Zebra 105Se Users Manual

2014-12-11

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115 VAC Operation 2-3

ZEBRA VALUE-LINETM

-Series

User's Guide

For the Zebra 105 ™

and 160 ™ Printers

Proprietary Statement

Product Improvements

FCC Compliance Statement

Canadian DOC Compliance Statement

Liability Disclaimer

No Liability for Consequential Damage

Copyrights

Table of Contents

Introduction

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ZebraProgrammingLanguageII(ZPLII)..........1-8

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

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

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

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

Zebra S-Series User’s Guide i

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

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

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

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

Installation

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

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

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

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

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

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

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

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

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

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

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

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

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

Appendix A

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

Appendix B

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

Appendix C

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

Appendix D

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

Glossary

Index

vi Zebra S-Series User’s Guide

Introduction

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. 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

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 Asso-

ciation (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 micro-

processor continuously monitors these signals along with the inputs re-

ceived from the control panel and various sensors. The microprocessor

interprets this information and controls the S-Series Printer me-

chanics, printhead, communications, command interpreta-

tion, label formatting, media control, and mechanical drive.

Print Mechanism Capabilities

The print mechanism has been designed to print random information la-

bels, 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 de-

signed 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 stan-

dard 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 com-

munication 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, polypropyl-

ene, 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 cool-

ing, 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, Sub-

part 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 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.

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 con-

tainer 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

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.

The 105Se with optional 300 dots/inch resolution supports programma-

ble 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 re-

wound 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 print-

ing; under software control.

1-6 Zebra S-Series User’s Guide

Media

Zebra S-Series User’s Guide 1-7

Ribbon

Zebra Programming Language II (ZPL II )

Bar Codes

1-8 Zebra S-Series User’s Guide

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)]

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

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 ex-

pandable on a dot-by-dot basis, height- and width-independent, while

maintaining smooth edges. Maximum size depends on available mem-

ory.

Fonts A, B, C, D, E, F, G, and H are expandable up to 10 times, height-

and 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 Type* Character Size

Inches Millimeters

Height

Width

Inter-

character

gap

Height

Width

Char./inch

Height

Width

Char./mm

A95 1 U-L-D 0.044 0.029 33.90 1.13 0.75 1.33

B11 7 2 U 0.054 0.044 22.60 1.38 1.13 0.89

C, D 18 10 2 U-L-D 0.088 0.059 16.95 2.25 1.50 0.67

E28 15 5 OCR-B 0.138 0.098 10.17 3.50 2.50 0.40

F26 13 3 U-L-D 0.128 0.079 12.71 3.25 2.00 0.50

G60 40 8 U-L-D 0.295 0.236 4.24 7.50 6.00 0.17

H21 13 6 OCR-A 0.103 0.093 10.71 2.63 2.38 0.42

GS 24 24 0 SYMBOL 0.118 0.118 8.48 3.00 3.00 0.33

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

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

Zebra S-Series User’s Guide 1-9

Font Matrices for 6 dots/mm Printhead

Font Matrix Type* Character Size

Inches Millimeters

Height

Width

Inter-

character

gap

Height

Width

Char./inch

Height

Width

Char./mm

A95 1 U-L-D 0.059 0.039 25.40 1.50 1.00 1.00

B11 7 2 U 0.072 0.059 16.93 1.83 1.50 0.67

C, D 18 10 2 U-L-D 0.118 0.079 12.70 3.00 2.00 0.50

E21 10 3 OCR-B 0.138 0.085 11.72 3.50 2.17 0.46

F26 13 3 U-L-D 0.171 0.105 9.53 4.33 2.67 0.38

G60 40 8 U-L-D 0.394 0.315 3.18 10.00 8.00 0.13

H17 11 4 OCR-A 0.112 0.098 10.16 2.83 2.50 0.40

GS 24 24 0 SYMBOL 0.157 0.157 6.35 4.00 4.00 0.25

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

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

1-10 Zebra S-Series User’s Guide

Font Matrices for 12 dots/mm Printhead

Font Matrix Type* Character Size

Inches Millimeters

Height

Width

Inter-

character

gap

Height

Width

Char./inch

Height

Width

Char./mm

A95 1 U-L-D 0.029 0.016 50.80 0.73 0.40 2.00

B11 7 2 U 0.036 0.023 33.86 0.91 0.58 1.34

C, D 18 10 2 U-L-D 0.059 0.033 25.40 1.49 0.83 1.00

E42 20 6 OCR-B 0.138 0.066 23.44 3.50 1.67 0.92

F26 13 3 U-L-D 0.185 0.042 19.06 2.15 1.06 0.76

G60 40 8 U-L-D 0.198 0.132 6.36 5.02 3.35 0.26

H34 22 8 OCR-A 0.112 0.072 20.32 2.84 1.82 0.80

GS 24 24 0 SYMBOL 0.079 0.079 12.70 2.00 2.00 0.50

0Default: 15 x 10 U-L-D Scalable

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

Zebra S-Series User’s Guide 1-11

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” 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 −40°C to +70°C

Non-condensing relative

humidity

Operating 20% to 85%

Storage 20% to 85%

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

Installation

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.

•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 en-

suring any damage claim validity and ultimate monetary compensa-

tion.

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 con-

tainer, a procedure similar to the original factory packaging should be

followed.

CAUTION: Do not package the printer in a rigid container without util-

izing shock mounts or shock-absorbing packing material. A rigid con-

tainer 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 ap-

propriate fuse is in place.

See Figure 2.1.

2-2 Zebra S-Series User’s Guide

Figure 2.1 AC Power Area

AC Power Fuse Replacement

A user-replaceable AC Power Fuse is located just above the Power

ON/OFFSwitch(seeFigure2.1).Fora115VACinstallation,there-

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. 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 dis-

engage 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 suf-

ficient 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 ware-

house 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, exces-

sive abrasion may cause premature printhead failure.

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

2-4 Zebra S-Series User’s Guide

Figure 2.2 Spindle Alignment

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 care-

ful 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.

Zebra S-Series User’s Guide 2-5

Figure 2.3 Making a Leader

2-6 Zebra S-Series User’s Guide

Figure 2.4 Ribbon Loading Diagram

Ribbon Loading (160S)

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 print-

head is not protected by the smooth backing of the ribbon, excessive abra-

sion 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 care-

ful not to crease or wrinkle the ribbon.

6. Place the leader around the Ribbon Take-Up Spindle and wind counter-

clockwise for several turns.

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

Zebra S-Series User’s Guide 2-7

Media Loading

To load media, move the Printhead Locking Lever to the OPEN posi-

tion.RefertoFigures2.5,2.6,2.7,and2.8.Whenthemediaisloaded,

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. See

the Configuration and Calibration Section.

Roll Media

Roll media may contain labels of a fixed length with gaps in between or

itmaybeformedasonecontinuouslengthwithnogaps(seeContinu-

ousMediaintheGlossary).Bothtypesofrollmediamountinsidethe

printerinthesamemanner.Toloadrollmedia,refertoFigure2.5

and/or2.6anddothefollowing:

1. Move the Media Guide and Media Supply Guide as far away from the

printer frame as possible.

