Zebra Technologies 160S, 105Se User Manual

ZEBRA VALUE-LINE

-Series

User's Guide

For the Zebra 105

and 160 ™ Printers

™

Proprietary Statement

This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the in- formation anduse of parties operating and maintaining the equipment described herein. Such proprietary in- formati on ma y n ot be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Corporation.

Product Improvements

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

FCC Compliance Statement

Note: This equipment has been tested and found to comply with the limits for a Class A digital Device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions manual, may cause harmful interference to radio com- munications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

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

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

Canadian DOC Compliance Statement

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

Liability Disclaimer

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

No Liability for Consequential Damage

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

Copyrights

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

Introduction

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

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

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

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

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

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

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

Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ZebraProgrammingLanguageII(ZPLII

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

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

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

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

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

Zebra S-Series User’s Guide i

Installation

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ii Zebra S-Series User’s Guide

Operation

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Zebra S-Series User’s Guide iii

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

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

Format2:SavingaLabelFormatAsaGraphicImage....3-15

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

Configuration and Calibration

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

Bank1

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

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

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

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

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

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

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

Interconnections

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

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

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

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

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

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

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

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

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

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

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

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

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

iv Zebra S-Series User’s Guide

Preventive Maintenance

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

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

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

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

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

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

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

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

Adjustments

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

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

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

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

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

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

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

Troubleshooting

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

Options

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

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

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

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

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

Zebra S-Series User’s Guide v

Appendix A

Appendix B

Appendix C

Appendix D

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

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

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

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

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

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

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

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

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

Glossary

Index

vi Zebra S-Series User’s Guide

Scope

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

structions for the Zebra 105Se and 160S thermal transferdemand printers.

It contains information on how to set up and operate the printer as well as adjustment and maintenance procedures that can be performed by the operator. Information covering the use and operation of Zebra S-Series Printer options is also included.

Additional documentation for the Zebra S-Series Printer is available:

The ZPL II®Programming Guide (part # 46469L).

•

The two-volume Maintenance Manual: Volume 1: General Mainte-

•

nance (part # 38452L) contains the information you will need to maintain your printer. Volume 2: Circuit Descriptions and Electrical Schematics (part # 38453L) contains the information you will need to repair the circuit boards at the component level. You may order both volumes as a set by ordering part # 31452L.

Model Designation

Introduction

Labels located inside the media compartment above the frame support

at the rear of the S-Series Printer include both the serial number and

model designation. If you need to contact our technical support staff for assistance, please have both the model designation and serial number available so that we may help you more efficiently.

System Overview

The S-Series Printer, when connected to an appropriate ASCII data source, functions as a complete label, ticket, and tag printing system. Customer-supplied asynchronous modems may be used to connect re-

mote hosts to the S-Series Printer. Connection of the S-Series Printer to data sources using data codes

other than ASCII requires the use of an appropriate protocol converter. Connection to data sources using interfaces other than the type installed in the printer requires the use of an appropriate interface converter.

Zebra S-Series User’s Guide 1-1

Communication Capabilities

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

Thermal Transfer Printer Internal Functions

Command/control data signals are received via the RS-232 port, parallel port, or DIP switches and are sent to the main logic board. The microprocessor continuously monitors these signals along with the inputs received from the control panel and various sensors. The microprocessor interprets this information and controls the S-Series Printer mechanics, printhead, communications, command interpretation, label formatting, media control, and mechanical drive.

Print Mechanism Capabilities

The print mechanism has been designed to print random information labels, tickets, and tags. It uses a thermal printhead that heats a ribbon as it passes beneath the print elements, melting its ink onto the media (direct thermal uses heat-sensitive media instead of an inked ribbon). Constant print speeds may be selected via software control.

The standard printhead for the S-Series Printer has a print resolution of 8 dots/mm (203.2 dots/inch). Optional printheads are available for the 105Se for either 6 dots/mm (152 dots/inch) or 12 dots/mm (300 dots/inch) resolution.

