=HEUD 6/ 8VHU·V *XLGH Customer order # 11342L Manufacturer part # 11342LB Rev.
3URSULHWDU\ 6WDWHPHQW This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Corporation.
Zebra 105SL User’s Guide iii
iv Zebra 105SL User’s Guide
2AOlÍyÍ ÏlÏÆ ÏÃcØYÏ ³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³¦ Hello! .......................................................................................................................1 Unpacking and Inspection........................................................................................2 Reporting Damage ..............................................................................................2 Storage .......................................................
ÆÏAOÆÍ ØYAÏ ³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³Ö¦ System Considerations .......................................................................................... 21 Interfaces .......................................................................................................... 21 Data Specifications........................................................................................... 21 Cabling Requirements ...............................................................................
/ØÏlÍ AÃlÍAcÍ cØÆÏlÏ ³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³³Ë{ Cleaning .................................................................................................................65 Cleaning the Exterior ........................................................................................66 Cleaning the Interior .........................................................................................66 Cleaning the Printhead and Platen Roller .........................................................
®®lcàÍ _ÍÍ Ö{Í lYÏÃÆ ³³³³³³³³³³³³³³³³³³³³³³³³³³³³³ Printer Interface Technical Information ................................................................ 99 RS-232/RS-422/RS-485 Serial Data Port ........................................................ 99 Parallel Data Port ........................................................................................... 103 ®®lcàÍ _ÍÍ ÍÍ lYÏÃÆ ³³³³³³³³³³³³³³³³³³³³³³³³³³³³¦ç{ Printer Interface Technical Information ............................
ÏÃcØYÏ +HOOR Thank you for purchasing this high-quality Zebra 105SL printer, manufactured by the industry leader in quality, service, and value — Zebra Technologies Corporation. For over 25 years, Zebra has provided customers with the highest caliber of products and support. • This manual provides all of the information you need to operate your printer. • The ZPL II Programming Reference Volumes I and II (part # 45540L) show you how to create the perfect label format for your application.
8QSDFNLQJ DQG ,QVSHFWLRQ Carefully unpack and inspect the printer for damage: • Check all exterior surfaces. • Raise the media access door and inspect the media compartment. Save the carton and all packing material in case the printer needs to be shipped. Contact your authorized Zebra reseller for instructions. 5HSRUWLQJ 'DPDJH If you discover shipping damage: • Immediately notify the shipping company and file a report with them.
0HGLD DQG 5LEERQ 5HTXLUHPHQWV Since print quality is affected by media and ribbon, printing speeds, and printer operating modes, it is very important to run tests for your applications. We STRONGLY RECOMMEND the use of Zebra Technologies Corporation-brand supplies for continuous high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the printing capabilities of the printer and to ensure against premature printhead wear.
3ULQWHU $QDWRP\ Figure 1 outlines the basic components of your printer. Depending on the installed options, your printer may look slightly different.
AOÃAÏÍÏlÍ-ÃÏlà This chapter of the user’s guide is so important that we’ve printed it on a different color paper! That way, it will be easy for you to find when you must calibrate (set up) the printer for your particular application. 3XUSRVH • To calibrate the printer. • To verify that the printer is properly set up by printing a test label. NOTE: This procedure must be performed when the printer is first installed or if it cannot properly detect the top of the label.
7\SHV RI 0HGLD 1RQ &RQWLQXRXV :HE 0HGLD Non-continuous web media (refer to Figure 2) refers to individual labels that are separated by a gap, notch, or hole. When you look at the media, you can tell where one label ends and the next one begins.
1RQ &RQWLQXRXV %ODFN 0DUN 0HGLD Non-continuous black mark media has black marks printed on the back of the liner material that indicate the start and end of each label (refer to Figure 3). Figure 3 &RQWLQXRXV 0HGLD Continuous media (refer to Figure 4) is one uninterrupted roll of material that allows the image to be printed anywhere on the label.
&KRRVLQJ WKH 3ULQW 0RGH • In Tear-Off mode, each label (or a strip of labels) can be torn off after it is printed. • In Peel-Off mode, backing material is peeled away from the label as it is printed. After this label is removed from the printer, the next one is printed. • In Cutter mode, the printer automatically cuts the label after a specified length has been printed. • In Rewind mode, the media and backing are rewound onto a core as the labels are printed.
/RDGLQJ WKH 0HGLD Figure 5 illustrates one method of media loading. For more detailed instructions, as well as information about how to load the different types of media and the various printing modes, refer to the instructions that begin on page 29.
3RVLWLRQLQJ WKH 0HGLD 6HQVRUV The correct positioning of the media sensors is important — it can make the difference between a perfect label and a call to Technical Support! 7UDQVPLVVLYH 6HQVRU The web or gap sensor, also known as the “transmissive sensor,” detects the gap between labels. The transmissive sensor actually consists of two sections: a light source (the lower media sensor) and a light sensor (the upper media sensor). The media passes between the two.
$GMXVWLQJ WKH 8SSHU 0HGLD 6HQVRU Refer to Figure 6. (For clarity, not all printer parts are shown.) 1. Remove the ribbon (if it is installed). Refer to page 42 for details. 2. Locate the upper media sensor. The upper media sensor “eye” is directly below the adjustment screw head. 3. Slightly loosen the upper media sensor adjustment screw (use a Phillips-head screwdriver). 4. Using the tip of the screwdriver, slide the upper sensor along the slot to the desired position. 5.
$GMXVWLQJ WKH /RZHU 0HGLD 6HQVRU Position the lower media sensor (refer to Figure 7) by sliding it in its slot until the lower media sensor is positioned directly below the upper media sensor. Figure 7 %ODFN 0DUN 6HQVRU The optional black mark sensor is in a fixed position and enabled via the front panel (refer to “Configuring the Printer” on page 15 for details).