2. Place the media roll on the Media Supply Hanger.

3. Push the Media Supply Guide inward until it is just touching the outer

side of the Media Supply Roll. (The Guide must not cause pressure or

excessive drag on the Media Supply Roll.)

4. Thread the media through the printhead as shown in the illustrations.

5. Adjust the Media Guide until it just touches the outer edge of the media

without causing it to buckle.

6. Close the printhead by moving the lever located on the upper printhead

assembly to the CLOSED position.

2-8 Zebra S-Series User’s Guide

Zebra S-Series User’s Guide 2-9

Figure 2.6 105Se Roll Media Loading (with Peel-Off)

Figure 2.5 Roll Media Loading Diagrams

Tear-Off Mode

Follow the instructions described in Roll Media.

Rewind Mode

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.

2. Invert the Rewind Plate so that the lip on the attached Hook Plate points

down.

3. Insert the Hook Plate lip a short distance (1/2") into the lower opening

in the Side Plate.

4. Align the upper end of the Rewind Plate with the corresponding opening

in the Side Plate and slide the Rewind Plate in so that it stops against the

Main Frame.

5. Remove the Hook from the Take-Up Spindle Shaft.

6.RoutethemediaasshowninFigures2.5and2.6,windit1-2times

around a 3" core.

Peel-Off Mode

After loading the media, follow these steps:

1. Remove the Rewind Plate if one is present and store it on the two

mounting screws on the inside of the front panel. Align the notch or

web in the media so that the Take Label Sensor can sense a peeled la-

bel.

2.LoadmediaasshowninFigures2.5and2.6.

3. Remove the Hook from the Take-Up Spindle Shaft.

4. Remove several labels from the media backing and then wind the back-

ing 1-2 times around the Media Take-Up Spindle and reinstall the

Hook.

2-10 Zebra S-Series User’s Guide

Cutter Mode

Follow the instructions described in Roll Media with the exception of

step6:firstroutethemediathroughtheCutterModule(seeFigures2.5

and2.6)andthenclosetheprintheadassemblybymovingtheleverlo-

cated on the upper printhead assembly to the CLOSED position.

Fanfold Media

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

threaditthroughtheprintheadasshowninFigures2.7and2.8.Adjust

the media guide using the thumb screw to keep the media from drifting

left or right.

Fanfold media from outside the printer feeds through one of the two ac-

cess slots, one at the bottom of the printer and one at the rear.

Zebra S-Series User’s Guide 2-11

Figure 2.7 Fanfold Media Loading Diagrams (105Se)

Removing Used Ribbon (105Se)

To remove used ribbon, refer to Figure 2.9 and follow the steps below.

1. Pull the hook out slightly, then rotate the hook back-and-forth several

times as shown and remove it from the spindle.

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.FollowtheRibbonLoadingprocedureonpage2-4toloadthenewrib-

bon.

2-12 Zebra S-Series User’s Guide

Figure 2.8 Fanfold Media Loading Diagrams (160S)

Figure 2.9 Removing Used Ribbon (105Se)

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. Slide the ribbon off of the Ribbon Take-Up Spindle. Once the used rib-

bon has been removed, ensure that the arrow on the knob aligns with

the indented notch in the Ribbon Take-Up Spindle (see inset).

3. Remove the empty core from the Ribbon Supply Spindle.

4.Followtheribbonloadingprocedureonpage2-7toloadthenewrib-

bon.

Zebra S-Series User’s Guide 2-13

Figure 2.10 Removing Used Ribbon (160S)

Initial Printer Power Up

After you finish loading the ribbon and media, continue reading through

“Operation”and“ConfigurationandCalibration.”Performthefollow-

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.See“Operation”and“ConfigurationandCalibration”forfur-

ther information.

2-14 Zebra S-Series User’s Guide

Operation

Operating Your Zebra S-Series Printer

Now that your printer is ready for operation, how does it work? The

Zebra S-Series Printer is designed to receive instructions from a host

computer, such as an IBM-compatible PC. To create a label, you will

either need to use label design software or write a format in ZPL II ,

which is a programming language for creating label formats. If you are

using label design software, refer to the instructions provided with your

software package to determine how to proceed.

If you are using, or plan to use, ZPL II, make sure you have a copy of

the ZPL II Programming Guide. This guide was available at the time

you ordered your printer, but if you do not have a copy then submit the

mail- or fax-in card in the front of this book to get a copy. For some

sample ZPL II label formats, refer to the information at the end of this

chapter. But first, we’ll describe the different operating modes.

Printer Operating Modes

The S-Series Printer can be configured for several different modes of

operation by sending the proper commands from the host computer.

Operating modes may also be configured via a bank of DIP switches at

therearoftheprinter.(See“ConfigurationandCalibration”formore

information about DIP switches.)

Media Sensing Modes

There are two basic modes by which the printer can sense the position

of the media: 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.

Zebra S-Series User’s Guide 3-1

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. To determine the

label length and top of label, the printer’s Black Mark Sensor detects

the black mark similar to the way in which the Transmissive Sensor de-

tects the notch or gap in the media.

Media Transport Modes

Tear-Off Mode

When the media is in the rest (idle) position, the webbing between la-

bels is over theTear-Off/Peel-Off Bar. 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.

After a label is printed, the media feeds forward until the end of the la-

bel is past the Tear-Off/Peel-Off Bar. This label position is determined

by commands sent to the printer from the host computer or by front

panel adjustments.

When a quantity of labels is required, a format for printing a batch of

labels can be sent to the printer. Once a label is printed, the media will

feed forward to the start of the next label and printing will continue. In

this way, the printer will print the batch and stop when it reaches the

quantity required.

When a quantity of individual labels is required, the format for printing

a batch of labels can still be sent to the printer. The operator can use

the PAUSE Key to cycle the printing one label at a time. The operator

can then tear off each label before printing the next one.

3-2 Zebra S-Series User’s Guide

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.

In this mode, once the label is printed, the media passes over the Tear-

Off/Peel-Off Bar at an extremely sharp angle. The backing material is

peeled away from the label and winds around the Peel-Off Spin-

dle or the Media Rewind Spindle. The media feeds forward until

most of the label hangs loose from the backing. The label is held

in this position by that portion of the backing that has not crossed

the Tear-Off/Peel-Off Bar.

The Label Available Sensor is located on the printer in a position where

it is activated by the label. When the operator removes the label, the

printer backfeeds the media either to the rest (idle) position or to the

printing position and prints the next label. When it is necessary to re-

move the media backing from the Take-Up Spindle, you do not need to

turn the printer OFF.

Rewind Mode

Some applications call for the media to be rewound onto a core as the

labels are printed.

When the media is in the rest (idle) position, the start of the next label is

directly under the printhead. After the label is printed, the media feeds

forward until the start of the next label is under the printhead. The media

never backfeeds in this mode.

When the printer completes a batch of labels, printing will stop.

Cutter Mode

In this mode the cutter, under software control, automatically cuts indi-

vidual labels (or at the end of batches of labels) after printing. The op-

tional Cutter Catch Tray gathers the completed labels.

Zebra S-Series User’s Guide 3-3

Front Panel Keys

PAUSE Key

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. Pressing the

PAUSE key a second time resumes the

printing process.