Media Transport Mechanism Capabilities

The media transport mechanism of the S-Series Printer has been designed to accommodate various types of media, including die-cut labels, ticket and tag stock, continuous roll, and fanfold media.

Media may be rewound internally onto standard three-inch cores if the Rewind Spindle option is installed. With the Peel-off option, backing material may be rewound internally.

Ribbons for the S-Series Printer are supplied on one-inch cores in standard widths and lengths.

1-2 Zebra S-Series User’s Guide

Additional System Requirements

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

Label, ticket, or tag stock

•

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

•

ZPL II formats

A data communication cable to connect the controlling device to the

•

printer (remote installations may require additional cables and communication devices, such as modems and/or protocol converters)

Thermal transfer ribbon (if using thermal transfer mode)

•

Media and Ribbon Requirements

Print quality not only depends on the Zebra S-Series Printer, but also

on the print media. Factors such as reflectivity and contrast are impor-

tant for bar code scanning applications. Factors such as paper abrasion and temperature requirements are important in maintaining the life of the printhead.

We STRONGLY RECOMMEND the use of Zebra-brand media for continuous high quality printing. A wide range of paper, polypropylene, polyester, and vinyl stock has been specifically engineered to en-

hance the printing capabilities of the printer and to ensure against premature printhead wear.

Zebra S-Series User’s Guide 1-3

Continuous roll form paper, fanfold media, or cardstock with optional perforations and registration holes may be used. The standard 160S Printer and 105Se Printer with an optional reflective sensor can use “black-mark media” (media having a black mark printed on the liner side for use in positioning the labels).

Since print quality is affected by media and ribbon, printing speeds, and printer operating modes, it is very important to run tests for your appli- cations. This is especially true if you’re operating in Peel-Off mode, where these variables combine with label size, backing content, diecut depth, and even humidity to affect printer operation.

Warnings and Precautions

Installation

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

230 VAC Operation

CAUTION:Referto“Installation”forinstructionsonconfiguringyour printer for 230 VAC operation before connecting to a 230 VAC power source.

Use of Shielded Cable

CAUTION:Refertothe“Interconnections”Section.

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

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

1-4 Zebra S-Series User’s Guide

Ribbons and Printhead Wear

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

Repacking

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

Referto“Installation”forfurtherrepackinginstructions.

Zebra S-Series User’s Guide 1-5

Printer Specifications

Printing Considerations

Specification 105Se 160S

Resolution (thermal transfer or direct thermal)

Dot size 0.00492"

Maximum print width 4.09"

Standard Maximum print length

Bar code modulus (X) dimension

Thin film printhead with Energy Control

memory

With 512 KB

addl memory

203 dots per inch (8 dots per mm)

(0.125 mm)

(104 mm) 15"

(381 mm) 39"

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

Print Speeds

Programmable constant printing speeds of 2" (51 mm), 3" (76 mm),

4" (102 mm), 5" (127 mm), and 6" (152 mm) per second.

Optional 152 dots per inch (6 dots per mm)

0.00656" (0.167 mm)

4.09" (104 mm)

26" (660 mm)

39" (991 mm)

Optional 300 dots per inch (12 dots per mm)

0.0033" x 0.0039" (0.084 x 0.100 mm)

4.09" (104 mm)

18" (457 mm)

N/A 25"

203 dots per inch (8 dots per mm)

0.00492" (0.125 mm)

6.30" (160 mm)

9.5" (241 mm)

(635 mm)

50 mil

The 105Se with optional 300 dots/inch resolution supports programmable constant printing speeds of 2.4" (61 mm), 3" (76 mm), and 4" (102 mm) per second.

Media Handling

•

Tear-off mode: Produced in strips.

•

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

•

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

•

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

1-6 Zebra S-Series User’s Guide

Media

Media Specifications 105Se 160S

Total media width Maximum 4.5" 114.3 mm 7.2" 182.9 mm

Minimum 0.75" 19.05 mm 2.0" 50.8 mm

Maximum Refer to Printing Considerations on page 1-6.

