Z E B R A V A L U E - L I N E
User's Guide
For the Zebra 105
and 160 ™ Printers

   Also See for Zebra 105Se

   Related Manuals for Zebra 105Se

   Summary of Contents for Zebra 105Se

  • Page 1

    Z E B R A V A L U E - L I N E -Series User's Guide For the Zebra 105 ™ and 160 ™ Printers...

  • Page 3

    Proprietary Statement Product Improvements FCC Compliance Statement Canadian DOC Compliance Statement Liability Disclaimer No Liability for Consequential Damage Copyrights...

  • Page 4: Table Of Contents

    Introduction Scope ....... . 1-1 Model Designation System Overview Communication Capabilities Thermal Transfer Printer Internal Functions Print Mechanism Capabilities Media Transport Mechanism Capabilities...

  • Page 5: Table Of Contents

    ......2-11 (105Se)....2-12 .

  • Page 6: Table Of Contents

    Operation Operating Your Zebra S-Series Printer Printer Printer Operating Modes Media Sensing Transmissive Sensing Mode Black-Mark Sensing Mode Media Transport Tear-Off Mode Peel-Off Mode Rewind Mode Cutter Mode Front Panel Keys PAUSE Key FEED CANCEL MODE Key Front Panel Lights Power On Self Test Printer Self Tests Introduction...

  • Page 7: Table Of Contents

    Sample ZPL II Label Formats Format 1: Simple Text and a Barcode Format 2: Saving a Label Format As a Graphic Image Format 3: Using a Serialized Data Configuration and Calibration Option Switches Bank 1 Bank 2 Configuration Mode Calibration......4-4 Adjusting the Print Darkness Adjusting the Media Rest Position Adjusting the Position of the Top of the Label...

  • Page 8: Table Of Contents

    Preventive Maintenance Overview Cleaning Exterior Surfaces Interior......6-1 Printhead and Platen Roller Media, Ribbon, and Label Available Cutter Module Lubrication...

  • Page 9: Table Of Contents

    Black-Mark (Reflective) Sensor (105Se Only) Optional Printer Fonts 230 VAC Factory Setup Memory Option 12-Dot/mm and 6-Dot/mm Printheads (105Se Only) Appendix A 230 VAC Power Appendix B ASCII Code Appendix C Adjusting Bar Code Appendix D Optional Printer Fonts Glossary Index .

  • Page 10: Scope, Model Designation, System Overview, Overview

    Scope This user’s guide contains descriptive information and operational in- structions for the Zebra 105Se and 160S thermal transfer demand 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.

  • Page 11: Communication Capabilities, Thermal Transfer Printer Internal Functions, Print Mechanism Capabilities, Media Transport Mechanism Capabilities

    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...

  • Page 12: Additional System Requirements, Media And Ribbon Requirements

    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 •...

  • Page 13: Warnings And Precautions, Installation, Vac Operation, Use Of Shielded Cable

    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).

  • Page 14: Ribbons And Printhead Wear, Repacking

    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 rib- bons 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.

  • Page 15: Printer Specifications, Printing Considerations, Print Speeds, Media Handling

    Programmable constant printing speeds of 2" (51 mm), 3" (76 mm), 4" (102 mm), 5" (127 mm), and 6" (152 mm) per second. The 105Se with optional 300 dots/inch resolution supports programma- ble constant printing speeds of 2.4" (61 mm), 3" (76 mm), and 4"...

  • Page 16: Media

    Media Zebra S-Series User’s Guide...

  • Page 17: Ribbon, Zebra Programming Language Ii (zpl Ii ® ), Bar Codes

    Ribbon 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 Bar Codes Code 11, Code 49, Code 93...

  • Page 18: Standard Fonts

    IBM Code Page 850 international character sets are standard in fonts A, B, C, D, E, F, G, and through software control. Note: See Font Matrices for 8 dots/mm Printhead (105Se and 160S) Font Matrix C, D...

  • Page 19

    Font Matrices for 6 dots/mm Printhead Font Matrix C, D Default: 15 x 12 * U = Uppercase, L = Lowercase, D = Descenders 1-10 Type* Inches U-L-D 0.059 0.039 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...

  • Page 20

    Font Matrices for 12 dots/mm Printhead Font Matrix C, D Default: 15 x 10 * U = Uppercase, L = Lowercase, D = Descenders Zebra S-Series User’s Guide Type* Inches U-L-D 0.029 0.016 0.036 0.023 U-L-D 0.059 0.033 OCR-B 0.138 0.066 U-L-D 0.185...

  • Page 21: Standard Printer Font Example, Physical, Electrical

    Standard Printer Font Example Physical 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”...

  • Page 22: Communications Interface, Environmental Ranges, Options And Accessories

    • 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 +41°F to +104°F...