FEED Key

The FEED key forces the printer to feed

one blank label. If the printer is idle, or

if the PAUSE function is active when

the FEED key is pressed, one blank la-

bel feeds from the printer immediately.

If the printer is printing, then one blank

label feeds out after completion of the

current batch of labels. After one blank

label feeds out, pressing FEED again

provides another blank label.

CANCEL Key

The CANCEL key is only recognized in

PAUSE mode. Press CANCEL to can-

cel the current label format. If no for-

mat is printing, then the next one to be

printed will be canceled. If no formats

are in memory, the CANCEL key is ig-

nored. If the CANCEL key is pressed

for an extended period of time (3 sec-

onds), the printer cancels all formats in

memory and the DATA light turns OFF.

3-4 Zebra S-Series User’s Guide

Figure 3.1

Printer Front Panel

MODE Key

The MODE key puts the printer in Configuration Mode. In this mode,

you can adjust the Print Darkness, Media Tear-Off Position, and Label

TopPosition,orperformaCalibration.See“ConfigurationandCali-

bration.”

Front Panel Lights

RefertoFigure3.1forthelocationofthelights.

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.

Zebra S-Series User’s Guide 3-5

3-6 Zebra S-Series User’s Guide

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. At the end of this self test, only the POWER light

willremainlit.Ifotherlightsarealsolit,refertotheTroubleshootingSec-

tion.

Printer Self Tests

Introduction

These self tests produce sample labels and provide specific information

that helps determine the operating conditions for the printer.

Each self test is enabled by holding in a specific Front Panel key or

combination of keys while turning the Power Switch ON. Keep the key

depressed until the Front Panel Lights turn ON.

When the Power On Self Test is completed, the selected self test auto-

matically starts.

Notes: When performing self tests, all data interface cables connected

to the rear of the printer must be removed.

When canceling a self test before its actual completion, always

turn the printer Power OFF and then back ON to reset the

printer.

When performing these self tests in the Peel-Off Mode, the

operator must remove the labels as they become available.

Unless specifically stated, all tests print in Tear-Off mode in

Tear-Off printers and in Peel-Off Mode for Peel and Rewind

printers.

Zebra S-Series User’s Guide 3-7

If your media is not wide enough, the test labels will only print

out to the edge of the label. If your media is too short, the test

label will continue printing on the next label.

Some of the printer self tests produce labels at varying print speeds.

These speeds may be referred to as “inches per second,” “millimeters

per second,” or by alphabetic letter designation (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).

3-8 Zebra S-Series User’s Guide

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.

The configuration may be changed

either temporarily (for specific label

formats or ribbon and label stock), or

permanently (by saving the new pa-

rameters in EEPROM Memory). Sav-

ing new parameters occurs whenever

a Printer Calibration procedure is

performed. Refer to the procedure

in“ConfigurationandCalibration.”

Zebra S-Series User’s Guide 3-9

Figure 3.2 CANCEL Key Test

Sample Printout

PAUSE Key Self Test

This self test is actually comprised of four individual test features.

1. The initial self test prints 15 labels at speed “A” then automatically

PAUSES the printer. Each time the PAUSE key is pressed, an addi-

tional 15 labels print out.

2. While the printer is PAUSED, pressing the CANCEL key once alters the

self test. Now each time the PAUSE key is pressed the printer prints 15 la-

bels at speed “D” (“C” for the 300 dpi 105Se).

3. While the printer is PAUSED, pressing the CANCEL key a second time al-

ters the self test again. Now, each time the PAUSE key is pressed the

printer prints 50 labels at speed “A.”

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

PAUSE Key Self Test. On printers with a rewind option, the

rewind plate must be removed for proper function of the peel

sensors during the test. The first label to print will say, “PEEL

OPTION INSTALLED”. Each label must be manually

removed from the sensor path before the next label will print.

Steps 1–4 will then be repeated in Rewind Mode.

3-10 Zebra S-Series User’s Guide

Figure 3.3 PAUSE Key Test Sample Printout

This self test can be used to provide the test printouts required when

making adjustments to the printer’s mechanical assemblies. See the

sampleprintoutinFigure3.3.

FEED Key Self Test

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.

The FEED Key Self Test will print out at various Darkness settings

above and below that of the Darkness value shown on the Configuration

Label. Inspect these labels and determine which one has the best

darkness setting for the application. This value can be entered into the

printer by setting the Darkness during the configuration procedure.

The value printed on that label is added

to (plus) or subtracted from (minus) the

“Darkness” value specified on the Con-

figuration Label. The resulting numeric

value (0 to 30) is the best darkness

value for that specific media/ribbon

combination.

Optionally, the Darkness value can be

programmed into the ZPL II formats

sent to the printer.

Zebra S-Series User’s Guide 3-11

Figure 3.4 FEED Key Test Sample Printout

FEED Key and PAUSE Key Self Test

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.

MODE Key Self Test

This test places the printer in the Communications Diagnostics Mode.

In this mode, the printer prints the ASCII characters and their corre-

sponding hexadecimal values for any data received from the host com-

puter. A typical printout from this test is shown in Figure 3.5.

Note: This label will be inverted when printed.

PAUSE Key and CANCEL Key Test

This test prints a maximum of 500 Head Test labels. Each label back-

feeds prior to printing and feeds forward to the rest position after print-

ing. A serialized number prints on each label. Press the PAUSE key or

turn the printer power OFF to stop printing. The labels look like the

oneinFigure3.3exceptthataserializednumberwillprintoneachla-

bel.

3-12 Zebra S-Series User’s Guide

Figure 3.5 Results of Communications Diagnostic Test

FEED Key and CANCEL Key Test

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. 1: General Maintenance (part # 38452L), provides the information

needed to perform these additional tests.

Zebra S-Series User’s Guide 3-13

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.

This section contains three sample label formats for you to begin ex-

perimenting with. It is not intended as an introduction to ZPL II. To

learn about ZPL II, send in the request card at the beginning of this

book for a copy of the ZPL II Programming Guide.

For each format, do the following:

1. Save the file.

2. Copy the file to the printer.

•Set-up the printer and turn the Power ON.

•Use a text editing program (ex: Windows Write or DOS Editor) and

type in the label format exactly as shown in the sample label format

shown below.

•Save the file in a directory for future use. Use the extension “ . zpl”.

•Copy the file to the Zebra S-Series Printer.

Note: Typically, computers running DOS use the “COPY” command

to send a file to the Zebra printer. For example, if your file

name is “format1.zpl” then type, “COPY FORMAT1.ZPL

COM1”.

3. Compare your results with those shown. If your printout does not look

like the one shown, confirm that the file you created is identical to the

format shown, then repeat the printing procedure. If nothing prints, re-

ferto“Installation”tomakesureyoursystemissetupcorrectly,other-

wisereferto“Troubleshooting.”

3-14 Zebra S-Series User’s Guide

Format 1: Simple Text and a Barcode

^XA

^LH30,30

^FO20,10^AD^FDZEBRA^FS

^FO20,60^B3N,Y,20,N^FDAAA001^FS

^XZ

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".

Line #5: End of label format.

Format 2: Saving a Label Format As a Graphic Image

^XA

^LH30,30

^FO20,10^AD^FDZEBRA^FS

^FO20,60^B3N,Y,20,N^FDAAA001^FS

^ISFORMAT2,N

^XZ

^XA

^ILFORMAT2

^XZ

Line #1-4: These commands were described in Format 1.

Line #5: Saves the format in the printer’s memory as a graphic image named

“FORMAT2", the ”N" indicates “do not print after saving”.

Line #6-7: (See Format 1)

Line #8: Load and print the graphic image saved as “FORMAT2".

Line #9: (See Format 1)

Zebra S-Series User’s Guide 3-15

Format 3: Using a Serialized Data Field

^XA

^LH30,30

^FO20,10^AD^FDZEBRA^FS

^FO20,60^B3,,40,,^FDAAA001^FS

^FO20,180^AF^SNSERIAL NUMBER

00000000111,1,Y^FS

^PQ10

^XZ Ten labels should print. The first and

last are shown here.

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 Zebra S-Series User’s Guide

Configuration and Calibration

Option Switches

These switches are located at the

rear of the printer above the Signal

Interface Cable Connection. See

Figure 4.2.

In the tables on the following page,

an “R” means the switch is OFF (po-

sitioned to the right), while an “L”

means the switch is ON (positioned

to the left). All switches are in the

OFF position when the printer is

shipped from the factory.

Zebra S-Series User’s Guide 4-1

Figure 4.1 Option Switches

Figure 4.2 Location of Option Switches

Bank 1 (For Serial Interface Printers Only)

The S-Series Printer, with the

RS-232 Serial Interface, uses

eight miniature switches located

on the rear of the printer, above

the Signal Interface Cable Con-

nector. The ON/OFF positions

of these switches establish some

of the Printer Configuration Pa-

rameters. Bank 1 switches must

be properly positioned to estab-

lish serial data communications

with the host computer. There-

after, the position of these

switches should not be changed.

Note: Parallel-interface

printers do not require

these configuration

parameters, therefore

they have no Bank 1

switches.

If these switches are in the

proper position to match the

communication configuration of

the host computer, and the

printer is not receiving data, re-

ferto“Interconnections”and

make sure the correct interface

cable is being used.

Note: The printer is fixed at 1

stop bit, so make sure

that your host device is

also set at 1 stop bit.

4-2 Zebra S-Series User’s Guide

Table 4.1

Bank 2

These switches can manually override any ZPL II commands that affect

print mode, media mode, and media type. They can also override set-

tings established during the calibration procedure. Reasons why you

might want to use these override switches:

•Troubleshooting. By using these switches,

you know beyond a doubt what operating

mode your printer is in.

•Lets you use a single ZPL II label format for

many different printers—without worrying if

the format contains a mode command that is

inappropriate for your printer configuration.

•Some third-party label design software pack-

ages work better if these switches control the

mode.

If you do not want to override ZPL II or the

calibration settings, disable one or more of the

override options by setting switches 1, 4, and/or

7 to the R (OFF) position and turning the power

ON. With these disabled, the printer will re-

quire ZPL II commands and/or re-calibration to

set print mode, media mode, and/or media type.

To override, set the switches to one of the

modes shown in the table. If you are in the pro-

cess of printing, this change takes effect on the

next label printed. If you change the switches

from active to disabled after printer power-up,

the printer remains in the current mode until a

ZPL II command or re-calibration changes the

mode.

105Se Note: Switch 5 must not be positioned to the right unless the

printer is equipped with the optional black mark sensor.

Zebra S-Series User’s Guide 4-3

Table 4.2

Configuration Mode

The Configuration Mode allows you to fine-tune the internal printer

configuration settings for your application. In this mode, you can

change the following parameters:

•Printing darkness

•Rest position of the media with respect to the “web” or “interlabel

gap”

•Position of printing relative to the top of the label

•Media and Ribbon Sensor values

•Label length

•Printing method

•Media type (continuous or non-continuous)

You can get a printout of the printer configuration (the values for each

of these parameters) at any time by performing the CANCEL Key Self

Test(see“Operation”).

Ifitisevernecessarytoresetthe printer configuration to the factory de-

faults,refertothe“FEEDKeyand PAUSE Key”SelfTestdescriptionin

“Operation.”

TheZPLIIProgrammingGuidecontainsinformation on instructions

that may be sent to the printer to disable the MODE key and set specific

label format values for each of these parameters. If you are not using

ZPL II, refer to the instructions provided with your software package to

determine if you also have this capability.

Calibration

IMPORTANT: Perform the Calibration Procedure when media and

ribbon are first installed and each time a different type of media or rib-

bon is installed.

4-4 Zebra S-Series User’s Guide

During this procedure, the printer automatically determines the media

type, label length, media and ribbon sensor settings, and printing

method. Media type is determined by sensing either continuous or

non-continuous media as blank labels move through the printer. If

non-continuous media is sensed, Label Length is also calibrated. If rib-

bon is sensed, the Thermal Transfer Print Method is configured. If no

ribbon is present, the Direct Thermal Print Method is configured.

The results of this calibration are stored in the printer’s memory. These

parameters will remain in effect until the next calibration is performed.

The Printer Configuration Printout, which prints when the CANCEL

Key Self Test is performed, lists these results as well as other printer

parameters.

Note: If the printer is in the Peel-Off Mode, the operator must

“catch” the labels as they are peeled away from the backing

during this procedure.

1. Load media and ribbon (if used). Make sure the Media Sensor is prop-

erlypositioned(see“Adjustments”).

IMPORTANT: To use the Black-Mark Sensing Mode, make sure you

settheBank2DIPswitchesappropriately(seepage4-3).

2. Turn the power switch ON. When the Power ON Self Test is complete,

the POWER, PAUSE, and PAPER/RIBBON lights will be ON.

3. Press the MODE key three times briefly. PAUSE and CALIBRATE

lights turn ON.

4. Press UP (FEED Key) to calibrate. The printer feeds some media. The

MODE lights will flash ON and OFF to indicate that the settings have

been saved in memory.

5. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF.

Zebra S-Series User’s Guide 4-5

Adjusting the Print Darkness

This procedure sets the darkness of the printing on the label. Use the

lowest setting which provides the necessary print quality.

1. Press the MODE key. PAUSE and DARKEN lights turn ON.

2. Press UP or DOWN to adjust the current setting.

3. Press the MODE key three times. The MODE lights will flash ON and

OFF to indicate that the settings have been saved in memory.

4. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF.

Adjusting the Media Rest Position

This procedure sets the end-of-label position relative to the Tear-Off

Bar or Cutter.

1. Press the MODE key twice briefly. PAUSE and POSITION lights turn

ON.

2. Press UP or DOWN to adjust the current setting.

3. Press the MODE key twice briefly. The MODE lights will flash ON

and OFF to indicate that the settings have been saved in memory.

4. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF.

Adjusting the Position of the Top of the Label

This procedure positions the printing on the label relative to the top

edge of the label.

1. Press the MODE twice briefly then press and hold for about five sec-

onds until the lights change. PAUSE and DARKEN and CALIBRATE

lights turn ON.

2. Press UP or DOWN to adjust the current setting.

3. Press the MODE key twice briefly. The MODE lights will flash ON

and OFF to indicate that the settings have been saved in memory.