Label length

Minimum

Total thickness (includes liner)

Core size 3.0" 76.2 mm 3.0" 76.2 mm Maximum roll diameter 8.0" 203.2 mm 8.0" 203.2 mm Interlabel gap (0.115"/3 mm preferred) 0.079" - 0.157" 2 mm-4mm 0.079"- 0.157" 2 mm -4 mm Maximum internal fanfold media pack

size (LxWxH)

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

Mark width (measuring perpendicular to label/tag edge)

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

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

which the black mark is printed

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

Minimum 0.0023" 0.0584 mm 0.0023" 0.0584 mm

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

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

0.015" 0.381 mm 0.015" 0.381 mm

8.0" x 7.2" x

6.2"

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

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

must

printers mainframe when loaded in the printer).

0.5 ODU maximum

203.2 mm x

182.8 mm x

157.4 mm

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

8.0" x 7.2" x

6.2"

203.2 mm x

182.8 mm x

157.4 mm

Zebra S-Series User’s Guide 1-7

Ribbon

Ribbon Width

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

Standard Lengths

2:1 media to ribbon roll ratio 984 ft 300 m 984 ft 300 m 3:1 media to ribbon roll ratio 1476 ft 450 m 1476 ft 450 m

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

105Se 160S

Roll size Inner diameter of core 1.0" 25.4 mm 1.0" 25.4 mm

Outside diameter of full roll of ribbon 3.2" 81 mm 3.2" 81 mm

Zebra Programming Language II (ZPL II®)

Downloadable graphics with data compression

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

Format inversion

Mirror image printing

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

Bitmap and scalable fonts

Programmable quantity with print pause

Communicates in printable ASCII characters

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

Serialized fields

In-Spec OCR-A and OCR-B

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

Bar Codes

Code 11, Code 49, Code 93

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

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

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

Industrial 2 of 5, Standard 2 of 5

Plessey

MAXICODE

1-8 Zebra S-Series User’s Guide

UPC-A

PDF 417

POSTNET

MSI

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

Interleaved 2 of 5

3of9

Data Matrix

Standard Fonts

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

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

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

Note:See“Options”fortheavailabilityofadditionalfonts.

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

Font Matrix

(indots)

Height

Width

Inter-

C, D

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

95 1

11 7 2

18 10 2

28 15 5

26 13 3

60 40 8

21 13 6

24 24 0

Type* CharacterSize

character

gap

U-L-D 0.044 0.029

U 0.054 0.044

U-L-D 0.088 0.059

OCR-B 0.138 0.098

U-L-D 0.128 0.079

U-L-D 0.295 0.236

OCR-A 0.103 0.093

SYMBOL 0.118 0.118

Height

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

Inches Millimeters

Width

33.90

22.60

16.95

10.17

12.71

4.24

10.71

8.48

Char./inch

Height

1.13 0.75 1.33

1.38 1.13 0.89

2.25 1.50 0.67

3.50 2.50 0.40

3.25 2.00 0.50

7.50 6.00 0.17

2.63 2.38 0.42

3.00 3.00 0.33

Width

Char./mm

Zebra S-Series User’s Guide 1-9

Font Matrices for 6 dots/mm Printhead

Font Matrix

(indots)

Height

Width

C, D

95 1

11 7 2

18 10 2

21 10 3

26 13 3

60 40 8

17 11 4

24 24 0

Default: 15 x 12

Inter-

Type* Character Size

character

gap

U-L-D 0.059 0.039

U 0.072 0.059

U-L-D 0.118 0.079

OCR-B 0.138 0.085

U-L-D 0.171 0.105

U-L-D 0.394 0.315

OCR-A 0.112 0.098

SYMBOL 0.157 0.157

U-L-D

Height

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

Inches Millimeters

Width

Char./inch

25.40

16.93

12.70

11.72

9.53

3.18

10.16

6.35

Scalable

Height

1.50 1.00 1.00

1.83 1.50 0.67

3.00 2.00 0.50

3.50 2.17 0.46

4.33 2.67 0.38

10.00 8.00 0.13

2.83 2.50 0.40

4.00 4.00 0.25

Width

Char./mm

1-10 Zebra S-Series User’s Guide

Font Matrices for 12 dots/mm Printhead

Font Matrix

(indots)