  • Page 24: Unpacking, Inspection, Reporting Damage, Storage And Reshipping

    • Retain all packaging material for shipping company inspection. • 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.

  • Page 25: Power Connection

    • 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.

  • Page 26: Vac Operation

    A user-replaceable AC Power Fuse is located just above the Power ON/OFF Switch (see placement 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.

  • Page 27: Site Requirements, Ribbon Loading (105se)

    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 ware- house or factory floor that conform to the specified environmental and electrical conditions. Ribbon Loading (105Se) Refer to Figure 2.4 Note:...

  • Page 28

    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.

  • Page 29

    Figure 2.4 Ribbon Loading Diagram Zebra S-Series User’s Guide...

  • Page 30: Ribbon Loading (160s)

    Ribbon Loading (160S) Refer to Figure 2.4 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.

  • Page 31: Media Loading, Roll Media

    Media Loading To load media, move the Printhead Locking Lever to the OPEN posi- tion. Refer to Figures 2.5, 2.6, 2.7, and 2.8. When the media is loaded, close the printhead by moving the lever on the upper printhead mechanism to the CLOSED position. Note: The first time you load media and whenever you subsequently change the media type you must re-calibrate the printer.

  • Page 32

    Figure 2.5 Roll Media Loading Diagrams Figure 2.6 105Se Roll Media Loading (with Peel-Off) Zebra S-Series User’s Guide...

  • Page 33

    Follow the instructions described in Roll Media. The Rewind Option must be installed in the printer. To initially config- ure the printer for this mode, follow these steps: 1. Remove the Media Rewind Plate from its storage location in front of the printhead inside the media compartment.

  • Page 34: Fanfold Media

    CLOSED position. To load fanfold media, place the fanfold media in the bottom or to the rear of the media compartment or Fanfold Supply Bin (105Se only) and thread it through the printhead as shown in Figures and 2.8.

  • Page 35: Removing Used Ribbon (105se)

    2. Grasp the used ribbon and remove it from the Ribbon Take-Up Spindle. 3. Remove the empty core from the Ribbon Supply Spindle. 4. Follow the bon. Figure 2.9 Removing Used Ribbon (105Se) 2-12 Ribbon Loading procedure on page 2-4 to load the new rib-...

  • Page 36: Removing Used Ribbon (160s)

    Removing Used Ribbon (160S) Refer to Figure 2.10. 1. Turn the knob at the end of the Ribbon Take-Up Spindle (1) clockwise until it stops. This will cause the Ribbon Release Bars to pivot down (2), easing the spindle’s “grip” on the wound ribbon. 2.

  • Page 37: Initial Printer Power Up

    Initial Printer Power Up After you finish loading the ribbon and media, continue reading through “Operation” ing initial printer power-up steps as you come to them: 1. Power On Self Test (POST) 2. Calibration Subsequent power-ups will not necessarily require step 2 to be per- formed.

  • Page 38: Printer Operating Modes

    Transmissive Sensing Mode and Black-Mark Sensing Mode. The 160S comes standard with both Transmissive Sensing Mode and Black-Mark Sensing Mode capabilities. The 105Se comes standard with Transmissive Sensing Mode capability, but may be fac- tory ordered with an additional Black Mark Sensor.

  • Page 39: Tear-off Mode, Transmissive Sensing Mode, Black-mark Sensing Mode

    Transmissive Sensing Mode In Transmissive Sensing Mode, a sensor detects a light shining through a web, notch, or hole in non-continuous media. In this way, the printer determines the position of the label/tag. Black-Mark Sensing Mode In Black-Mark Sensing Mode, you use media having black marks printed on the back of the label liner for each label.

  • Page 40: Rewind Mode, Peel-off Mode, Cutter Mode

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

  • Page 41: Front Panel Keys, Pause Key, Feed Key, Cancel Key

    Front Panel Keys The PAUSE key stops and restarts the printing process. If the printer is idle (not printing) when the PAUSE key is pressed, no printing can occur. If the PAUSE key is pressed while printing is in progress, the printing stops once the current label is complete.

  • Page 42: Mode Key, Front Panel Lights

    The MODE key puts the printer in Configuration Mode. In this mode, you can adjust the Print Darkness, Media Tear-Off Position, and Label Top Position, or perform a Calibration. See bration.” Front Panel Lights Refer to Figure 3.1 Note: If an operating condition which causes a light to be ON constantly and one which causes the same light to flash occur simultaneously, the light flashes.

  • Page 43

    Zebra S-Series User’s Guide...

  • Page 44: Power On Self Test, Printer Self Tests, Troubleshooting

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

  • Page 45

    (i.e., “A,” “B,” “C,” etc.). The following chart shows the relationships between the different speeds. * Speed “A” for the 105Se with the optional 300 dots-per-inch print- head is 2.4" (61 mm). Zebra S-Series User’s Guide...