4. Press PAUSE to exit PAUSE mode. PAUSE light turns OFF.

4-6 Zebra S-Series User’s Guide

Interconnections

System Components

System Considerations

Communications Code

The Zebra S-Series Printer sends and receives American Standard Code

for Information Interchange (ASCII). This code consists of 128 charac-

ters (256 for Code Page 850) including upper and lower case letters,

punctuation marks, and various control codes.

Interfaces

The method of interfacing the Zebra S-Series Printer to a data source

depends on the communication options installed in the printer. Depend-

ing on how the printer was ordered, the interface is either an RS-232 se-

rial data port or a parallel port.

Zebra S-Series User’s Guide 5-1

Figure 5.1 System Components

Data Specifications

When communicating via the serial data port (RS-232), the baud rate,

numberofdatabits,andtheparityareuser-selectable(see“Configura-

tionandCalibration”foracceptablesettingcombinations).Parityonly

applies to data transmitted by the printer, 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.

When communicating via the parallel port, the previously mentioned

parameters are not considered.

RS-232 Serial Data Port

The connections for the standard interface are made through the DB25S

connector on the rear panel. For all RS-232 input and output signals, the

S-Series Printer follows both the Electronics Industries Association’s (EIA)

RS-232 and the Consultative Committee for International Telegraph and Tele-

phone (CCITT) V.24 standard signal level specifications.

5-2 Zebra S-Series User’s Guide

Table 5.1 RS-232 Pinouts

Hardware Control Signal Descriptions

Request To Send (RTS) is a Control Signal from the S-Series Printer to

the host computer. RTS is always in the ACTIVE condition (positive

voltage) whenever the printer is powered ON.

Data Set Ready (DSR) is a control signal from the host computer to the

printer. When DSR is in the ACTIVE condition (positive voltage), the

printer can transmit status to the host. When CTS is in the INACTIVE

condition (negative voltage), the printer will not transmit any data.

When DTR/DSR handshaking is selected, via DIP Switch #7 at the rear

of the printer, the Data Terminal Ready (DTR) Control Signal output

from the printer controls when the host computer may send data. DTR

ACTIVE (Positive voltage), permits the host to send data. When the

printer places DTR in the INACTIVE (negative voltage) state, the host

must not send data.

Note: When XON/XOFF handshaking is selected, data flow is

controlled by the ASCII Control Codes DC1 (XON) and DC3

(XOFF). The DTR Control lead will have no effect.

RS-232 Cabling Requirements

The required cable must have a 25-pin “D” Type (DB25P) male con-

nector on one end, which is plugged into the mating (DB25S) female

connector located at the upper rear of the printer. Tighten the locking

screws.

The other end of the Signal Interface Cable connects to an appropriate

point at the host computer. This cable will be one of two types depend-

ing on the specific interface requirements. Refer to the following pages

for information on the standard and null modem cables.

Data cables must be fully shielded and fitted with metal or metallized

connector shells. Shielded cables and connectors are required to pre-

vent radiation and reception of electrical noise.

Zebra S-Series User’s Guide 5-3

To minimize electrical noise pickup in the cable:

•Keep data cables as short as possible.

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

•Do not tie data cables to power wire conduits.

Interconnect to DTE Devices

The printer is configured as Data

Terminal Equipment (DTE). To

connect the printer to other DTE de-

vices (such as the serial port of a

PC), use an RS-232 Null Modem

(crossover) cable. Figure 5.2 illus-

trates the connections required for

this cable.

Interconnect to DCE Devices

When the printer is connected via its

RS-232 interface to Data Communi-

cation Equipment (DCE) such as a

modem, use a standard RS-232

(straight-through) interface cable.

Figure 5.3 illustrates the connections

required for this cable.

5-4 Zebra S-Series User’s Guide

Figure 5.2 DTE to DTE Connections

Figure 5.3 DCE to DTE Connections

Parallel Cabling Requirements

The required cable must have a standard 36-pin parallel connector on

one end, which is plugged into the mating connector located at the up-

per rear of the printer. The parallel interface cable is connected using

bail clips, instead of screws, in a similar position to that of the serial

data cable.

The other end of the parallel interface cable connects to an appropriate

point at the host computer.

Data cables must be fully shielded and fitted with metal or metallized

connector shells. Shielded cables and connectors are required to pre-

vent radiation and reception of electrical noise.

To minimize electrical noise pickup in the cable:

•Keep data cables as short as possible (maximum length: 10 ft.).

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

•Do not tie data cables to power wire conduits.

Parallel Interface

The Parallel Interface provides a means of communication that is typi-

cally faster than the previously mentioned Serial Interface method. In

this method, the bits of data which make up a character are sent all at one

time over several wires in the cable, one bit per wire.

Data signals are defined as either HIGH or LOW, while Control Sig-

nals are either Active or Inactive. Some Control Signals are active

HIGH while others are active LOW. The voltage levels which rep-

resent these conditions are:

Data Signal Voltage Level

HIGH +5 VDC

LOW 0 VDC

Zebra S-Series User’s Guide 5-5

Signal Descriptions

The following chart provides a description of each of the pins in the

parallel connector. A standard parallel data cable will provide the re-

quired interconnection between the computer and the printer.

Description

5-6 Zebra S-Series User’s Guide

Preventive Maintenance

Overview

This section contains preventive maintenance information for the Zebra

S-Series Printer. These procedures may be performed by the operator.

Cleaning

Exterior Surfaces

The exterior surfaces of the printer may be cleaned as required by using

a lint free cloth. Do not use harsh or abrasive cleaning agents or sol-

vents. If necessary, a mild detergent solution or desktop cleaner may be

used sparingly.

Interior

Remove any accumulated dirt/lint from the interior of the printer using

a soft bristle brush and/or vacuum cleaner. This area should be in-

spected after every four rolls of media.

Zebra S-Series User’s Guide 6-1

Table 6.1 Cleaning Schedule

Printhead and Platen Roller

Inconsistent print quality, such as voids in the bar code or graphics, may

indicate a dirty printhead. For optimum performance, Zebra recom-

mendsperformingthecleaningprocedureonpage6-3aftereveryroll

of ribbon (after every roll of media, for direct thermal printing).

Note: Label Available Sensors are shown for location purposes only.

They are not standard on all printers.

6-2 Zebra S-Series User’s Guide

Figure 6.1 Printhead Cleaning (105Se shown)

It is not necessary to turn printer power OFF prior to cleaning. If power is

turned OFF, all label formats, images, and parameter settings stored in the

printer’s formatting RAM will be lost. Permanent parameter settings stored

in EEPROM will be retained. When power is turned back ON, it may be

necessary to reload some items.

To clean the printhead and platen roller, open the media compartment door,

refertoFigure6.1,andperformthefollowingsteps:

1. Open the printhead by moving the printhead handle to the OPEN posi-

tion.

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

3. Moisten an applicator tip with Zebra Technologies Corporation-

recommended solvent and wipe the print elements from end to end.

(The print elements form the gray/black strip just behind the chrome

strip.SeeFigure6.1.)Allowafewsecondsforthesolventtoevapo-

rate.

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

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

ers and the media and ribbon sensors.

