Zebra Technologies R-140 User Manual

ZEBRA PERFORMANCE-LINE

R-140

User's Guide

R-140

Zebra R-140

User's Guide

Customer order # 48040L Manufacturer part # 48040LB Rev. 1

Proprietary Statement

This manual contains proprietary information of Zebra Technologies Corporation. 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 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 communications. 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 Cables.

"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.

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 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 liability 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 Corporation 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 printer described herein 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 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.

ii Zebra R-140 User’s Guide

Zebra R-140 User’s Guide iii

iv Zebra R-140 User’s Guide

TableofContents

Introduction

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

PrintMechanismCapabilities............................2

RFIDCapabilities..................................2

MediaTransportMechanismCapabilities......................2

SystemRequirements................................2

UnpackingandInspection.............................3

ReportingDamage ...............................3

Storage......................................3

MediaandRibbonRequirements .........................4

PowerCord.....................................4

PrinterAnatomy101................................5

RFIDOverview...................................6

SupportedTags..................................6

Tag-itTags....................................7

I•CodeTags...................................8

CalibratingthePrinter

Purpose.......................................9

TypesofMedia..................................10

Non-ContinuousWebMedia..........................10

Non-ContinuousBlackMarkMedia .....................11

ContinuousMedia...............................11

ChoosingthePrintMode.............................12

LoadingtheMedia.................................13

PositioningtheMediaSensors ..........................14

TransmissiveSensor..............................14

BlackMarkSensor ..............................16

ZebraR-140User’sGuide v

LoadingtheRibbon................................17

OperatorControls.................................18

POWERSwitch.................................18

FrontPanel...................................18

ConfiguringthePrinter..............................19

ConfiguringtheSoftwareorPrinterDriver....................20

MediaandRibbonCalibration ..........................21

PrintingaTestLabel................................23

EstablishingCommunication

SystemConsiderations ..............................25

Interfaces....................................25

DataSpecifications...............................25

CablingRequirements ..............................26

PrinterBasics

OperatorControls.................................27

POWERSwitch................................27

FrontPanelDisplay..............................28

FrontPanelKeys ...............................29

FrontPanelLights...............................30

RollMediaLoading ...............................31

Tear-OffMode.................................31

Peel-OffMode.................................32

RewindMode(forPrintersWithouttheCutterOption).............34

CutterMode..................................36

RewindMode(forPrintersWiththeCutterOption)..............38

FanfoldMediaLoading..............................40

RemovingtheLabelBackingMaterial......................42

RibbonLoading .................................43

RibbonRemoval .................................45

vi ZebraR-140User’sGuide

Configuration

EnteringtheSetupMode.............................47

ChangingPassword-ProtectedParameters ...................48

LeavingtheSetupMode..............................49

ConfigurationandCalibrationSequence.....................50

RoutineCareandAdjustment

Cleaning......................................69

CleaningtheExterior..............................70

CleaningtheInterior..............................70

CleaningthePrintheadandPlatenRoller...................70

CleaningtheSensors..............................71

CleaningtheSnapPlate............................72

CleaningtheCutterModule..........................74

Lubrication.....................................74

FuseReplacement.................................74

Adjustments....................................76

TogglePositioning...............................76

PrintheadPressureAdjustment ........................77

MediaSensorPositionAdjustment......................77

Troubleshooting

LEDErrorConditionsandWarnings ......................79

PrintQualityProblems..............................82

WrinkledRibbon.................................83

Communications..................................83

RFIDSymptoms..................................85

PrinterDiagnostics ................................87

Power-OnSelfTest..............................87

AdditionalPrinterSelfTests..........................87

ZebraR-140User’sGuide vii

Specifications

MediaHandling..................................93

Options ......................................93

ZebraProgrammingLanguage(ZPLII

BarCodes.....................................94

GeneralSpecifications ..............................95

PrintingSpecifications ..............................96

RibbonSpecification...............................96

MediaSpecifications...............................97

PowerLineCordSpecifications .........................98

).....................94

Appendix

PrinterInterfaceTechnicalInformation......................99

RS-232/RS-422/RS-485SerialDataPort...................99

ParallelDataPort...............................103

ZPLIICommandsforRFID...........................104

^WT–WriteTag...............................104

^RT–ReadTag................................105

^RS–RFIDSetup...............................107

^RI-RFIDGetTagUniqueID........................107

SampleZPLIILabelFormats..........................109

Format1:SimpleTextandaBarcode.....................110

Format2:SavingaLabelFormatAsaGraphicImage............110

Format3:UsingaSerializedDataField...................111

Format4:RFIDSample............................111

Index

viii ZebraR-140User’sGuide

Hello!