  • Page 46: Cancel Key Self Test

    This self test prints a single label which contains a listing of the printer’s current configuration parameters stored in Configuration (EEPROM) Memory. Press the CANCEL key while turning the AC Power Switch ON. See Figure 3.2. Figure 3.2 CANCEL Key Test Sample Printout Zebra S-Series User’s Guide The configuration may be changed...

  • Page 47: Pause Key Self Test

    4. While the printer is PAUSED, pressing the CANCEL key once alters the self test a third time. Now, each time the PAUSE key is pressed the printer prints 50 labels at speed “D” (“C” for the 300 dpi 105Se). Note: On printers with either the rewind or peel option installed, the Peel Mode is activated during the first half (steps 1–4) of the...

  • Page 48: Feed Key Test

    This self test can be used to provide the test printouts required when making adjustments to the printer’s mechanical assemblies. See the sample printout in The CANCEL Key Self Test should be performed before this self test. Information on the “Configuration” printout (CANCEL Key Self Test) can be used with the results of this self test to determine the best Darkness setting for a specific media/ribbon combination.

  • Page 49

    Pressing these two keys at the same time, while turning the Power ON, temporarily resets the Printer Configuration to the factory default val- ues. These values will be active until Power is turned OFF. Whenever the printer is reset to factory defaults, a Media Calibration procedure must be performed immediately.

  • Page 50: Extended Printer Diagnostics

    This test prints seven pre-programmed label formats at different speeds. The printer automatically pauses after each format. The sequence of la- bel formats is as follows: * “C” for the 105Se with the 300 dots/inch printhead Extended Printer Diagnostics Extended diagnostic tests are available. The maintenance manual, Vol.

  • Page 51: Introduction, Sample Zpl Ii Label Formats

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

  • Page 52

    ^LH30,30 ^FO20,10^AD^FDZEBRA^FS ^FO20,60^B3N,Y,20,N^FDAAA001^FS Line #1: Indicates start of label format. Line #2: Sets label home position (in dots) from the upper left-hand corner of the label. Line #3: Sets field origin, selects font “D”, defines field data as “ZEBRA”. Line #4: Sets field origin, selects bar code Code 39, sets barcode height at 20 dot rows, defines field data for bar code as “AAA001".

  • Page 53

    ^LH30,30 ^FO20,10^AD^FDZEBRA^FS ^FO20,60^B3,,40,,^FDAAA001^FS ^FO20,180^AF^SNSERIAL NUMBER 00000000111,1,Y^FS ^PQ10 Line #1 - 3: These commands were described in Format 1. Line #4: Defines field data for bar code as “AAA001". Line #5: Defines serialized field, starting value of 111, increment by 1, insert leading zeros. Line #6: Sets print quantity to 10 Line #7: (See Format 1) 3-16...

  • Page 54: Option Switches

    Configuration and Calibration Option Switches Figure 4.1 Option Switches Figure 4.2 Location of Option Switches...

  • Page 55

    Table 4.1...

  • Page 56

    Table 4.2...

  • Page 57: Configuration Mode

    Configuration Mode ZPL II Programming Guide...

  • Page 60: System Components, System Considerations

    Interconnections System Components Figure 5.1 System Components System Considerations...

  • Page 61

    since it ignores the parity of re- ceived data. The S-Series Printer is fixed at 1 stop bit, so make sure that your host is also set at 1 stop bit. RS-232 Serial Data Port Table 5.1 RS-232 Pinouts...

  • Page 62


  • Page 63

    Figure 5.2 DTE to DTE Connections Figure 5.3 DCE to DTE Connections...

  • Page 64

    Data Signal Voltage Level...

  • Page 66: Cleaning

    Preventive Maintenance Overview Cleaning Table 6.1 Cleaning Schedule...

  • Page 67

    Figure 6.1 Printhead Cleaning (105Se shown)

  • Page 69

    Figure 6.2 Cleaning the Cutter Blade CAUTION: Maintenance Manual...

  • Page 70: Toggle Positioning, Printhead Pressure Adjustment

    Toggle Positioning The 105Se has one toggle, the 160S printer has two toggles. The toggle(s) should be positioned to provide even pressure on the me- dia. Toggles are positioned by sliding them left or right to the desired location. On the 105Se, the single toggle should normally be positioned over the center of the media.

  • Page 71: Calibration, Black-mark Media Sensor Position Adjustment, Transmissive Media Sensor Position Adjustment

    Figure 7.1 Printhead Pressure Adjustment (105Se shown) Black Mark Media Sensor Position Adjustment This sensor position requires no adjustment or calibration by the user. Transmissive Media Sensor Position Adjustment The transmissive media sensor senses either the “web” between labels or a hole or notch in the media to determine the length of the label or ticket.