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

power (if necessary) and continue printing after the self test.

Media, Ribbon, and Label Available Sensors

These sensors should be cleaned on a regular basis to ensure proper op-

eration of the printer. To locate the position of these sensors, refer to

Figures6-1,7-2,and7-3.

Cutter Module

Periodically, the Cutter Module should be cleaned to remove paper dust

and label residue. Cleaning the Cutter Module ensures that labels will

be cut properly and not jam in the cutter mechanism. Refer to

Figure6.2.

Zebra S-Series User’s Guide 6-3

Clean the stationary cutter blade with a cotton swab moistened with iso-

propyl alcohol when it becomes gummed up with label adhesive or pa-

per debris. If the cutter performs unsatisfactorily after it has been

cleaned, refer to Volume 1 of the Maintenance Manual.

Lubrication

CAUTION: Some commercially available lubricants will damage the

printer if used.

Lubrication of the Zebra S-Series Printer should be performed by a

qualified service technician according to the directions provided in the

Volume 1 of the Maintenance Manual (part # 38452L).

6-4 Zebra S-Series User’s Guide

Figure 6.2 Cleaning the Cutter Blade

Adjustments

Toggle Positioning

Note: 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. If your printer has two toggles

and you are using media too narrow to accommodate both toggles, posi-

tion one toggle over the center of the media and decrease the pressure

on the unused toggle.

Printhead Pressure Adjustment

If printing is too light on one side, or if thick media is used, you may

needtoadjusttheprintheadpressure.RefertoFigure7.1andfollow

the procedure below.

1. Perform a PAUSE Key Self Test.

2. Lower the Darkness Setting until the printing is gray.

3. Loosen the Toggle Position locking nut(s) located inside the “U”

shaped bracket at the top of the toggle.

4. Slide toggle(s) in the direction of the light printing.

5. Using the knurled Adjusting Nuts on the shaft(s) of the toggle(s), in-

crease or decrease spring pressure until the left and right edges of the

printed area are equally dark.

6. Increase Darkness to optimum level for the media being used.

7. Retighten the Toggle Position locking nut(s).

Note: Printhead life can be maximized by using the lowest pressure

that produces the desired print quality.

Zebra S-Series User’s Guide 7-1

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. The

factory-set position should be sufficient for any width label using media with a

web. However, if position adjustments are needed, follow these procedures be-

ginning with the upper sensor.

7-2 Zebra S-Series User’s Guide

Figure 7.1 Printhead Pressure Adjustment (105Se shown)

Upper Transmissive Media Sensor Position Adjustment

To adjust the upper media sensor, refer to Figure 7.2 and follow these

steps.

1. Remove the ribbon and locate the Upper Media Sensor.

2. Loosen the Phillips head screw.

3. Slide the upper sensor along the slot to the desired position. When using

media that has a web between labels, position the media sensor anywhere

along the web (except if you have labels with rounded corners, do not posi-

tion the sensor where the rounded corners of the label might be detected).

When using tag stock, position the upper sensor directly over the hole or

notch.

4. Tighten the Phillips head screw.

Note: To adjust the upper section of the Transmissive Media Sensor

for the outside half of the media width, call a service

technician.

Zebra S-Series User’s Guide 7-3

Figure 7.2 Upper Media Sensor (105Se shown)

Lower Transmissive Media Sensor Position Adjustment

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.

3. Gently pull wires out of the printer frame as required. (Wires should

have a little slack.)

Note: If the sensor is being moved inward and a large loop of wire

develops, remove the cover from the electronics side of the

printer and gently pull the wires through. It is important that

the wires be properly clamped so that they are not rubbed by

any belts.

7-4 Zebra S-Series User’s Guide

Figure 7.3 Lower Transmissive Media Sensor Locations

Media and Ribbon Sensor Sensitivity Adjustment

Note: 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.

This adjustment may need to be performed if the Paper/Ribbon light

comes ON with (1) the media and ribbon properly installed for thermal

transfer mode or (2) media only properly installed for the direct thermal

mode.

The following procedure is used to perform the Media and Ribbon Sen-

sor and Sensitivity Range Adjustment.

1. Turn the printer OFF.

2. Open the printhead.

3. Remove as many labels as needed to create at least 12 inches of blank

backing material. Load the blank backing material under the printhead.

Note: Be sure that blank backing material is positioned between the

upper and lower Media Sensors.

4. Remove the ribbon. (Sliding it as far from the printer wall as possible

will have the same effect as removing it.)

5. Close the printhead.

6. Hold the PAUSE, FEED, and CANCEL keys depressed while turning

the printer ON. Once the printer is ON, release the keys.

7. The following two sets of lights will begin flickering, signifying that the

adjustment has been made.

•The PRINTHEAD and PAPER/RIBBON lights

•The DARKEN and POSITION lights

Zebra S-Series User’s Guide 7-5

Note: 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. Move the ribbon back to its normal position.

Note: Be sure that label is positioned between the upper and lower

Media Sensors.

10. Close the printhead.

11. Press the MODE key to print a Media and Sensor Profile and save the

new values (see Figure 7.4.).

12.PerformtheMediaCalibrationprocedurein“ConfigurationandCali-

bration.”

7-6 Zebra S-Series User’s Guide

Figure 7.4 Media Sensor Profile Sample Printout

Troubleshooting

This section contains troubleshooting charts used to localize and repair

the printer when faults occur. The procedures called out in the

ACTION column may be performed by the operator or by a service

technician when indicated.

Zebra S-Series User’s Guide 8-1

8-2 Zebra S-Series User’s Guide

Zebra S-Series User’s Guide 8-3

8-4 Zebra S-Series User’s Guide

Zebra S-Series User’s Guide 8-5

Options

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.

This option cannot be added to a printer equipped with the optional Cutter.

Cutter Module

Your printer may be factory equipped with a Cutter Module that cuts la-

bels after they have been printed. In addition, an optional Cutter Catch

Tray can be added to gather the labels once they have been cut.

Media Rewind

Your printer may be equipped with a Media Rewind Option. This option

supports both the Rewind and Peel-Off modes of operation.

In Rewind mode, both labels and backing material rewind internally

onto a user-supplied three-inch core. A Rewind Bracket guides the media

back to the Rewind Spindle after printing.

This option cannot be added to a printer equipped with the optional

Cutter.

(SeePeel-OffOptionforPeel-Offmodeofoperation.)

Zebra S-Series User’s Guide 9-1

Fanfold Supply Bin

Your printer may be equipped with an optional internal Fanfold Supply

Bin. It is used to load fanfold media within the media compartment,

and it protects the media from environmental contaminants such as dust

and dirt.

The Fanfold Media Supply Bin is fully adjustable. It accommodates

media from 1.57" (40 mm) to 3.54" (90 mm) wide (7.17" [183 mm]

wide for the 160S) and 3.5" (89 mm) to 8" (203mm) long. The maxi-

mum stack height for 8" long media is 4.5". Stack heights of 6.5" may

be achieved with media less than 3.5" long.

The Fanfold Supply Bin may be installed in the field by the operator.

To install the Fanfold Supply Bin, follow the instructions included

with the option.