/RDGLQJ WKH 5LEERQ Figure 8 illustrates the ribbon path. For more detailed information, refer to the instructions that begin on page 40.
2SHUDWRU &RQWUROV 32:(5 6ZLWFK The POWER switch is located at the back of the printer above the power cord connector. Turn on the printer. )URQW 3DQHO The step-by-step instructions in this section tell you which keys to press and what appears on the liquid crystal display (LCD) during the calibration procedure. For a more detailed explanation of the front panel keys and lights (shown in Figure 9), refer to the instructions that begin on page 26.
&RQILJXULQJ WKH 3ULQWHU The configuration procedure in the following table contains the information you need to get your printer up and running, but it is not comprehensive. Refer to page 43 for more information. • Enter the configuration mode by pressing the SETUP/EXIT key at the “PRINTER READY” display. NOTE: You need to press the NEXT/SAVE key more than once to advance to or skip some of the displays. • To increase the value, answer “yes,” indicate “on,” or move to the next selection, use the (+) key.
Press Display Shows — PRINTER READY Normal printer operation. DARKNESS Press the (+) or (–) keys to increase or decrease the print darkness setting. (You may need to change this setting when you print your label.) PRINT MODE Press the (+) or (–) keys to select tear-off, peel-off, cutter, or rewind mode. MEDIA TYPE Press the (+) or (–) keys to select continuous or non-continuous media type. (If you choose continuous media, you must also include a label length instruction in your label format.
0HGLD DQG 5LEERQ &DOLEUDWLRQ Initially, you may want to try autocalibrating the printer rather than proceeding with the full calibration procedure described below. To autocalibrate the printer: 1. Load the media and ribbon. 2. Close the printhead. The printer autocalibrates. If the media fails to load or an error occurs, then perform the steps listed below. NOTE: All steps must be performed in the following procedure, even if only one sensor needs to be adjusted. 1. Press the SETUP/EXIT key. 2.
5. Press the (+) key. The front panel display shows “REMOVE RIBBON CANCEL CONTINUE.” 6. Slide the ribbon as far from the printer frame as possible. 7. Close the printhead, trapping the ribbon in this position. 8. Press the (+) key. The front panel shows “CALIBRATING PLEASE WAIT.” 9. When this part of the calibration process is completed, the display reads “RELOAD ALL CONTINUE.” 10. Open the printhead. Pull the backing material until a label is positioned between the media sensors. 11.
3ULQWLQJ D 7HVW /DEHO To print a test label: 1. Turn off the printer. 2. Press and hold the CANCEL key while turning on the printer. A configuration label prints showing the printer’s currently stored parameters (similar to the one shown in Figure 11). If you encounter any problems while you are configuring or calibrating the printer or printing a test label, refer to “Troubleshooting” beginning on page 79.
20 Zebra 105SL User’s Guide
ÆÏAOÆÍ ØYAÏ 6\VWHP &RQVLGHUDWLRQV NOTE: Depending on the date of manufacture, your Zebra 105SL printer may be equipped with either a DB25 serial connector or a DB9 serial connector. ,QWHUIDFHV The method of interfacing this printer to a data source depends on the communication options installed in the printer.
Figure 12 Figure 13 22 Zebra 105SL User’s Guide
When communicating via the parallel port (refer to Figure 14), the previously mentioned parameters are not considered. Refer to page 54 to configure the communication parameters for the printer. The values selected must be the same as those used by the host equipment connected to the printer. For serial and parallel pinout and technical information, refer to “Appendix A: DB25 Connectors” on page 99 or “Appendix B: DB9 Connectors” on page 105.
24 Zebra 105SL User’s Guide
-ÃÏlÃÍ AÆYÆ 2SHUDWRU &RQWUROV This section discusses the functions of the controls and indicators on the printer. Become familiar with each of these functions before operating your 105SL printer. 32:(5 6ZLWFK This switch is located at the back of the printer above the power cord. The POWER switch should be turned off before connecting or disconnecting any cables. External influences, such as lightning storms or noise on the power or data cables, may cause erratic printer behavior.
)URQW 3DQHO 'LVSOD\ The front panel display (shown in Figure 15) communicates operational status and programming modes and parameters.
)URQW 3DQHO .H\V Key Function Starts and stops the printing process. • If the printer is not printing: no printing can occur. • If the printer is printing: printing stops once the current label is complete. Press to remove error messages from the display. NOTE: Pause mode can also be activated via ZPL II (~PP, ^PP). Forces the printer to feed one blank label each time the key is pressed. • Printer not printing: one blank label immediately feeds.
)URQW 3DQHO /LJKWV NOTE: If two operating conditions occur simultaneously (for example, one that causes a light to be on constantly and one that causes the same light to flash), the light flashes. Light POWER TAKE LABEL ERROR CHECK RIBBON PAPER OUT PAUSE DATA 28 Status Indication Off The printer is off or power is not applied. On The printer is on. Off Normal operation. Flashing (Peel-off mode only.) The label is available. Printing is paused until the label is removed.
5ROO 0HGLD /RDGLQJ NOTE: A calibration must be performed with all loading modes during the following circumstances if the printer is set to feed or no motion at power up or head close: • When media and ribbon (if used) are first installed in the printer. • When media or ribbon is changed to a different type. 7HDU 2II 0RGH Refer to Figure 16. 1. Open the printhead. 2. Slide the media guide and media supply guide as far from the printer frame as possible. 3. Load media as shown. 4.
3HHO 2II 0RGH NOTE: The following instructions pertain to printers with the rewind option only. Refer to Figure 17. 1. Remove the rewind plate from the front of the printer (if installed). Store it upside down on the two mounting screws on the inside of the front panel. 2. Open the printhead. 3. Slide the media guide and media supply guide as far from the printer frame as possible. 4. Load media as shown. 5.
Figure 17 Zebra 105SL User’s Guide 31
5HZLQG 0RGH (Rewind option required) Refer to Figure 18. 1. Remove the rewind plate from its storage location in front of the print mechanism 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 (½" or 13 mm) 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.
Before closing the printhead, make sure: • The media is positioned against the inside guides. • The media is taut and parallel with itself and the pathway when wound onto the rewind spindle/core. 12. Close the printhead.
&XWWHU 0RGH (Cutter option required) Refer to Figure 19. 1. Open the printhead. 2. Slide the media guide and media supply guide as far from the printer frame as possible. 3. Load media as shown. 4. Slide in the media guide and media supply guide so they just touch, but don’t restrict, the edge of the roll. 5. Close the printhead. 6. The printer automatically feeds out and cuts one label when the printer is turned on.
3HHO 2QO\ 0RGH (Peel option required) Refer to Figure 20. 1. Press the printhead open lever. The printhead assembly springs up. 2. Slide out the media supply guide as far from the printer frame as possible. 3. Place the roll of media on the media supply hanger and orient the media properly. 4. Slide in the media supply guide so that it just touches, but does not restrict, the edge of the roll. 5. Feed the media under the inner media guide in the print mechanism. 6.
Figure 20 36 Zebra 105SL User’s Guide
5HPRYLQJ WKH /DEHO %DFNLQJ 0DWHULDO NOTE: Since the rewind spindle holds the backing from a standard-size media roll, we recommend that you perform this procedure whenever you change the media. To remove the backing material from the rewind spindle, follow these steps (you don’t need to turn off the printer for this procedure): 1. Unwind approximately 36" (915 mm) of backing from the rewind spindle. Cut it off at the spindle. 2. Pull out the hook.
)DQIROG 0HGLD /RDGLQJ NOTE: A calibration must be performed when media and ribbon (if used) are first installed in the printer, or when a different type of media or ribbon is being used. Fanfold media feeds through either the bottom or rear access slot from outside the printer. Refer to Figure 21 and Figure 22. 1. Open the printhead. 2. Slide the media guide as far from the printer frame as possible. 3. Load media as shown. If the printer is in cutter mode, route the media through the cutter. 4.
Figure 21 Figure 22 Zebra 105SL User’s Guide 39
5LEERQ /RDGLQJ To load ribbon, refer to Figure 23 and follow the procedure below. NOTE: Always use ribbon that is at least as wide as the media. The smooth backing of the ribbon protects the printhead from wear and premature failure due to excessive abrasion. (For direct thermal print mode, ribbon is not used and should not be loaded in the printer.) 1. Align the segments of the ribbon supply spindle. 2. Place the ribbon roll on the ribbon supply spindle.
Figure 23 Figure 24 Zebra 105SL User’s Guide 41
5LEERQ 5HPRYDO Refer to Figure 25. 1. If the ribbon is not exhausted, cut or break it as close to the ribbon take-up spindle as possible. 2. Push the hook either forward or backward with your thumb until it slips out of the groove (1). Slide the hook to the side (2), then rotate it back and forth several times to loosen it (3). 3. Remove the loosened hook from the spindle (4). 4. Lightly tap the top of the used ribbon to loosen it; grasp the used ribbon and remove it from the ribbon take-up spindle. 5.
yØÃAÏ After you have installed the media and ribbon and the power-on self test (POST) is complete, the front panel display shows “PRINTER READY.” (If the printer fails its POST, refer to page 85.) Using the front panel display and the five keys directly below it, set the printer parameters for your application. NOTE: Printers that are operating on an IP network can be quickly configured using ZebraLink WebView (optional ZebraNet PrintServer II required).
&KDQJLQJ 3DVVZRUG 3URWHFWHG 3DUDPHWHUV Certain parameters are password-protected by factory default. CAUTION: Do not change password-protected parameters unless you are sure you know what you are doing! If the parameters are set incorrectly, they could cause the printer to function in an unpredictable way. The first attempt to change one of these parameters (pressing either the (+) or (–) key) requires you to enter a four-digit password at the “ENTER PASSWORD” display.
/HDYLQJ WKH 6HWXS 0RGH You can leave the program mode at any time by pressing the SETUP/ EXIT key. The “SAVE CHANGES” display appears. There are five choices, as described below. Pressing the (–) or (+) key displays other choices and pressing the NEXT/SAVE key selects the displayed choice. • PERMANENT — Permanently saves the changes. Values are stored in the printer even when power is turned off. • TEMPORARY — Saves the changes until you change them again or until power is turned off.
&RQILJXUDWLRQ DQG &DOLEUDWLRQ 6HTXHQFH Press — Display Shows PRINTER READY Action/Explanation Normal printer operation. Setting Print Parameters DARKNESS TEAR OFF PRINT MODE 46 Adjusting Print Darkness: Press the (+) key to increase darkness. Press the (–) key to decrease darkness. Default: +10 Range: 0 to +30 Darkness settings are dependent upon a variety of factors including ribbon type, media, and the condition of the printhead. You may adjust the darkness for consistent high-quality printing.
Press Display Shows Action/Explanation MEDIA TYPE Setting Media Type: Press the (+) or (–) key to display other choices. Default: Non-Continuous Selections: Continuous, non-continuous This parameter tells the printer the type of media you are using. Selecting continuous media requires that you include a label length instruction in your label format (^LLxxxx if you are using ZPL or ZPL II).
Press Display Shows PRINT WIDTH Action/Explanation Setting Print Width: Press the (+) key to increase the value, press the (–) key to toggle to a different digit. To change the unit of measurement, press the (–) key until the unit of measurement is active, then press the (+) key to toggle to a different unit of measure (inches, mm, or dots). Default; Range: The default and range of acceptable values vary depending on what printer you have.
Listing Printer Information Press Display Shows LIST FONTS LIST BAR CODES Action/Explanation List Fonts: Press the (+) key to print a label listing all of the available fonts. This selection is used to print a label that lists all of the fonts currently available in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM, FLASH memory, font EPROMs, or font cards. List Bar Codes: Press the (+) key to print a label listing all of the available bar codes.
Press Display Shows INITIALIZE CARD 50 Action/Explanation Initialize Memory Card CAUTION: Perform this operation only when it is necessary to erase all previously stored information from the optional memory card (for printers with a PCMCIA slot). Press the NEXT/SAVE key to bypass this function. 1. Press the (+) key to select “YES.” If your printer is set to require a password, you are prompted to enter the password. Enter the password and then press the NEXT/SAVE key. 2.
INIT FLASH MEM Zebra 105SL User’s Guide Initialize Flash Memory CAUTION: Perform this operation only when it is necessary to erase all previously stored information from the FLASH memory. Press the NEXT/SAVE key to bypass this function. 1. Press the (+) key to select “YES.” If your printer is set to require a password, you are prompted to enter the password. Enter the password and then press the NEXT/SAVE key. 2. The display asks “INITIALIZE FLASH?”. Press the (+) key to select “YES.” 3.
0HGLD DQG 5LEERQ 6HQVRU &DOLEUDWLRQ NOTE: Before you begin this procedure, make sure that the maximum length is set to a value equal to or greater than the length of the labels you are using. If the maximum length is set to a lower value, the calibration process assumes that continuous media is in the printer. See page 48 for more information. There are two different types of calibration that can be performed by the printer: 1) Auto Calibration.
Press Display Shows MEDIA AND RIBBON CALIBRATE Action/Explanation Media and Ribbon Sensor Sensitivity: Press NEXT/SAVE to skip the calibration procedure and continue with the host port selection parameters that follow. Press the (+) key to start the calibration procedure. This procedure is used to adjust the sensitivity of the media and ribbon sensors. NOTE: The procedure must be followed exactly as presented. All steps must be performed even if only one of the sensors requires adjustment.
Setting Communication Parameters Communication parameters must be set correctly for the printer to communicate with the host computer. These parameters make sure that the printer and host computer are “speaking the same language.” All communications parameters are password protected. Press Display Shows SERIAL COMM PARALLEL COMM BAUD DATA BITS 54 Action/Explanation Setting Serial Communications: Press the (+) or (–) key to display other choices.
Press Display Shows PARITY STOP BITS Action/Explanation Setting Parity: Press the (+) or (–) key to display other choices. Default: Even Selections: Even, odd, none The parity of the printer must match the parity of the host computer for accurate communications to take place. Select the parity that matches the one being used by the host computer. NOTE: Depending on the model you have, this menu item may not be available. Setting Stop Bits: Press the (+) or (–) key to display other choices.
Press Display Shows NETWORK ID COMMUNICATIONS 56 Action/Explanation Setting Network ID: Press the (–) key to move to the next digit position, press the (+) key to increase the value of the digit. Default: 000 Range: 000 - 999 Network ID is used to assign a unique number to a printer used in an RS-422/RS-485 network. This gives the host computer the means to address a specific printer. If the printer is used in a network, you must select a network ID number. This does not affect TCP/IP or IPX networks.
Selecting Prefix and Delimiter Characters Prefix and delimiter characters are 2-digit hex values used within the ZPL/ZPL II formats sent to the printer. The printer uses the last prefix and delimiter characters sent to it, whether from a ZPL II instruction or from the front panel. NOTE: DO NOT use the same hex value for the control, format, and delimiter character. The printer needs to see different characters to function properly.
Selecting ZPL Mode Press Display Shows ZPL MODE Action/Explanation Selecting ZPL Mode: Press the (+) or (–) key to display other choices. Default: ZPL II Selections: ZPL II, ZPL The printer remains in the selected mode until it is changed by this front panel instruction or by using a ZPL/ZPL II command. The printer accepts label formats written in either ZPL or ZPL II. This eliminates the need to rewrite any ZPL formats you already have.
Label Positioning Parameters Press Display Shows BACKFEED Action/Explanation Backfeed Sequence: Press the (+) or (–) key to display other choices. Default: Default (90%) Selections: Default, after, before, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, off This parameter establishes when and how much label backfeed occurs after a label is removed or cut in the peel-off, cutter, and applicator modes. It has no effect in rewind or tear-off modes.
HEAD RESISTOR 60 NOTE: Depending on the model you have, this menu item may not be available. Setting the Head Resistor Value: Press the (–) key to move to the next digit position, press the (+) key to increase the value of the digit. CAUTION: This parameter should only be changed by qualified personnel! Initial Value: Factory-set to match the printhead shipped with your printer.
Press Display Shows Action/Explanation WEB S. MEDIA S. RIBBON S. MARK S. MARK MED S. These parameters are automatically set during the calibration procedure. They should only be changed by a qualified service technician. Refer to the maintenance manual for more information on these parameters. Press the NEXT/SAVE key repeatedly to skip these parameters.
Press Display Shows Action/Explanation IP Resolution: Press the (+) or (–) key to display other choices. Default: Dynamic Selections: Dynamic, permanent IP RESOLUTION* Depending on the selection, allows either the user (”permanent”) or the server (”dynamic”) to select the IP address. For more information, refer to ZebraNet Networking: PrintServer II Installation and User’s Guide. IP PROTOCOLS* IP ADDRESS* SUBNET MASK* DEFAULT GATEWAY* IP Protocols: Press the (+) or (–) key to display other choices.
Press Display Shows LANGUAGE Action/Explanation Selecting the Display Language: Press the (+) or (–) key to display other choices. Default: English Selections: English, Spanish, French, German, Italian, Norwegian, Portuguese, Swedish, Danish, Dutch, Finnish, and Japanese This parameter allows you to change the language used on the front panel display. You have completed the entire configuration and calibration sequence. You may either press the NEXT/ SAVE key or the SETUP/EXIT key.
64 Zebra 105SL User’s Guide
/ØÏlÍ AÃlÍAcÍ cØÆÏlÏ &OHDQLQJ Table 1 provides a brief cleaning schedule. Specific cleaning procedures are provided on the following pages.
&OHDQLQJ WKH ([WHULRU The exterior surfaces of the printer may be cleaned with a lint-free cloth. Do not use harsh or abrasive cleaning agents or solvents. If necessary, a mild detergent solution or desktop cleaner may be used sparingly. &OHDQLQJ WKH ,QWHULRU Inspect this area after every four rolls of media. Remove any dirt and lint from the interior of the printer using a soft bristle brush and/or vacuum cleaner.
4. Rotate the platen roller and clean thoroughly with solvent and an applicator. 5. Brush/vacuum any accumulated paper lint and dust away from the rollers. 6. Reload ribbon and/or media, and close the printhead. NOTE: If print quality has not improved after performing this procedure, try cleaning the printhead with Save-a-Printhead cleaning film. This specially-coated material removes contamination buildup without damaging the printhead. Call your authorized Zebra reseller/distributor for more information.
([WHQG WKH /LIH RI
Next, press the swab tip against the printhead and swipe the print elements from end to end. Then, turn the platen rollers while wiping them from side to side. Repeat this step until the swab no longer shows dirt. $YRLG WKH &RQWULEXWLQJ )DFWRUV WR 3UHPDWXUH 3ULQWKHDG )DLOXUH Abrasion- Over time, the movement of media/ribbon across the printhead wears through the protective ceramic coating, exposing and eventually damaging the print elements (dots).
6DYH D 3ULQWKHDG &OHDQLQJ )LOP What is Save-a-Printhead cleaning film? A specially coated film that removes contamination buildup without damaging the printhead. What are the benefits of Save-a-Printhead cleaning film? • Extends the life of your printhead. • Reduces maintenance downtime and the cost of replacing a printhead. • An inexpensive, easy and quick way to remove contaminants without having to remove the printhead.
• Only one pass is required to remove contamination buildup. • Each strip of film can be used up to 10 times. • Discard the strip when residue buildup or other contamination is apparent. NOTE: In the case that a replacement printhead is needed, product from the Original Equipment Manufacturer (OEM) is strongly recommended to ensure that your printer and part warranties remain intact, and that the product performs optimally. +RZ WR 2UGHU 6DYH D 3ULQWKHDG &OHDQLQJ )LOP .
&OHDQLQJ WKH 6HQVRUV The media, ribbon, and label available sensors should be cleaned on a regular basis to ensure proper operation of the printer. To locate these sensors, refer to Figure 27 on page 67, Figure 6 on page 11, and Figure 7 on page 12. Brush/vacuum any accumulated paper lint and dust off of these sensors. &OHDQLQJ WKH 6QDS 3ODWH Clean the snap plate to remove label adhesive or a label that has adhered to the underside of the snap plate. Refer to Figure 28. Figure 28 1.
Refer to Figure 29. Figure 29 5. To reinstall the snap plate, insert the two tabs on the bottom of the snap plate into the two slots of the media pathway. 6. Slide the snap plate toward you. 7. Press down on the loops to lock the snap plate into place.
&OHDQLQJ WKH &XWWHU 0RGXOH (For printers equipped with the optional cutter.) If labels are not being cut properly or if the cutter jams with labels, turn off the printer power and unplug the printer. Then, clean the stationary cutter blade with cleaning solvent. This removes label adhesive and/or paper debris. If further cutter cleaning is necessary, or if the cutter continues to perform unsatisfactorily, contact an authorized service technician.
)XVH 5HSODFHPHQW The printer uses a metric-style fuse (5 x 20 mm IEC) rated at F5A, 250V. The end caps of the fuse must bear the certification mark of a known international safety organization (see Figure 37 on page 97). Depending on the model you have, the fuse may not be user-replaceable (see Figure 30) and may need to be replaced by a qualified service technician. Please see the maintenance manual (part # 32056L) for details.
$GMXVWPHQWV 7RJJOH 3RVLWLRQLQJ The toggle should be positioned so that it provides even pressure on the media. Position the toggle by sliding it to the desired location (see Figure 31).
3ULQWKHDG 3UHVVXUH $GMXVWPHQW This adjustment may be necessary if printing is too light on one side or if thick media is used. Refer to Figure 31. 1. Perform the toggle positioning procedure. If the problem is solved, you may stop here; otherwise, continue with the rest of this procedure. 2. Print some labels at speed A by running the PAUSE Key Self Test (see page 87). 3. While printing labels, lower the darkness setting until a gray level of printing is seen. 4.
78 Zebra 105SL User’s Guide
2ÃØOlÆÏ /(' (UURU &RQGLWLRQV DQG :DUQLQJV (UURU &RQGLWLRQ ³ 5LEERQ 2XW Problem Solution In thermal transfer mode, the ribbon is not loaded or loaded incorrectly. Load the ribbon correctly. See “Ribbon Loading” on page 40. In thermal transfer mode, the ribbon sensor is not sensing correctly loaded ribbon. Perform the media and ribbon sensor calibration (see page 17).
(UURU &RQGLWLRQ ³ +HDG 2SHQ Problem The printhead is not fully closed. Solution Close the printhead. :DUQLQJ ³ 5LEERQ ,Q Problem Solution Remove the ribbon and set the printer to direct thermal mode. The ribbon is loaded. Ensure that the printer driver and/or software settings are correctly set (if applicable). :DUQLQJ ³ +HDG 7RR +RW Problem The printhead is over temperature. 80 Solution Allow the printer to cool.