  • Page 72: Upper Media Sensor

    4. Tighten the Phillips head screw. To adjust the upper section of the Transmissive Media Sensor for the outside half of the media width, call a service technician. Figure 7.2 Upper Media Sensor (105Se shown) Zebra S-Series User’s Guide...

  • Page 73: Lower Media Sensor

    To adjust the lower media sensor, follow these steps. 1. Locate the lower media sensor assembly (a spring clip holding a small printed circuit board) under the rear idler roller. 2. Position the sensor so that the two brass-colored infrared emitters are under the upper sensor by sliding it in its slot.

  • Page 74: Media And Ribbon Sensor Sensitivity Adjustment

    Media and Ribbon Sensor Sensitivity Adjustment This adjustment is initially set by Zebra Technologies Corporation during final printer calibration. Under normal circumstances, further adjustments should not be necessary. The exception to this might be the use of media with exceptionally thick or thin backing, which could require re-adjustment of the Sensor Sensitivity.

  • Page 75

    If only one pair of lights is flickering, it indicates that the adjustment was not successful. Go back to step 1 and start over. 8. Open the printhead. 9. Pull the media out of the printer until a label is positioned under the printhead.

  • Page 82: Cutter Module, Peel-off, Media Rewind

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

  • Page 83: Interfaces, Fanfold Supply Bin, Zebranet (ethernet) Interface, Black-mark (reflective) Sensor (105se Only)

    Allows you to connect your printer to your ethernet network. Available for both 10Base-2 and 10Base-T networks. Black Mark (Reflective) Sensor (105Se Only) Utilizes continuous media with black marks printed on the back of the label liner. The Black Mark Sensor determines the label length and the top of the label by detecting the black mark (similar to the way a Trans- missive Sensor detects the gap or notch).

  • Page 84: Cancel Key Self Test, Optional Printer Fonts, Vac Factory Setup

    Optional Printer Fonts The S-Series Printer can be optioned with character fonts in addition to those which are standard in the unit. Only one additional font can be installed in the printer at a time. This installation should be performed by a service technician. Once in- stalled, this font can be used in addition to the standard fonts available in the printer.

  • Page 85

    12-Dot/mm and 6-Dot/mm Printhead Optional 300 dot-per-inch and 152 dot-per-inch printhead densities sat- isfy specified requirements for printing UPC/EAN symbologies or high-density graphics and small, crisp text. (Not available for 105Se (105Se Only) Zebra S-Series User’s Guide...

  • Page 86: Vac Power Cord

    Appendix A - 230 VAC Power Cord 230 VAC Power Cord Figure A.1 AC Power Cord Figure A.2 International Safety Organizations...

  • Page 88: Ascii Code Chart

    Appendix B - ASCII Code Chart...

  • Page 90: Adjusting Bar Code Darkness

    Appendix C - Adjusting Bar Code Darkness Adjusting Darkness For “In-Spec” Bar Codes...

  • Page 91

    Too Dark Slightly Dark Slightly Light Too Light In-Spec...

  • Page 92

    Figure C.1 Bar Code Examples...

  • Page 94

    Appendix D - Optional Printer Fonts ZPL II Programming Guide ® ® ®...

  • Page 95

    CG Triumvirate™ - Bold 0123456789.,?!AaBbCcDd CG Triumvirate™ - Italic 0123456789.,?!AaBbCcDdEe CG Triumvirate™ - Bold Italic 0123456789.,?!AaBb CG Times™ - Bold 0123456789.,?!AaBbCcDdEeFfGgHh CG Times™ - Italic 0123456789.,?!AaBbCcDdEeFfGg CG Times™ - Bold Italic 0123456789.,?!AaBbCcDdEeFf CG Palacio™ - Bold 0123456789.,?!AaBbCcDdEeFfGg CG Palacio™ - Italic 0123456789.,?!AaBbCcDdEeFfGg CG Palacio™...

  • Page 96

    Figure D.3 Point Size Examples...

  • Page 98

    Glossary alphanumeric backfeed bar code black mark sensing calibration (of a printer) character set check digit continuous media core diameter diagnostics direct thermal printing fanfold media font ips “inches-per-second”...

  • Page 99

    label label available sensor label backing (label liner) mark sensing media media hanger non-volatile memory print speed printhead wear reflective media sensor registration ribbon...

  • Page 100

    ribbon wrinkle roll media supplies take label sensor thermal direct printing thermal transfer printing transmissive media sensor void...

  • Page 106

    Customer order #31460L Manufacturer part #31460LB © 1996 Zebra Technologies Corporation...

This manual also for:


Comments to this Manuals

Symbols: 0
Latest comments: