE: Printhead life can be maximized by using the
lowest pressure that produces the desired print quality.

6. Increase darkness setting to the optimum level for the media being

used.

7. Re-tighten locking nuts.

Media Sensor Position Adjustment

See “Positioning the Media Sensors” on page 10.

Zebra 105SL User Guide 73

Routine Care and Adjustment

74 Zebra 105SL User Guide

Troubleshooting

LED Error Conditions and Warnings

Error Condition— Ribbon Out

Problem Solution

In Thermal Transfer Mode, the ribbon is not
loaded or loaded incorrectly.

In Thermal Transfer Mode, the ribbon
sensor is not sensing correctly loaded
ribbon.

In Direct Thermal Mode, when ribbon is not
used:

Load the ribbon correctly. See “Ribbon Loading” on

page 41.

Perform the media and ribbon sensor calibration (see

page 17).

Put the printer in Direct Thermal Mode via the front panel
and remove ribbon (if loaded).

Ensure that the printer driver or software settings are
correctly set (if applicable).

Error Condition— Paper Out

Problem Solution

The media is not loaded or loaded
incorrectly.

The media sensor is not adjusted properly. Check the position of the upper and lower media

The printer is set for non-continuous
media, but continuous media is loaded.

Reload the media. Refer to “Roll Media Loading” on

page 29.

sensors. See “Positioning the Media Sensors” on

page 10.

Either load the correct media or set the printer for the
correct media type via the front panel.

Ensure that the printer driver or software settings are
correctly set (if applicable).

Calibrate the printer (see page 17).

Zebra 105SL User Guide 75

Troubleshooting

The incorrect media sensor is being used.

The maximum label length is set shorter
than the label length being used.

Via the front panel, check the sensor type to ensure that
the correct one is used for the media loaded. See

page 16. Calibrate the printer (see page 17).

Via the front panel, set the label length to a value that is
slightly longer than the length of the label being used.

Error Condition— Head Open

Problem Solution

The printhead is not fully closed. Close the printhead.

Warning— Ribbon In

Problem Solution

Remove the ribbon and set the printer to Direct Thermal

The ribbon is loaded.

Mode.

Ensure that the printer driver and/or software settings are
correctly set (if applicable).

Warning— Head Too Hot

Problem Solution

The printhead is over temperature.

Allow the printer to cool. Printing automatically resumes
when the printhead elements cool to an acceptable
operating temperature.

Warning— Head Cold

Problem Solution

Continue printing while the printhead reaches the correct

The printhead is under temperature.

76 Zebra 105SL User Guide

operating temperature. If the error remains, the
environment may be too cold for proper printing.
Relocate the printer to a warmer area.

Troubleshooting

Printhead data cable is not properly

WARNING: The printhead can be very hot and can

connected.

Disconnect and reconnect data cable to the printhead.
Ensure that the cable connector is fully inserted into the
printhead connector.

cause severe burns. Allow the printhead to
cool.

Warning— Cutter Jammed

Problem Solution

Cutter blade is in the media path. Turn off the printer power and unplug the printer. Inspect

the cutter module for debris and clean as needed
following the cleaning instructions on page 70.

Out of Memory*

Problem Solution

Insufficient memory for the label length, downloaded

fonts/graphics, and images.
*There is not enough memory to perform
the function shown on the second line of
the error message.

Ensure that the device, such as Flash memory or

PCMCIA card, is installed and not write-protected or full.

Ensure that the data is not directed to a device that is not

installed or available.

Print Quality Problems

General Print Quality Issues

Problem Solution

You are using an incorrect media and
ribbon combination for your application.

The printer is set at the incorrect print
speed.

Zebra 105SL User Guide 77

Consult your authorized Zebra reseller/distributor for
information and advice.

For optimal print quality, set the print speed to the lowest
possible setting via ZPL II, the driver, or the software.

Troubleshooting

The printer is set at the incorrect darkness
level.

The printhead is dirty. Clean the printhead according to the instructions on

There is light printing (or no printing) on the
left or right side of the label or the printed
image is not sharp.

For optimal print quality, set the darkness to the lowest
possible setting via the front panel, the driver, or the
software.

page 66.

The toggle pressure needs to be adjusted. Follow the
printhead pressure adjustment instructions on page 73.

Gray lines on blank labels with no consistent pattern

Problem Solution

The printhead is dirty. Clean the printhead according to the instructions on

page 66.

Light, consistent vertical lines running through all of the labels

Problem Solution

The printhead or platen roller is dirty. Clean the printhead, platen roller, or both according to

the instructions on page 66.

Intermittent creases on the left and right edges of the labels

Problem Solution

There is too much toggle pressure on the
printhead.

78 Zebra 105SL User Guide

Reduce the toggle pressure. See “Printhead Pressure

Adjustment” on page 73.

