Z E B R A P E R F O R M A N C E - L I N E TM 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 Telephone 847.634.6700 Facsimile 847.913.
Zebra R-140 TM User's Guide Customer order # 48040L Manufacturer part # 48040LB Rev.
Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Corporation.
Zebra R-140 User’s Guide iii
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Table of Contents Introduction Hello! . . . . . . . . . . . . . . . . . . . Print Mechanism Capabilities . . . . . . . RFID Capabilities . . . . . . . . . . . . . Media Transport Mechanism Capabilities. System Requirements . . . . . . . . . . . Unpacking and Inspection . . . . . . . . Reporting Damage . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . Media and Ribbon Requirements . . . . Power Cord . . . . . . . . . . . . . . . . Printer Anatomy 101 . . . . . . . . . . . RFID Overview . . . . .
Loading the Ribbon . . . . . . . . . . . . Operator Controls . . . . . . . . . . . . . POWER Switch . . . . . . . . . . . . . Front Panel . . . . . . . . . . . . . . . Configuring the Printer . . . . . . . . . . Configuring the Software or Printer Driver Media and Ribbon Calibration . . . . . . Printing a Test Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration Entering the Setup Mode . . . . . . . . . . . . . Changing Password-Protected Parameters . . . Leaving the Setup Mode . . . . . . . . . . . . . . Configuration and Calibration Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 48 49 50 Routine Care and Adjustment Cleaning . . . . . . . . . . . . . . . . . . . Cleaning the Exterior . . . . . . . . . . . Cleaning the Interior . .
Specifications Media Handling . . . . . . . . . . . . . Options . . . . . . . . . . . . . . . . . Zebra Programming Language (ZPL II®) Bar Codes . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . Printing Specifications . . . . . . . . . Ribbon Specification . . . . . . . . . . Media Specifications . . . . . . . . . . Power Line Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction Hello! Congratulations! You have just purchased the highest quality thermal demand printer with RFID capability in the industry. Manufactured by Zebra Technologies Corporation, the industry leader in quality, service, and value. For over 30 years, Zebra Technologies Corporation has provided customers with the highest caliber of products and support n n n This manual provides all of the information you will need to operate your printer.
Print Mechanism Capabilities The Zebra R-140 print mechanism has been designed to print information on labels, tickets, and tags. It uses a square or rectangular dot thermal printhead that heats a ribbon as it passes beneath the print elements, melting its ink onto the media (direct thermal print mode involves using heat-sensitive media instead of an inked ribbon). Print speeds are selected via software control. RFID Capabilities Transponders used with the R-140 work on the 13.
n n A device, such as a personal computer (PC), for data entry and output of label formats to the printer. A data communication cable to connect the controlling device to the Zebra R-140 printer. (Remote installations may require additional cables and communication devices such as modems and/or protocol converters.) Unpacking and Inspection Inspect the printer for possible damage incurred during shipment. n Check all exterior surfaces. n Raise the media access door and inspect the media compartment.
Media and Ribbon Requirements 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. High quality RFID Labels are recommended to ensure against premature printhead wear. For non-RFID applications, we STRONGLY RECOMMEND the use of Zebra Technologies Corporation-brand supplies for continuous high-quality printing.
Make sure that the POWER on/off switch (located at the back of the printer) is in the off position before connecting the power cable to an electrical outlet.
RFID Overview The R140 printer contains special hardware necessary to program RFID tags. To use the RFID capabilities of this printer, you will need the appropriate RFID media. Currently the Tag-It and I•Code tag types are supported. This media is collectively known as an RFID tag, and includes the label, backing, and an RFID transponder inlay encased by the label material.
Tag-it Tags Tag-it labels are high frequency (13.56MHz) devices. Tag-it is a read/write RFID tag with 256 bits of storage capacity for user data. Data is addressed in eight blocks of 32 bits, each block containing four bytes.