Note: The Fanfold Supply Bin, Peel-Off Option, and Rewind Option

are mutually exclusive. The Fanfold Supply Bin may not be

installed in S-Series Printers with the Peel-Off Option or the

Rewind Option. Fanfold media may be used with the Rewind

Spindle installed by using one of the external Fanfold supply

access slots (at the bottom and rear of the printer).

External ZebraNet™ (Ethernet) Interface

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).

This option is in addition to the standard transmissive sensor and is soft-

ware- or switch-selectable.

9-2 Zebra S-Series User’s Guide

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. Refer to the ZPL II Programming Guide for further ap-

plication information.

Once an optional font is installed in the printer, the Configuration print-

out from the CANCEL Key Self Test will indicate the font type.

The following optional scalable smooth fonts are presently available

(each is supplied as a complete set of standard, bold, italic, and bold

italic styles): CG Triumvirate™, CG Times™, CG Palacio™, Futura™,

Univers .

The following Bitmap Smooth Fonts (supplied in bold style only) are

presently available:

CG Triumvirate™ Bold, CG Triumvirate™ Bold Condensed, Futura™

Bold, Univers Bold, CG Times™Bold and CG Palacio™ Bold (type

sizes of 6 pt, 8 pt, 10 pt, 12 pt, 14 pt, 18 pt, 24 pt, 30 pt, 36 pt are avail-

able.)

Examples of these optional fonts can be found in “Appendix D.”

230 VAC Factory Setup

Your Zebra S-Series Printer will be factory set for 230 VAC operation

if requested when the order is placed. If it is necessary to reconfigure

your printer for operation at 115 VAC, see “Installation.”

Zebra S-Series User’s Guide 9-3

512 KB DRAM Memory Expansion (Not available for 105Se

300 dots/inch)

This option increases the printer’s dynamic memory capacity from 0.5

MB to 1 MB. This supports longer label lengths and provides more ca-

pacity for downloadable fonts and large graphic image files. Extra

memory may be installed at the factory or in the field.

12-Dot/mm and 6-Dot/mm Printhead (105Se Only)

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.

9-4 Zebra S-Series User’s Guide

Appendix A - 230 VAC Power Cord

230 VAC Power Cord

Depending on how the Zebra printer was ordered, a power cord may or

may not be included when the printer is optioned for 230 VAC,

50/60 Hz operation.

If a power cord is not supplied, you will need to obtain one with the fol-

lowing specifications:

•The overall length must be less than 3.8 meters.

•It must be rated for at least 5 amps, 250 V.

•The CHASSIS GROUND (EARTH) MUST BE CONNECTED to

assure safety and reduce electromagnetic interference. This is done

by the third wire in the power cord.

•The plug cap should bear the certification mark of a known interna-

tional safety organization (see Figure A.2).

Zebra S-Series User’s Guide A-1

Figure A.1 AC Power Cord

Figure A.2 International Safety Organizations

Appendix B - ASCII Code Chart

Zebra S-Series User’s Guide B-1

Shaded values are NOT recommended for Command Prefix,

Format Prefix, or Delimiter characters.

Appendix C - Adjusting Bar Code Darkness

Adjusting Darkness For “In-Spec” Bar Codes

All direct thermal and thermal transfer materials do not use the same

darkness setting. The best way to check for the proper darkness is to

use a bar code verifier that actually measures bars/spaces and will cal-

culate the Print Contrast Signal (PCS) ratio. Without the assistance of a

verifier, your eyes and/or the scanner to be used in the system may be used

for picking the optimum darkness setting. What follows is a simple yet

effective method for adjusting the darkness to print “in-spec” bar codes.

1. Load media according to the appropriate media loading and ribbon

loading instructions in “Installation.” Ensure that the proper print

method has been selected.

2. With power off, press and hold the FEED key.

3. Turn the printer power on, then release the FEED key. The printer be-

gins printing test labels.

4. Print a label, then press the PAUSE key. The label will contain several

bar codes as well as other printer information. Normal bar codes are

printed in a horizontal format as they feed out of the printer. Rotated

bar codes are printed in a vertical format.

5.ComparethetestlabelprintedtothebarcodesinFigureC.1.Ifthetest

label appears too dark or too light, increase or decrease the darkness

setting accordingly.

6. Resume printing by pressing the PAUSE key again. Print a few labels

at the new setting and verify that proper “in-spec” bar codes are being

printed. Repeat steps 4, 5, and 6 until satisfied.

7. To stop printing test labels, press the PAUSE key, then press the CAN-

CEL key.

Zebra S-Series User’s Guide C-1

Too Dark -Dark labels are fairly obvious. The normal bar code bars

increase in size, and the openings in small alphanumeric characters may fill

in with ink. It may be readable but not “in-spec”. Rotated bar code bars

and spaces will run together.

Slightly Dark -Slightly dark labels are not as obvious. The normal bar

code will be “in-spec”. Small character alphanumerics will be bold and

could be slightly filled in. The rotated bar code spaces are small when

compared to the “in-spec” code, possibly making the code unreadable.

Slightly Light -Slightly light labels are, in some cases, preferred to

slightly dark for “in-spec” bar codes. Both normal and rotated bar

codes will be “in-spec”, but small alphanumeric characters may not be

complete.

Too Light -Light labels are obvious. Both normal and rotated bar

codes have incomplete bars and spaces. Small alphanumeric characters

are unreadable.

In-Spec -The “in-spec” bar code can only be confirmed by a verifier,

but it should exhibit some very visible characteristics. The normal bar

code will have complete, even bars and clear, distinct spaces. The rotated

bar code will also have complete bars and clear distinct spaces. Although it

may not look as good as a slightly dark bar code, it will be “in-spec”. In

both normal and rotated styles, small alphanumeric characters will look

complete.

C-2 Zebra S-Series User’s Guide

Zebra S-Series User’s Guide C-3

Figure C.1 Bar Code Examples

Appendix D - Optional Printer Fonts

Your printer can be optioned with character fonts in addition to those

that are standard in the unit. The following pages illustrate the Optional

Fonts in each of the available styles. From time to time, additions may

be made to the list of available fonts. Contact Zebra Technologies

Corporation or your sales representative for further information.

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. Refer to the ZPL II Programming Guide for further ap-

plication information.

Once an optional font is installed in the printer, the configuration label

printed during the CANCEL Key Self Test will indicate the font type as

the “Socket 2 ID”.

Optional Printer Fonts Currently Available

*When equipped with the Bitmap CG Triumvirate™ Bold Condensed font, the 105Se and

160S have the same font styles as the Stripe S-300 printer.

