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
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