Troubleshooting

Wrinkled Ribbon

Problem Solution

The ribbon is not loaded correctly. Load the ribbon correctly. See “Ribbon Loading” on

page 41.

The darkness setting is incorrect. Set the darkness to the lowest possible setting for good

Incorrect printhead pressure or balance. Set the pressure to the minimum required for good print

The media is not feeding correctly. It is
“walking” from side to side.

print quality. See “DARKNESS” on page 48.

quality. See “Printhead Pressure Adjustment” on page 73.

Make sure that the media guide and media supply guide
touch the edge of the media.

Communications

A label format was sent to the printer but not recognized. The
DATA light does not flash.

Problem Solution

Check the printer driver or software communications
settings (if applicable).

Check the printer host port setting via the front panel (see

page 54). Select the port that matches the one being

The communication parameters are
incorrect.

used by the host computer.

Ensure you are using the correct communication cable.
See page 23 for the requirements.

Via the front panel, check the protocol setting. It should
be set to “none.” See page 54.

Ensure that the correct driver is being used, if applicable.

Zebra 105SL User Guide 79

Troubleshooting

A label format was sent to the printer. Several labels print, then the
printer skips, misplaces, misses, or distorts the image on the label.

Problem Solution

The host computer is set to EPP parallel
communications.

The serial communication settings are
incorrect.

Change the settings on the host computer to standard
parallel communications.

Ensure that the flow control settings match.

Check the communication cable length. See page 54 for
requirements.

Check the printer driver or software communications
settings (if applicable).

A label format was sent to the printer but not recognized. The
DATA light flashes but no printing occurs.

Problem Solution

The prefix and delimiter characters set in
the printer do not match the ones in the
label format.

Incorrect data is being sent to the printer.

Verify the prefix and delimiter characters. See “Selecting

Prefix and Delimiter Characters” on page 57.

Ensure that ZPL is being used.

Check the communication settings on the host computer.
Ensure that they match the printer settings.

The printer fails to calibrate or detect the top of the label.

Problem Solution

The printer was not calibrated for the label
being used.

The printer is configured for continuous
media.

The driver or software configuration is not
set correctly.

80 Zebra 105SL User Guide

Perform the calibration procedure on page 17.

Set the media type to non-continuous media.

As driver or software settings produce ZPL commands
that can overwrite the printer configuration, check the
driver or software media-related setting.

Printer Diagnostics

Power-On Self Test

A full Power-On Self Test (POST) is performed automatically each time
the printer is turned on (additional self tests can be performed by pressing
CANCEL when you turn the printer on). During either test sequence, the
front panel lights and LCD monitor the progress of the POST. If the printer
fails any of these tests, the word “FAILED” is added to the LCD. If this
occurs, notify an authorized Zebra reseller.

Additional Printer Self Tests

These self tests produce sample printouts and provide specific information
that help determine the operating conditions for the printer.

Each self test is enabled by pressing a specific front panel key or
combination of keys while turning the POWER on (l). Keep the key(s)
depressed until the DATA light turns off. When the POST is complete, the

.

selected self test starts automatically.

Troubleshooting

NOTE: When performing self tests, avoid sending a label
format to the printer. In the case of a remote host,
disconnect all data interface cables from the printer. When
cancelling a self test prior to its actual completion, always
turn the printer power off and then back on to reset the
printer.
When performing these self tests while in Peel-Off Mode,

you must remove the labels as they become available.
If your media is not wide enough or long enough, unex­pected or undesired results may occur. Make sure that your
print width is set correctly for the media you are using
before you run any self tests, otherwise the test may print
out on the platen roller. See page 50 for information on set-
ting the print width

.

.

Zebra 105SL User Guide 81

Troubleshooting

CANCEL Key Self Test

This self test prints a listing of the
configuration parameters currently
stored in the printer’s memory. See

Figure 33 (depending on the options

ordered, your label may look
different).

1. Turn the printer off (O).

2. Press and hold CANCEL while

turning on the power (l).

The configuration may be changed
either temporarily (for specific label
formats or ribbon and label stock) or
permanently (by saving the new
parameters in memory). Saving new
parameters occurs whenever a
calibration procedure is performed.
Refer to page 15 for further
information about the configuration
procedure. Additional Power-Up Self
Tests are also performed during the
POST for this test.

Figure 33. Test Label

82 Zebra 105SL User Guide

Troubleshooting

PAUSE Key Self Test

This self test can be used to provide the test labels required when making
adjustments to the printer’s mechanical assemblies; these test labels also
ensure the printhead has been aligned correctly after it has been adjusted.
See the sample printout in Figure 34.

1. Turn off the printer (O).

2. Press and hold PAUSE while turning on the power (l).

• The initial self test prints 15 labels at 2.4 in. or 61 mm per second,
then automatically pauses the printer. When PAUSE is pressed, an
additional 15 labels print.