Height

Width

C, D

95 1

11 7 2

18 10 2

42 20 6

26 13 3

60 40 8

34 22 8

24 24 0

Default: 15 x 10

Inter-

Type* Character Size

character

gap

U-L-D 0.029 0.016

U 0.036 0.023

U-L-D 0.059 0.033

OCR-B 0.138 0.066

U-L-D 0.185 0.042

U-L-D 0.198 0.132

OCR-A 0.112 0.072

SYMBOL 0.079 0.079

U-L-D

Height

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

Inches Millimeters

Width

50.80

33.86

25.40

23.44

19.06

6.36

20.32

12.70

Scalable

Char./inch

Height

0.73 0.40 2.00

0.91 0.58 1.34

1.49 0.83 1.00

3.50 1.67 0.92

2.15 1.06 0.76

5.02 3.35 0.26

2.84 1.82 0.80

2.00 2.00 0.50

Width

Char./mm

Zebra S-Series User’s Guide 1-11

Standard Printer Font Example

Physical

Physical Characteristics 105Se 160S

Height Width Length Weight (without options)

15.4" 391 mm 15.4" 391 mm

10.5" 267 mm 13.1" 333 mm

18.9" 480 mm 18.9" 480 mm

43 lbs. 19.5 kg 55 lbs. 24.9 kg

Electrical

•

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

•

5 Amps @ 115V, 3 Amps @ 230V

•

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

•

Carries the CE mark of compliance.

1-12 Zebra S-Series User’s Guide

Communications Interface

RS-232 at 110 to 19,200 baud (select from standard rates). Baud

•

rate, data bits, parity, error detection protocol, and XON-XOFF or DTR/DSR handshaking are all switch-selectable. Stop bits are fixed at 1

Compatibility Mode Parallel Interface. Maximum cable length: 10 ft.

•

(304.8 cm)

Environmental Ranges

Operating temperature +41°F to +104°F +5°C to +40°C

Storage temperature -40°F to +158°F

Non-condensing relative humidity

Operating 20% to 85%

Storage 20% to 85%

−40°C to +70°C

Options and Accessories

• Peel-Off capability only*

• Cutter Module

• Cutter Catch Tray

•

Media Rewind with rewind and peel-off capabilities*

•

Fanfold Supply Bin

•

ZebraNet™

•

Black-Mark (Reflective) Sensor (105Se only)

•

Scalable and bit-mapped smooth fonts

•

Additional 512 KB memory (not available for 105Se [300 dots/inch])

* Peel Off and Media Rewind options are mutually exclusive of the Cutter option.

Zebra S-Series User’s Guide 1-13

Unpacking

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

Inspection

Inspect the printer for possible damage incurred during shipment.

Check all exterior surfaces for damage.

•

Raise the Media Access Door and inspect compartment for damage

•

to components.

Reporting Damage

If you discover shipping damage upon inspection:

• Immediately notify the shipping company of the damage.

• Retain all packaging material for shipping company inspection.

Installation

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

cal distributor and Zebra Technologies Corporation of the damage.

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

shipping company or its insuring agency will generally result in ensuring any damage claim validity and ultimate monetary compensation.

Storage and Reshipping

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

Zebra S-Series User’s Guide 2-1

Temperature: -40° to +158° F (-40° to +70° C)

•

Relative humidity: 20% to 85% non-condensing

•

Should it become necessary to ship your printer, remove any ribbon

and paper roll from the supply spools, otherwise damage to the printer could result. Carefully pack the printer in a suitable container to avoid damage during transit. Whenever possible, use the original container and packaging material from the factory. If you use a different container, a procedure similar to the original factory packaging should be followed.