Introduction

Congratulations! You have just purchased the highest quality thermal demand printer with RFID capability in the industry. Manufactured by Zebra Technologies Corporation, the industry leader in quality, service, and value. For over 30 years, Zebra Technologies Corporation has provided customers with the highest caliber of products and support

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

The ZPL IIProgramming Reference Volumes I and II (part # 45540L) show you how to create the perfect label format for your application. These books also explain how, through ZBI extend 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. In addition, the books contain 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), and printed manuals can be ordered from your distributor.



, you can

The ZebraNetâNetworking: PrintServer IIäInstallation and User’s Guide (part # 45537L) explains how you can quickly set up your printer

on an IP network (optional ZebraNet PrintServer II required).

The Zebra R-140 printer, when connected to a host computer, functions as a complete system for printing and encoding “Smart” labels, tickets, and tags. The printer receives instructions from the host computer. Microprocessors continuously monitor these signals along with the inputs received from the control panel and various sensors. The microprocessors interpret this information and control the Zebra R-140 printer’s mechanical drive, printhead, RFID Subsystem, command interpretation, label formatting, and media and ribbon movement.

Zebra R-140 User’s Guide 1

Print Mechanism Capabilities

The Zebra R-140 print mechanism has been designed to print information on labels, tickets, and tags. It uses a square or rectangular dot thermal printhead that heats a ribbon as it passes beneath the print elements, melting its ink onto the media (direct thermal print mode involves using heat-sensitive media instead of an inked ribbon). Print speeds are selected via software control.

RFID Capabilities

Transponders used with the R-140 work on the 13.56 MHZ international frequency for RFID. Currently, smart labels based on chip/antenna inlays using Texas Instruments’ Tag-It RFID transponder chips are fully supported. Transponder data may be read, written and write-verified through RFID enhancements to Zebra’s ZPL II programming language. Encoding and verifying data through ZPL II is as easy as printing a bar code.



, and Philips Semiconductors’ I•Code



Media Transport Mechanism Capabilities

The media transport mechanism of the Zebra R-140 printer has been designed to accommodate various types of media including die-cut labels, ticket and tag stock, continuous roll media, fanfold media, and black-mark media.

System Requirements

In addition to the Zebra R-140 printer, you will need the following items to form a complete label preparation system:

Label-, ticket-, tag-, or “Smart” RFID label-stock

Thermal transfer ribbon (if printing in Thermal Transfer mode).

2 Zebra R-140 User’s Guide

A device, such as a personal computer (PC), for data entry and output of label formats to the printer.

A data communication cable to connect the controlling device to the Zebra R-140 printer. (Remote installations may require additional cables and communication devices such as modems and/or protocol converters.)

Unpacking and Inspection

Inspect the printer for possible damage incurred during shipment.

Check all exterior surfaces.

Raise the media access door and inspect the media compartment.

In case shipping is required, save the carton and all packing material. Contact your authorized Zebra reseller for instructions.

Reporting Damage

If you discover shipping damage:

Immediately notify and file a damage report with the shipping company.

Zebra Technologies Corporation 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: -4° to +140° F (-20° to +60° C)

Relative humidity: 5 to 85% non-condensing

Zebra R-140 User’s Guide 3

MediaandRibbonRequirements

Sinceprintqualityisaffectedbymediaandribbon,printingspeeds,and printeroperatingmodes,itisveryimportanttoruntestsforyour applications.

HighqualityRFIDLabelsarerecommendedtoensureagainstpremature printheadwear.

Fornon-RFIDapplications,weSTRONGLYRECOMMENDtheuseof ZebraTechnologiesCorporation-brandsuppliesforcontinuoushigh-quality printing.Awiderangeofpaper,polypropylene,polyester,andvinylstock hasbeenspecificallyengineeredtoenhancetheprintingcapabilitiesofthe printerandtoensureagainstprematureprintheadwear.

Continuousrollmedia,fanfoldmedia,orcardstockwithoptional perforationsandregistrationholesmaybeused.

Printheadlifemaybereducedbytheabrasionofexposedpaperfibers whenusingperforatedmedia.

TheribbonMUSTbeaswideasorwiderthanthemediabeingused.If theribbonisnarrowerthanthemedia,areasoftheprintheadwillbe unprotectedandsubjecttoprematurewear.(Whenprintingindirect thermalmode,ribbonisnotusedandshouldnotbeloadedinthe printer.)

PowerCord

WARNING!Forpersonnelandequipmentsafety,alwaysusea

three-prongplugwithaground(earth)connection.

NOTE:Dependingonhowyourprinterwasordered,apowercordmayor

maynotbeincluded.Ifoneisnotincluded,oriftheoneincluded isnotsuitableforyourrequirements,referto“PowerLineCord

Specifications”onpage98.