:DUQLQJ ³ +HDG &ROG Problem The printhead is under temperature. Printhead data cable is not properly connected. Solution Continue printing while the printhead reaches the correct operating temperature. If the error remains, the environment may be too cold for proper printing. Relocate the printer to a warmer area. WARNING: The printhead can be very hot and can cause severe burns. Allow the printhead to cool. Disconnect and reconnect data cable to the printhead.
3ULQW 4XDOLW\ 3UREOHPV *HQHUDO 3ULQW 4XDOLW\ ,VVXHV Problem Solution You are using an incorrect media and ribbon combination for your application. Consult your authorized Zebra reseller/distributor for information and advice. The printer is set at the incorrect print speed. For optimal print quality, set the print speed to the lowest possible setting via ZPL II, the driver, or the software. The printer is set at the incorrect darkness level.
:ULQNOHG 5LEERQ Problem Solution The ribbon is not loaded correctly. Load the ribbon correctly. See “Ribbon Loading” on page 40. The darkness setting is incorrect. Set the darkness to the lowest possible setting for good print quality. See “DARKNESS” on page 46. Incorrect printhead pressure or balance. Set the pressure to the minimum required for good print quality. See “Printhead Pressure Adjustment” on page 77. The media is not feeding correctly. It is “walking” from side to side.
$ ODEHO IRUPDW ZDV VHQW WR WKH SULQWHU 6HYHUDO ODEHOV SULQW WKHQ WKH SULQWHU VNLSV PLVSODFHV PLVVHV RU GLVWRUWV WKH LPDJH RQ WKH ODEHO Problem The host is set to EPP parallel communications. Solution Change the settings on the computer host to standard parallel communications. Ensure that the flow control settings match. The serial communication settings are incorrect. Check the communication cable length. See page 23 for requirements.
3ULQWHU 'LDJQRVWLFV 3RZHU 2Q 6HOI 7HVW A full Power-On Self Test (POST) is performed automatically each time the printer is turned on (additional self tests can be performed by pressing the CANCEL key when you turn the printer on). During either test sequence, the front panel lights and liquid crystal display (LCD) monitor the progress of the POST. If the printer fails any of these tests, the word “FAILED” is added to the display. If this occurs, notify an authorized Zebra reseller.
CANCEL Key Self Test This self test prints a listing of the configuration parameters currently stored in the printer’s memory. See Figure 32 (depending on the options ordered, your label may look different). 1. Turn the printer off. 2. Press and hold the CANCEL key while turning on the power. The configuration may be changed either temporarily (for specific label formats or ribbon and label stock) or permanently (by saving the new parameters in memory).
PAUSE Key Self Test This self test can be used to provide the test labels required when making adjustments to the printer’s mechanical assemblies; these test labels also ensure the printhead has been aligned correctly after it has been adjusted. See the sample printout in Figure 33. 1. Turn off the printer. 2. Press and hold the PAUSE key while turning on the power. • The initial self test prints 15 labels at 2.4"/61 mm per second, then automatically pauses the printer.
FEED Key Self Test See Figure 34. 1. Turn off the printer. 2. Press and hold the FEED key while turning on the power. The FEED Key Self Test prints out at various darkness settings above and below that of the darkness value shown on the configuration label. Examine these labels and determine which one has the best darkness setting for your application. This value can be entered into the printer by setting the darkness during the configuration procedure. Refer to page 46 for more information.
FEED Key and PAUSE Key Self Test 1. Turn off the printer. 2. Press and hold the FEED and PAUSE keys while turning on the power. Performing this self test temporarily resets the printer configuration to the factory default values. These values are active only until power is turned off unless you save them permanently in memory. Communications Diagnostics Test This test is controlled from the front panel display. Refer to page 56. A typical printout from this test is shown in Figure 35.
90 Zebra 105SL User’s Guide
0®lYyYAÏÆ NOTE: Printer specifications are subject to change without notice. 0HGLD +DQGOLQJ • Tear-off mode: Labels are produced in strips. • Peel-off mode: Labels are dispensed and peeled from the liner as needed. • Cutter mode: Labels are printed and individually cut. • Rewind mode: Labels are rewound internally.
=3/ 3URJUDPPLQJ /DQJXDJH =3/ ,, • Downloadable graphics, scalable and bitmap fonts, and label formats • Status message to host upon request • Object copying between memory areas (RAM, memory card, and internal FLASH) • Programmable quantity with print, pause, and cut control • Code Page 850 character set • Communicates in printable ASCII characters • Adjustable print cache • Error-checking protocol • Data compression • Controlled via mainframe, mini-computer, PC, portable data terminal • Automat
*HQHUDO 6SHFLILFDWLRQV General Specifications 105SL Height 15.5" Width 11.2" 284 mm Depth 18.9" 480 mm 55 lb 25 kg Weight (without options) General (auto adjusting) 90-264 VAC; 48-62 Hz Printing PAUSE test label at slowest speed Electrical Power Consumption Printer idle Operating environment Thermal transfer Direct thermal Storage Relative Humidity 180 W 19 W Complies with FCC class “B” and Canadian Doc. class “A” rules. Carries the CE mark of compliance.
3ULQWLQJ 6SHFLILFDWLRQV Printing Specifications 105SL Resolution 203 dots/inch (8 dots/mm)/ 300 dots/inch (12 dots/mm) Dot size (width x length) 0.0049" x 0.0049" (0.125 mm x 0.125 mm)/ 0.0033" x 0.0039" (0.084 mm x 0.10 mm) First dot location measured from inside media edge 0.10" ± 0.035" (2.5 mm ± 0.89 mm) Maximum print width Print Length (maximum) 4.1" (104 mm) Continuous printing Media registration toleration* (non-continuous media) 90" (2286 mm) 300 dpi 41" (1041 mm) Vertical = ≤ ±0.