I·Code Tags I•Code labels are also high frequency (13.56MHz) devices but have 512 bits of storage capacity. Data is addressed in sixteen blocks of 32 bits, each block containing four bytes. The first two blocks of data (block 0 and 1) are used for storage of a unique 64 bit serial number. The next two blocks (blocks 2 and 3) are used for storage of configuration information; block 4 is used for family or application identification and blocks 5 to 15 are free for user application use.
Calibrating the Printer This chapter of the user’s guide is so important that we’ve printed it on a different color paper! That way, it will be easy for you to find when you must calibrate (set up) the printer for your particular application. Purpose n To calibrate the printer. n 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 when it cannot properly detect the top of the label.
Types of Media Non-Continuous Web Media Non-continuous web media (refer to Figure 2) refers to individual labels that are separated by a gap, notch, or hole. When you look at the media, you can tell where one label ends and the next one begins.
Non-Continuous Black Mark Media Non-continuous black mark media has black marks printed on the back that indicate the start and end of each label (refer to Figure 3). Black mark Black mark Non-continuous media for black mark sensing Figure 3 Continuous Media Continuous media (refer to Figure 4) is one uninterrupted roll of material that allows the image to be printed anywhere on the label.
Choosing the Print Mode n n n n Tear-off mode allows you to tear off each label, or a strip of labels, after it is printed. In Peel-off mode, backing material is peeled away from the label as it is printed. After this label is removed from the printer, the next one is printed. When in cutter mode, the printer automatically cuts the label after it is printed. In rewind mode, the media and backing are rewound onto a core as the labels are printed.
Loading the Media 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 31.
Positioning the Media Sensors The correct positioning of the media sensors is important. It can make the difference between a perfect label and a call to Technical Support! Transmissive Sensor The web or gap sensor, better known as the “transmissive sensor,” detects the gap between labels. The transmissive sensor actually consists of two sections: a light source (the lower media sensor) and a light sensor (the upper media sensor). The media passes between the two.
Adjusting the Upper Media Sensor Refer to Figure 6. (For clarity, not all printer parts are shown.) 1. Remove the ribbon (if it is installed). 2. Locate the upper media sensor. The upper media sensor “eye” is directly below the adjustment screw head. 3. Slightly loosen the upper media sensor adjustment screw (Phillips head). 4. Using the tip of the screwdriver, slide the upper sensor along the slot to the desired position. 5. Secure the upper media sensor adjustment screw.
Adjusting the Lower Media Sensor Position the lower media sensor (refer to Figure 7) by sliding it in its slot until it is positioned under the upper media sensor. Figure 7 Black Mark Sensor The black mark sensor is in a fixed position and enabled via the front panel (details in “Configuring the Printer” on page 19).
Loading the Ribbon To load ribbon, refer to Figure 8. For more detailed information, refer to the instructions that begin on page 43.
Operator Controls POWER Switch The POWER switch is located at the back of the printer above the power cord and fuse. Turn on the printer. Front Panel 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 (as shown in Figure 9), refer to the instructions that begin on page 28.
Configuring the Printer The configuration procedure in the next table contains the information you need to get your printer up and running, but it is not comprehensive. Refer to page 47 for more information. n Enter the configuration mode by pressing the SETUP/EXIT key at the “PRINTER READY” display. NOTE: You will need to press the NEXT/SAVE key more than once to advance to some of the displays.
Press - Display Shows Action/Explanation PRINTER READY Normal printer operation. DARKNESS Press the BLACK OVAL keys to increase or decrease the print darkness setting. (You may need to change this setting when you print your label.) PRINT MODE Press the BLACK OVAL keys to select tear-off, peel-off, cutter, or rewind mode. MEDIA TYPE Press the BLACK OVAL keys to select continuous or non-continuous media type.
Media and Ribbon Calibration NOTE: All steps must be performed in the following procedure, even if only one sensor needs to be adjusted. 6. Press the SETUP/EXIT key. 7. Press the NEXT/SAVE key until “MEDIA AND RIBBON CALIBRATE” displays. 8. To start the calibration procedure, press the RIGHT BLACK OVAL key. “LOAD BACKING CANCEL CONTINUE” displays. 9. Open the printhead.