Zebra S-Series User’s Guide D-1

D-2 Zebra S-Series User’s Guide

CG Triumvirate™ - Normal 0123456789.,?!AaBbCc

CG Triumvirate™ - Bold 0123456789.,?!AaBbCcDd

CG Triumvirate™ - Italic 0123456789.,?!AaBbCcDdEe

CG Triumvirate™ - Bold Italic 0123456789.,?!AaBb

CG Times™ - Normal 0123456789.,?!AaBbCcDdEeFfGg

CG Times™ - Bold 0123456789.,?!AaBbCcDdEeFfGgHh

CG Times™ - Italic 0123456789.,?!AaBbCcDdEeFfGgHhIi

CG Times™ - Bold Italic 0123456789.,?!AaBbCcDdEeFf

CG Palacio™ - Normal 0123456789.,?!AaBbCcDdEeFf

CG Palacio™ - Bold 0123456789.,?!AaBbCcDdEeFfGg

CG Palacio™ - Italic 0123456789.,?!AaBbCcDdEeFfGg

CG Palacio™ - Bold Italic 0123456789.,?!AaBbCcDdEe

Univers® - Normal 0123456789.,?!AaBbCcDdEeFf

Univers® - Bold 0123456789.,?!AaBbCcDdEeFfGgHh

Univers® - Italic 0123456789.,?!AaBbCcDdEeFfGgHh

Figure D.1 Scalable Smooth Fonts (Optional)

CG Triumvirate™ - Bold 0123456789.,?!AaBbCcDd

CG Triumvirate™ Condensed - Bold 0123456789.,?!AaBb

Univers® - Bold 0123456789.,?!AaBbCcDdEeFfGgHh

CG Times™ - Bold 0123456789.,?!AaBbCcDdEeFfGgHh

CG Palacio™ - Bold 0123456789.,?!AaBbCcDdEeFfGg

Figure D.2 Bitmap Smooth Fonts (Optional)

Zebra S-Series User’s Guide D-3

Figure D.3 Point Size Examples

Glossary

alphanumeric Indicating letters, numerals, and characters such as punctuation marks.

backfeed The printer pulls the media and ribbon (if used) backward into the printer so that the

beginning of the label to be printed is properly positioned behind the printhead. Backfeed

occurs when you’re operating the printer in tear-off or peel-off mode.

bar code A code by which alphanumeric characters can be represented by a series of adjacent

stripes of different widths. Many different code schemes exist, such as the universal prod-

uct code (UPC) or Code 39.

black mark sensing See “reflective media sensor”.

calibration (of a printer) A process in which the printer determines some basic information

needed to print accurately with a particular media/ribbon combination. To do this, the

printer feeds some media and ribbon (if used) through the printer and senses whether to use

the direct thermal or thermal transfer print method, whether continuous or non-continuous

media will be used, and (if non-continuous media) the length of individual labels/tags.

character set The set of all letters, numerals, punctuation marks, and other characters that can

be expressed by a particular barcode.

check digit A character added to a barcode symbol that indicates to the scanner that it has read

the symbol correctly.

continuous media Label or tagstock that has no web (space between labels), notch, or gap to

separate each label/tag, but rather the media is one long piece of material.

core diameter The inside diameter of the cardboard core at the center of a roll of media/ribbon.

diagnostics Information about what printer functions are not working. This information is used

for troubleshooting.

direct thermal printing Printing in which direct thermal media is used. No ribbon is used. In-

stead, the media is coated with a substance which reacts to heat to produce an image.

fanfold media Media that comes folded in a rectangular stack, rather than on a roll.

font A complete set of alphanumeric characters in one style of type (ex: Times, Helvetica).

ips “inches-per-second” The speed at which the label or tag is printed. Zebra offers printers

that can print from 2 ips to 12 ips.

Zebra S-Series User’s Guide Glossary - 1

label An adhesive-backed piece of paper, plastic, or other material on which information is

printed.

label available sensor For printers equipped with the Peel-Off Option, this sensor detects a

printed label waiting to be taken or “picked” by the operator. While it detects this label, the

printer will not print additional labels. Once the label has been taken, printing resumes.

Also called “take-label sensor”.

label backing (label liner) The material on which labels are affixed during manufacture and

which is discarded or recycled by the end-users. Label backing (or liner) has a non-stick

surface which allows the label to be easily removed by the end-user and placed in the de-

sired location.

mark sensing See “reflective media sensor”.

media Material onto which data is printed by the printer. Types of media include: tagstock,

continuous, fanfold, roll, etc.

media hanger The hanger that supports media rolls and provides consistent media feed to the

printhead.

non-volatile memory Electronic memory that retains data even when power is removed.

print speed The speed at which printing occurs. For thermal transfer printers, this speed is ex-

pressed in terms of ips (inches per second). Zebra offers printers that can print from 2 ips

to 12 ips.

printhead wear The degradation of the surface of the printhead and/or the print elements over

time. Heat and abrasion can cause printhead wear. Therefore, to maximize the life of your

printhead use the lowest print darkness setting (sometimes called “burn temperature” or

“head temperature”) and the lowest printhead/toggle pressure necessary. Also, use ribbon

that is as wide or wider than the media, to protect the printhead from the rougher media.

reflective media sensor A sensor that detects a black mark on the back of media by measuring

the reflectivity of the media. This mark helps the printer determine label size and print reg-

istration.

registration Alignment of printing with respect to the top of a label/tag.

ribbon A band of inked material that is pressed by the printhead against the media to transfer

an image onto the media, which in turn is pressed against the platen. A ribbon consists of a

base film coated with wax or resin “ink”. Zebra ribbons also have a back coating that pro-

tects the printhead from damage. The ribbon transfers ink onto the media when heated by

the printhead.

Glossary - 2 Zebra S-Series User’s Guide

ribbon wrinkle A wrinkling of the ribbon caused by improper alignment of the strip plate

and/or printhead pressure. This wrinkle can be seen just above the strip plate. Ribbon

wrinkle can cause voids in the print and/or the spent ribbon to rewind unevenly. This is a

condition that should be corrected by performing adjustment procedures.

roll media Media that comes supplied rolled up on a core (usually cardboard). Contrast this

with fanfold media, which comes folded in a rectangular stack.

supplies Supplies is a general term for ribbon and media.

tag A type of media having no adhesive backing but featuring a hole or notch by which the tag

can be hung on something. Usually tags are made of cardboard or other durable material.

take label sensor See “label available sensor”.

thermal direct printing See “direct thermal printing”.

thermal transfer printing A printing method in which the printhead heats an ink- or resin-

coated ribbon against the media, causing the ink/resin to transfer onto the media. By selec-

tively heating the ribbon, you can form an image on the media. See also “ribbon”.

transmissive media sensor This sensor is located behind the printhead to detect the presence

of media and, for non-continuous media, the position of the web, hole, or notch that sepa-

rates each label.

void A space where printing should have occurred but, due to some error condition, it did not

occur. A void can cause a bar code symbol to be read incorrectly or not be read at all.

Zebra S-Series User’s Guide Glossary - 3

100

A
B
C
D
E
F
Zebra S-Series User’s Guide Index - 1
Index
101

I
L
M
N
Index - 2 Zebra S-Series User’s Guide
102

O
P
R
Zebra S-Series User’s Guide Index - 3
103

S
T
U
V
W
X
Index - 4 Zebra S-Series User’s Guide
104

Customer order #31460L

Manufacturer part #31460LB

Zebra House

The Valley Centre, Gordon Road

High Wycombe

Buckinghamshire HP13 6EQ, UK

Telephone +44 (0)1494 472872

Facsimile +44 (0)1494 450103

Zebra Technologies Europe Limited

333 Corporate Woods Parkway

Vernon Hills, Illinois 60061.3109 U.S.A.

Telephone +1 847.634.6700

Facsimile +1 847.913.8766

Zebra 105Se Users Manual

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