)RQW 6SHFLILFDWLRQV Fonts Matrix (in dots) (H x W) 203 dpi (8 dots/mm) Type* Minimum Char. Size (H x W) Maximum C.P.I. A 9x5 U-L-D 0.044" x 0.029" 33.9 B 11 x 7 U 0.054" x 0.044" 22.6 C,D 18 x 10 U-L-D 0.088" x 0.059" 16.9 E 28 x 15 OCR-B 0.138" x 0.098" 10.1 12.7 F 26 x 13 U-L-D 0.128" x 0.079" G 60 x 40 U-L-D 0.295" x 0.236" 4.2 H 21 x 13 OCR-A 0.103" x 0.093" 10.7 GS 24 x 24 SYMBOL 0.118" x 0.118" 8.
0HGLD 6SHFLILFDWLRQV Media Specifications Minimum label length* Total media width (label + liner, if any) Total thickness (includes liner, if any) 105SL Tear-off 0.7" (18 mm) Peel-off 0.5" (13 mm) Cutter 1.5" (38 mm) Rewind 0.25" (6 mm) Minimum 0.79" (20 mm) Maximum 4.52" (115 mm) Minimum 0.003" (0.076 mm) Maximum 0.012" (0.305 mm) Cutter maximum full-width media thickness 0.009" (0.229 mm) Roll media core inside diameter 3" (76 mm) Maximum roll diameter 8.
3RZHU /LQH &RUG 6SHFLILFDWLRQV • The overall length must be less than 9.8 feet (3.0 meters). • It must be rated for at least 5 A, 250 V. • The chassis ground (earth) MUST be connected to assure safety and reduce electromagnetic interference. The ground connection is handled by the third wire (earth) in the power line cord. See Figure 36. • The AC power plug and IEC 320 connector must bear the certification mark of at least one of the known international safety organizations shown in Figure 37.
98 Zebra 105SL User’s Guide
®®lcàÍ _ÍÍ Ö{Í lYÏÃÆ 3ULQWHU ,QWHUIDFH 7HFKQLFDO ,QIRUPDWLRQ 56 56 56 6HULDO 'DWD 3RUW The connections for these standard interfaces are made through the DB25S connector on the rear panel. For all RS-232 input and output signals, the printer follows both the Electronics Industries Association’s (EIA) RS-232 specifications and the Consultative Committee for International Telegraph and Telephone (CCITT) V.24 standard signal level specifications.
Figure 38 RS-232 Interconnections The printer is configured as Data Terminal Equipment (DTE). Figure 38 illustrates the internal connections of the printer’s RS-232 connector. Figure 39 illustrates the connections required to interconnect the printer with the standard 9-pin serial port connector on a computer. NOTE: If using a 9-pin to 25-pin adapter plug attached to the computer, use a null modem cable between the adapter plug and the printer.
Figure 39 When the printer is connected via its RS-232 interface to Data Communication Equipment (DCE) such as a modem, use a standard RS-232 (straight-through) interface cable. Figure 40 illustrates the connections required for this cable.
Figure 41 RS-422/RS-485 Interconnections The printer may be connected to a host computer by either an RS-422 or an RS-485 interface. The DB25 connector on the rear of the printer uses specific pins for this purpose. Figure 41 illustrates the required cable wiring for interconnecting to the printer’s DB25 connector. Figure 42 illustrates the internal connections of the printer’s RS-422 or RS-485 connector.
3DUDOOHO 'DWD 3RUW A standard 36-pin parallel connector is available at the rear of the printer for connection to the data source. Under normal circumstances, data sent from the printer to the host computer in response to a “Printer Status Request” command is sent through the RS-232 serial port. However, if the host computer has a properly configured IEEE-1284 parallel port that is recognized by the printer, status information is returned through the parallel port.
104 Zebra 105SL User’s Guide
®®lcàÍ _ÍÍ ÍÍ lYÏÃÆ 3ULQWHU ,QWHUIDFH 7HFKQLFDO ,QIRUPDWLRQ 56 6HULDO 'DWD 3RUW The connection for this standard interface is made through the female DB9 connector on the rear panel. A DB9 to DB25 interface module is required for all RS-232 connections through a DB25 cable (see page 108 for details).
RS-232 Interface Connections The printer is configured as Data Terminal Equipment (DTE). Figure 43 illustrates the internal connections of the printer’s RS-232 connector. Figure 43 NOTE: The cable used to connect the printer to a computer must be a null modem (crossover) cable. If you want to connect the printer to any other DTE devices, a null modem cable must also be used.
When the printer is connected via its RS-232 interface to Data Communication Equipment (DCE) such as a modem, use a standard RS-232 (straight-through) interface cable. Figure 44 illustrates the connections required for this cable.
RS-232 Interconnections Using a DB25 Cable In order to connect the printer’s RS-232 DB9 interface to a DB25 connector, an interface adapter is required (Zebra part # 33138). A generic DB25 adapter may also be used, however the +5VDC signal source would not be passed through. Figure 45 illustrates the connections required for the DB9 to DB25 interface. NOTE: The cable used to connect the printer to a computer must be a null modem (crossover) cable.
RS-422/RS-485 Interconnections NOTE: A jumper on the computer’s main logic board needs to be installed on JP1, Pins 2 and 3, in order for the RS-422/RS-485 interface adapter to function properly. To connect the printer’s RS-232 DB9 interface to a host computer through an RS-422 or an RS-485 interface, an interface adapter is required (Zebra part # 33130). Figure 46 illustrates the required cable wiring for interconnecting to the interface adapter’s DB25 female connector.
3DUDOOHO 'DWD 3RUW A standard 36-pin parallel connector is available at the rear of the printer for connection to the data source. Under normal circumstances, data sent from the printer to the host computer in response to a “Printer Status Request” command is sent through the RS-232 serial port. However, if the host computer has a properly configured IEEE-1284 parallel port that is recognized by the printer, status information is returned through the parallel port.