Thepowercordconnectormustbepluggedintothematingconnectoron therearoftheprinter.

4 ZebraR-140User’sGuide

Make sure that the POWER on/off switch (located at the back of the printer) is in the off position before connecting the power cable to an electrical outlet.

Printer Anatomy 101

Tear-off/

peel-off

bar

Printhead

lever

Platen

roller

Snap

plate

Lower

roller

Spindle

hook

Ribbon take-up

spindle

Ribbon supply

spindle

Dancer

roller

assembly

Media

guide

Rewind

spindle

(optional)

Only on select models

Media

supply

guide

Media

supply

hanger

Figure 1

Depending on the options you have selected, your printer may look slightly different.

Zebra R-140 User’s Guide 5

RFID Overview

The R140 printer contains special hardware necessary to program RFID tags. To use the RFID capabilities of this printer, you will need the

appropriate RFID media. Currently the Tag-It and I•Code tag types are

supported. This media is collectively known as an RFID tag, and includes the label, backing, and an RFID transponder inlay encased by the label material.

The RFID capabilities of the printer allow you to program, read, and obtain certain information regarding the status of the RFID subsystem. The RFID printers incorporate an antenna to program the RFID tags. RFID tags have coils built into them. When these tags line-up over the antenna, you are able to communicate to the tag to obtain information and program the tag.

Before printing on the label, the RFID commands are executed. This is done through newly added ZPL commands. After the RFID tag is programmed and verified, the printer will format and print the remaining ZPL commands.

Each tag has memory blocks that are programmed and read through ZPL commands. The ZPL commands allow the user to adjust the number of retries to get a successful execution of the command. If a block can not be programmed within the number of retries, then the formatted label is fed out with the word VOID overlaid.

After the failed tag is fed, an attempt will be made to program the tag again with the corresponding format. The reprogramming of the tag will follow the same series of commands to the tag, and the same number of retries for each block. If this tag fails to program, then this label will be fed out overlaid with a the word VOID. One final attempt will be made to reprogram the tag. If unsuccessful, a third VOID tag will be printed.

After three VOID tags, the customer format will be removed from the print

queue, and will proceed with the next format (if one exists in the buffer).

Supported Tags

The R-140 currently supports two transponder types: Tag-it and I•Code.

6 Zebra R-140 User’s Guide

Tag-it Tags

Tag-it labels are high frequency (13.56MHz) devices. Tag-it is a read/write RFID tag with 256 bits of storage capacity for user data. Data is addressed in eight blocks of 32 bits, each block containing four bytes.

Tag-it Blocks

Block # Description Bytes

0 User Data 1 User Data 2 User Data 3 User Data 4 User Data 5 User Data 6 User Data 7 User Data

32 User

Zebra R-140 User’s Guide 7

I·Code Tags

I•Code labels are also high frequency (13.56MHz) devices but have 512

bits of storage capacity. Data is addressed in sixteen blocks of 32 bits, each block containing four bytes. The first two blocks of data (block 0 and 1) are used for storage of a unique 64 bit serial number. The next two blocks (blocks 2 and 3) are used for storage of configuration information; block 4 is used for family or application identification and blocks 5 to 15 are free for user application use.

If you are using I•Code tags for your own use, and don’t require universal

special function or family codes, then you can program blocks 3 through 15.

I•Code Blocks

Block # Description Bytes

0 Serial Number (write protected) 1 Serial Number (write protected) 2 Write Protect Block (Caution!) 3 Special Function Block 4 Family Code 5 User Data 6 User Data 7 User Data 8 User Data

9 User Data 10 User Data 11 User Data 12 User Data 13 User Data 14 User Data 15 User Data

8 Optional

40 User

8 Zebra R-140 User’s Guide

This chapter of the user’s guide is so important that we’ve printed it on a different color paper! That way, it will be easy for you to find when you must calibrate (set up) the printer for your particular application.

Purpose

NOTE: This procedure must be performed when the printer is first

To calibrate the printer, you must do the following (all of the instructions are contained in this chapter):

Calibrating the Printer

To calibrate the printer.

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

installed or when it cannot properly detect the top of the label.

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 used.

Perform a media and ribbon calibration.

Print a test label.

Zebra R-140 User’s Guide 9

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.

Hole

Label gap (2-4 mm)

Notch

Non-continuous media with a hole or notch

Label gap (2-4 mm)

Non-continuous media with gaps between the labels

(individual labels on a continuous liner)

Figure 2

10 Zebra R-140 User’s Guide

Non-Continuous Black Mark Media

Non-continuous black mark media has black marks printed on the back that indicate the start and end of each label (refer to Figure 3).