10. Press the RIGHT BLACK OVAL key. The front panel display will show “REMOVE RIBBON CANCEL CONTINUE.” 11. Either remove the ribbon or slide it as far from the printer frame as possible. 12. Close the printhead, trapping the ribbon in this position. 13. Press the RIGHT BLACK OVAL key. The front panel will show “CALIBRATING PLEASE WAIT.” 14. When this part of the calibration process is completed, the display will read “RELOAD ALL CONTINUE.” 15. Open the printhead.
Printing a Test Label To print a test label: 19. Turn off the printer. 20. Press and hold the CANCEL key while turning on the printer. A configuration label, which shows the printer’s currently stored parameters, will print (similar to the one shown in Figure 11).
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Establishing Communication System Considerations Interfaces The method of interfacing this printer to a data source depends on the communication options installed in the printer. The standard interfaces are an RS-232/RS-422/RS-485 serial data port and a bi-directional parallel port. The optional ZebraNet PrintServer II enables printers to be connected to 10 BaseT Ethernet networks. In addition, the IBM® Twinax or IBM Coax option is available for those applications that require them.
When communicating via the parallel port (refer to Figure 13), the previously mentioned parameters are not considered. Refer to page 57 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. Printer Computer 36-pin male PC 25-pin female For serial and parallel pinout and technical information, refer to the Appendix on page 99.
Printer Basics Operator Controls This section discusses the functions of the various controls and indicators on the printer. The operator should become familiar with each of these functions. POWER Switch This switch is located at the back of the printer above the power cord and fuse. 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.
Front Panel Display The front panel display communicates operational status and programming modes and parameters.
Front Panel Keys 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.
Front Panel Lights 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 will flash. Light POWER Status The printer is off or power is not applied. On The printer is on. TAKE LABEL Off ERROR CHECK RIBBON PAPER OUT PAUSE DATA 30 Indication Off Normal operation. Flashing (Peel-off mode only.) The label is available. Printing is paused until the label is removed.
Roll Media Loading 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. Tear-Off Mode Refer to Figure 15. 1. Open the printhead. 2. Slide the media guide and media supply guide as far from the printer frame as possible. Flip down the media supply guide. 3. Load media as shown. 4. Flip up the media supply guide.
Peel-Off Mode NOTE: Rewind option required. NOTE: The Peel-Off Mode may not be suitable for some RFID media types. The user should test for each application Refer to Figure 16. 1. Remove the rewind plate from the front of the printer (if installed). Store it 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. Flip down the media supply guide. 4. Load media as shown. 5.
Figure 16 Zebra R-140 User’s Guide 33
Rewind Mode (for Printers Without the Cutter Option) NOTE: Rewind option required. NOTE: Rewind mode may not be suitable for RFID applications. Refer to Figure 17. 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"/13 mm) into the lower opening in the side plate. 4.
Before closing the printhead, make sure: n n 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.
Cutter Mode NOTE: Cutter option required. Refer to Figure 18. 1. Open the printhead. 2. Slide the media guide and media supply guide as far from the printer frame as possible. Flip down the media supply guide. 3. Load media as shown. 4. Flip up the media supply guide. Slide in the media guide and media supply guide so they just touch, but not restrict, the edge of the roll. 5. Close the printhead. 6. The printer will automatically feed out and cut one label when the printer is turned on.
Figure 18 Zebra R-140 User’s Guide 37
Rewind Mode (for Printers With the Cutter Option) NOTE: Cutter and rewind options required. NOTE: Rewind mode may not be suitable for RFID applications. Refer to Figure 19. 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"/13 mm) into the lower opening in the side plate.
Before closing the printhead, make sure: n n 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.
Fanfold Media Loading 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 Figures 20 and 21. 1. Open the printhead. 2. Slide the media guide as far from the printer frame as possible. 3. Load media as shown. If in cutter mode, route media through the cutter. 4.