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

Power Connection

AC Voltage Selection Procedure

The S-Series Printer’s AC voltage may be set for either 115 VAC or 230 VAC operation. To match the printer’s power entry selection to the available power source, refer to Figure 2.1 and follow the procedure outlined below:

1. Locate the AC power area at the rear of the printer.

2. Using a small flatblade screwdriver or similar tool, move the Voltage Selection switch to the 115 V or 230 V position as required. (The initial position of the switch depends on how the printer was ordered.) Make sure that the appropriate fuse is in place. See Figure 2.1.

Figure 2.1 AC Power Area

2-2 Zebra S-Series User’s Guide

AC Power Fuse Replacement

A user-replaceable AC Power Fuse is located just above the Power ON/OFFSwitch(seeFigure2.1).Fora115VACinstallation,thereplacement fuse is a 3AG Fast Blow style rated at 5 Amp/250VAC. For a 230 VAC installation, the fuse is the same style but rated at 3 Amp/250 VAC. Make sure the fuse you use is correct for the voltage source.

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

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

115 VAC Operation

1. Confirm that the voltage selector switch is set to 115 V.

2. Attach the supplied power cord to the AC power receptacle located on the rear of the printer.

3. Connect the opposite end of the power cord to a properly grounded source of 115 VAC (50 or 60 Hz) power rated for at least 5 Amps.

230 VAC Operation

1. Confirm that the voltage selector switch is set to 230 V.

2. Depending on how the printer was ordered, a power cord may or may not be provided for 230 VAC operation. If not provided, obtain a cord set with the proper AC Power plug. The cord may then be connected to the standard (international) IEC-type 3-prong AC connector provided

ontheS-SeriesPrinter. Refer to “Appendix A” for more information.

Zebra S-Series User’s Guide 2-3

Site Requirements

CAUTION: To ensure that the S-Series Printer has proper ventilation

and cooling, do not place any padding or cushioning material on the back of or underneath the unit because this will restrict the air flow.

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

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

Ribbon Loading (105Se)

RefertoFigure2.4throughoutthisprocedure.

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

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

Note: Do not

load ribbon if the printer is to be used in the Direct

Thermal Mode.

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

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

Figure 2.2 Spindle Alignment

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

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

4. Important.....To make ribbon loading and unloading easier, make a

leader for your ribbon roll if it doesn’t already have one (refer to Figure 2.3):

Tear off a strip of media (labels and backing) about 6 to 12 inches long from the roll.

Peel off a label from this strip. Remove the remaining labels. Apply half of this label

to the end of the strip and the other half to the end of the ribbon. This acts as a ribbon

leader.

5. Thread the leader and attached ribbon as shown in the illustration. Be careful not to crease or wrinkle the ribbon.

6. Remove the Hook from the Ribbon Take-Up Spindle.

7. Place the leader under the long leg of the Hook and wind for several turns.

8. Close the printhead by moving the lever to the CLOSED position.

Figure 2.3 Making a Leader

Zebra S-Series User’s Guide 2-5

Figure 2.4 Ribbon Loading Diagram

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Ribbon Loading (160S)

RefertoFigure2.4throughoutthisprocedure.

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

Note: Do not

load ribbon if the printer is to be used in the Direct

Thermal Mode.

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

1.AlignthesegmentsoftheRibbonSupplySpindle.SeeFigure2.2.

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

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

4. Important.....To make ribbon loading and unloading easier, make a

leader for your ribbon roll if it doesn’t already have one (refer to

Figure2.3):

Tear off a strip of media (labels and backing) about 6 to 12 inches long from the roll.

Peel off a label from this strip. Remove the remaining labels. Apply half of this label

to the end of the strip and the other half to the end of the ribbon. This acts as a ribbon

leader.

5. Thread the leader and attached ribbon as shown in the illustration. Be careful not to crease or wrinkle the ribbon.

6. Place the leader around the Ribbon Take-Up Spindle and wind counterclockwise for several turns.

7. Close the printhead by moving the lever to the CLOSED position.

Zebra S-Series User’s Guide 2-7

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