Black mark

Non-continuous media for black mark sensing

Figure 3

Continuous Media

Black mark

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

Continuous media (no gaps, holes, notches, or black marks)

Figure 4

Zebra R-140 User’s Guide 11

Choosing the Print Mode

Tear-off mode allows you to tear off each label, or a strip of labels, 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.

When in cutter mode, the printer automatically cuts the label after it is printed.

In rewind mode, the media and backing are rewound onto a core as the labels are printed.

NOTE: Peel-off and Rewind mode may not be suitable for all RFID media

types.

12 Zebra R-140 User’s Guide

LoadingtheMedia

Figure5illustratesonemethodofmedialoading.Formoredetailed instructions,aswellasinformationabouthowtoloadthedifferenttypesof mediaandthevariousprintingmodes,refertotheinstructionsthatbeginon

page31.

Figure5

ZebraR-140User’sGuide 13

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, better 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 so that the printer can detect an out-of-paper condition.

14 Zebra R-140 User’s 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).

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 (Phillips head).

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

5. Secure the upper media sensor adjustment screw.

Figure 6

Zebra R-140 User’s Guide 15

AdjustingtheLowerMediaSensor

Positionthelowermediasensor(refertoFigure7)byslidingitinitsslot untilitispositionedundertheuppermediasensor.

Figure7

BlackMarkSensor

Theblackmarksensorisinafixedpositionandenabledviathefrontpanel (detailsin“ConfiguringthePrinter”onpage19).

16 ZebraR-140User’sGuide

LoadingtheRibbon

Toloadribbon,refertoFigure8.Formoredetailedinformation,referto theinstructionsthatbeginonpage43.

Figure8

ZebraR-140User’sGuide 17

OperatorControls

POWERSwitch

ThePOWERswitchislocatedatthebackoftheprinterabovethepower cordandfuse.Turnontheprinter.

FrontPanel

Thestep-by-stepinstructionsinthis sectiontellyouwhichkeystopress andwhatappearsontheliquidcrystal display(LCD)duringthecalibration procedure.

Foramoredetailedexplanationofthe frontpanelkeysandlights(asshown inFigure9),refertotheinstructions thatbeginonpage28.

Figure9

18 ZebraR-140User’sGuide

ConfiguringthePrinter

Theconfigurationprocedureinthenexttablecontainstheinformationyou needtogetyourprinterupandrunning,butitisnotcomprehensive.Refer topage47formoreinformation.

EntertheconfigurationmodebypressingtheSETUP/EXITkeyatthe “PRINTERREADY”display.

NOTE:YouwillneedtopresstheNEXT/SAVEkeymorethanonceto

advancetosomeofthedisplays.

Toincreasethevalue,answer“yes,”indicate“on,”ormovetothenext selection,usetheRIGHTBLACKOVALkey.

Todecreasethevalue,answer“no,”indicate“off,”orreturntothe previousselection,usetheLEFTBLACKOVALkey.

NOTE:Whenchangingparameters,anasterisk(*)intheupperleft-hand

cornerofthedisplayindicatesthatyouhavechangedthissetting fromwhatiscurrentlystoredinmemory.

ZebraR-140User’sGuide 19

Press Display Shows Action/Explanation

- PRINTER READY Normal printer operation.

DARKNESS

PRINT MODE

MEDIA TYPE

SENSOR TYPE

PRINT METHOD

MAXIMUM LENGTH

SAVE SETTINGS

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

Press the BLACK OVAL keys to select tear-off, peel-off, cutter, or rewind mode.

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

Press the BLACK OVAL keys to set the value that is closest to, but not less than, the length of the label you are using.

Press the BLACK OVAL keys to select:

PERMANENT -- saves the changes when the power is turned

off.

Press NEXT/SAVE to accept the selection.

- PRINTER READY

You have exited the configuration mode and are now 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. Refer to the driver or software documentation for more information.

20 Zebra R-140 User’s Guide

Media and Ribbon Calibration

NOTE: All steps must be performed in the following procedure, even if

only one sensor needs to be adjusted.

6. Press the SETUP/EXIT key.

7. Press the NEXT/SAVE key until “MEDIA AND RIBBON CALIBRATE” displays.

8. To start the calibration procedure, press the RIGHT BLACK OVAL key. “LOAD BACKING CANCEL CONTINUE” displays.

9. Open the printhead. Remove approximately 8” (203 mm) of labels from the media roll, enough so that only the backing material is threaded between the media sensors when the media is loaded (refer to Figure 10).

Figure 10

Zebra R-140 User’s Guide 21

+ 96 hidden pages