• While the printer is paused, pressing CANCEL alters the self test.
When PAUSE is pressed, 15 labels print at 6 in. or 152 mm per
second.

• While the printer is paused, pressing CANCEL alters the self test a
second time. When PAUSE is pressed, 50 labels print at 2.4 in. or
61 mm per second.

• While the printer is paused, pressing CANCEL again alters the self
test a third time. When PAUSE is pressed, 50 labels print at 6 in. or
152 mm per second.

• While the printer is paused, pressing CANCEL again alters the self
test a fourth time. When PAUSE is pressed, 15 labels print at the
printer’s maximum speed.

• To exit this self test at any time, press and hold CANCEL.

Figure 34. PAUSE Key Test Label

Zebra 105SL User Guide 83

Troubleshooting

FEED Key Self Test

See Figure 35.

1. Turn off the printer (O).

2. Press and hold FEED while

turning on the power (l).

The FEED Key Self Test prints out
at various darkness settings above
and below that of the darkness
value shown on the configuration
label (Figure 33). Examine these
labels and determine which one
has the best darkness setting for
your application. This value can be
entered into the printer by setting
the darkness during the
configuration procedure. Refer to

page 48 for more information.

Figure 35. FEED Key Test Label

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.

84 Zebra 105SL User Guide

Troubleshooting

FEED Key and PAUSE Key Self Test

1. Turn off the printer (O).

2. Press and hold FEED and PAUSE while turning on the power (l).

Performing this self test temporarily resets the printer configuration to the
factory default values. These values are active only until power is turned
off unless you save them permanently in memory.

Communications Diagnostics Test

This test is controlled from the front panel display. A typical printout from
this test is shown in Figure 36. Turn off the power to exit this self test.

NOTE: This label is inverted when printed.

Figure 36. Communications Test Label

Additional Printer Diagnostics

Additional diagnostic tests are available for this printer, however, they are
beyond the scope of this users guide. Refer to the maintenance manual for
information about these additional tests.

Zebra 105SL User Guide 85

Troubleshooting

86 Zebra 105SL User Guide

NOTE: Printer specifications are subject to change without
notice.

Media Handling

• Tea r- Of f Mode: Labels are produced in strips.

• Peel-Off Mode: Labels are dispensed and peeled from the liner as
needed.

• Cutter Mode: Labels are printed and individually cut.

• Rewind Mode: Labels are rewound internally.

Specifications

Options

• Printhead 300 dpi (12 dots/mm) • PCMCIA Card Slot

• Cutter and catch tray* • BAR-ONE Windows™-based WYSIWYG on­screen label design and print application software

• Rewind • ZebraNet PrintServer II, including Ethernet
interface (10Base-T), ZebraNet WebView
graphical setup and printer control, and ZebraNet
Alert unsolicited error notification

• Label peel and liner rewind • ZebraNet Wireless Card Socket, and integrated
wireless 802.11b Ethernet option that supports
multiple third party LAN radio cards

• Internal fanfold media supply bin* • IBM twinax or coax interface

• Font cards

* Not compatible with rewind and peel options.

Zebra 105SL User Guide 87

Specifications

ZPL Programming Language (ZPL II)

• Downloadable graphics, scalable and bitmap
fonts, and label formats

• Object copying between memory areas
(RAM, memory card, and internal Flash)

• Code Page 850 character set • Communicates in printable ASCII characters

• Adjustable print cache • Error-checking protocol

• Data compression • Controlled via mainframe, mini-computer, PC,

• Automatic virtual input buffer management • Serialized fields

• Format inversion • In-spec OCR-A and OCR-B

• Mirror image printing • UPC/EAN

• Four-position field rotation (0°, 90°, 180°, 270°) • User-programmable password

• Slew command

• Status message to host upon request

• Programmable quantity with print, pause, and cut
control

portable data terminal

Bar Codes

• Bar code ratios (2:1 up to 3:1) • Industrial 2 of 5 (supports ratios of 2:1 up to 3:1,
Modulus 10 Check Digit)

• Code 11 • Interleaved 2 of 5

• Code 39 (supports ratios of 2:1 up to 3:1) • LOGMARS

• Code 93 • MSI

• Code 128 (with subsets A, B, and C and UCC

case codes)

• ISBT-128 • Codablock (2-dimensional bar code)

• UPC-A, UPC-E, UPC extensions • PDF-417 (2-dimensional bar code)

• EAN-8, EAN-13, EAN extensions • Code 49 (2-dimensional bar code)

• Plessey • DataMatrix (2-dimensional bar code)

• Postnet • Maxi Code (2-dimensional bar code)

• Standard 2 of 5 • QR Code (2-dimensional bar code)

• Check digit calculation where applicable

• Codabar

88 Zebra 105SL User Guide