®®lcàÍ _ÍÍ- " Í AÃc 3&0&,$ &DUG ,QVWDOODWLRQ The PCMCIA card slot is a factory-installed option. If your printer has this option, you may install or change the card at any time. Use the following procedure to install a PCMCIA card. CAUTION: Observe proper electrostatic safety precautions when handling any static-sensitive components such as printed circuit boards and printheads. 1. Turn the AC power switch in the Off (2) position and disconnect the AC power cord. Disconnect the data cables. 2.
Card Eject Button PCMCIA Card Option Card Shield Figure 47 112 Zebra 105SL User’s Guide
clà A Adjustments Lower Media Sensor, 12 Media Sensor Position, 77 Printhead Pressure, 77 Toggle Positioning, 76 Upper Media Sensor, 11 B Bar Codes Specifications, 92 Black Mark Sensor Positioning, 12 C Cabling Requirements, 23 Calibration, 5–20 CANCEL Key Self Test, 86 Cleaning Cutter Module, 74 Exterior, 66 Interior, 66 Printhead and Platen Roller, 66 Sensors, 72 Snap Plate, 72 Communications Diagnostics Test, 89 Configuration Calibration Sequence, 46–64 Changing Password-Protected Parameters, 44 Ente
L Label Backing Material Removal, 37 Loading the Media, 9 Lower Media Sensor Adjustment, 12 Lubrication, 74 M Media and Ribbon Calibration, 17 Media and Ribbon Requirements, 3 Media Handling Specifications, 91 Media Loading Cutter Mode, 34 Peel-Off Mode, 30 Peel-Only Mode, 35 Rewind Mode, 32 Tear-Off Mode, 29 Media Sensor Position Adjustment, 77 Media Sensors Positioning Black Mark Sensor, 12 Transmissive Sensor, 10 Media Specifications, 96 Media Types Continuous Media, 7 Non-Continuous Black Mark Media, 7
Specifications Bar Codes, 92 Font, 95 General, 93 Media Handling, 91 Media, 96 Options, 91 Power Line Cord, 97 Printing, 94 Ribbon, 94 ZPL Programming Language, 92 Storage, 2 System Interfaces, 21 T Test Label Printing, 19 Toggle Positioning, 76 Transmissive Sensor Positioning, 10 Troubleshooting Communications, 83 LED Error Conditions and Warnings, 79 Print Quality Problems, 82 Wrinkled Ribbon, 83 U Upper Media Sensor Adjustment, 11 Z ZPL Programming Language Specifications, 92 Zebra 105SL User’s Guide
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Warranty Information All Zebra products are sold with warranties. Refer to the User’s Guide for warranty information specific to each product. Here is some general information: 3ULQWHU 3URGXFWV Printers. All printers (excluding printheads) are warranted against defect in material or workmanship for twelve (12) months from the purchase date. Proof of purchase or shipment date is required to validate the warranty period.
To qualify for this warranty, the printhead must be returned to the factory or to an authorized service center. Customers are not required to purchase Zebra supplies (media and/or ribbons) for warranty qualification. However, if it is determined that the use of other manufacturer supplies has caused any defect in the printhead for which a warranty claim is made, the user is responsible for Zebra’s labor and material charges required to repair the defect.
:DUUDQW\ ([FOXVLRQV &RQGLWLRQV 6WDWHPHQW The warranties provided above are the only warranties applicable. No other warranties, expressed or implied, are given. Zebra does not make any IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE in connection with its sale of products or services.
4 Zebra 105SL User’s Guide
ZebraLink License Agreement Printer Software and Firmware License Agreement YOU SHOULD CAREFULLY READ THE FOLLOWING TERMS AND CONDITIONS OF THIS ZEBRA TECHNOLOGIES CORPORATION PRINTER SOFTWARE AND FIRMWARE LICENSE AGREEMENT ("PSFLA") BEFORE USING THE PRINTER WHICH IS ENCLOSED OR OTHERWISE ASSOCIATED WITH THIS AGREEMENT. IF YOU DO NOT AGREE WITH THESE TERMS AND CONDITIONS, DO NOT OPERATE THE PRINTER AND PLEASE PROMPTLY RETURN THE PRINTER, ENCLOSURES AND ALL PACKAGING FOR A FULL REFUND.
• Limitations of Reverse Engineering, Decompilation and Disassembly. You may not reverse engineer, decompile, or disassemble the SOFTWARE or the FIRMWARE, except and only to the extent that such activity is permitted by applicable law notwithstanding this limitation. • Rental. You may not rent or lease or lend the SOFTWARE or FIRMWARE. • Support Services. ZEBRA may provide you with support services related to the SOFTWARE and/or FIRMWARE ("SUPPORT SERVICES"), in its discretion.
FAR, 48 CFR 52.227-14 (JUNE 1987) or DFAR, 48 CFR 252.227-7013 (OCT 1988), as applicable. 7. EXPORT RESTRICTIONS. You agree that you will not export or re-export the SOFTWARE and/or FIRMWARE, any part thereof, or any process or service that is the direct product of the SOFTWARE and/or FIRMWARE (the foregoing collectively referred to as the "RESTRICTED COMPONENTS"), to any country, person or entity subject to U.S. export restrictions.
• If the emulation library is sold separately by an authorized party other than ZEBRA ("RESELLER" -- A party other than ZEBRA which is authorized by ZEBRA to distribute the SOFTWARE and/or FIRMWARE with its application so long as the SOFTWARE and/ or FIRMWARE is used with a ZEBRA printer) or is sold bundled with a printer to an enduser by a RESELLER, and if claims are made by the RESELLER that the emulation library performs as a 100% emulation solution, ZEBRA is not responsible if the emulation library does