Figure 20 Figure 21 Zebra R-140 User’s Guide 41
Removing the Label Backing Material 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” (914 mm) of backing from the rewind spindle. Cut it off at the spindle. 2. Pull out the hook. Slide the backing material off of the rewind spindle and discard.
Ribbon Loading To load ribbon, refer to Figure 22 and follow the procedure below. NOTE: 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.
7. Before wrapping the ribbon around the ribbon take-up spindle, ensure that the arrow on the knob aligns with the indented notch (see Figure 23 inset). 8. Place the ribbon (with leader, if used) around the ribbon take-up spindle and wind counterclockwise for several turns. 9. Close the printhead.
Ribbon Removal s 1. Break the ribbon as close to the ribbon take-up spindle as possible. 2. Refer to Figure 23. While holding the ribbon take-up spindle, turn the knob (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. 3. Slide the ribbon off of the ribbon take-up spindle.
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Configuration After you have installed the media and ribbon and the power-on self test (POST) is complete, the front panel display will show “PRINTER READY.” (If the printer fails its POST, refer to page 87.) You may now set printer parameters for your application using the front panel display and the five keys directly below it. NOTE: Printers that are operating on an IP network can be quickly configured via ZebraNet WebView (optional ZebraNet PrintServer II required).
Changing Password-Protected Parameters 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 they are set incorrectly, these parameters could cause the printer to function in an unpredictable way. The first attempt to change one of these parameters (pressing one of the BLACK OVAL keys) will require you to enter a four-digit password. This is done via the “ENTER PASSWORD” display.
Leaving the Setup Mode You can leave the program mode at any time by pressing the SETUP/EXIT key. The “SAVE CHANGES” display will appear. There are five choices, described below. Pressing the LEFT or RIGHT BLACK OVAL key displays other choices and pressing the NEXT/SAVE key selects the displayed choice. n n n n PERMANENT - Permanently saves the changes. Values are stored in the printer even when power is turned off. TEMPORARY - Saves the changes until changed again or until power is turned off.
Configuration and Calibration Sequence Press ---- Display Shows PRINTER READY Action/Explanation Normal printer operation. Setting Print Parameters DARKNESS Adjusting Print Darkness Press the RIGHT BLACK OVAL key to increase darkness. Press the LEFT BLACK OVAL 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 RIGHT or LEFT BLACK OVAL key to display other choices. Default: 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 52 Display Shows Action/Explanation PRINT WIDTH Setting Print Width Press the RIGHT BLACK OVAL key to increase the value, press the LEFT BLACK OVAL key to decrease the value. To change the unit of measurement, press the LEFT BLACK OVAL key until the unit of measurement is active, then press the RIGHT BLACK OVAL 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 Action/Explanation LIST FONTS List Fonts Press the RIGHT BLACK OVAL 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.
Press 54 Display Shows Action/Explanation INITIALIZE CARD Initialize Memory Card CAUTION: Perform this operation only when it is necessary to erase all previously stored information from the optional memory card. Press the NEXT//SAVE key to bypass this function. 1. Press the RIGHT BLACK OVAL key to select “YES.” If your printer is set to require a password, you will now be prompted to enter the password. Enter the password and then press the NEXT/SAVE key. 2. The display will ask “INITIALIZE CARD?”.
Media and Ribbon Sensor Calibration 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 will assume that continuous media is in the printer. See page 52 for more information. There are two different types of calibration that can be performed by the printer: 1) Standard 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 RIGHT BLACK OVAL 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. These parameters make sure that the printer and host are “speaking the same language.” All communications parameters are password protected. Press Display Shows Action/Explanation PARALLEL COMM Setting Parallel Communications Press the RIGHT or LEFT BLACK OVAL key to display other choices.
Press 58 Display Shows Action/Explanation PARITY Setting Parity Press the RIGHT or LEFT BLACK OVAL key to display other choices. Default: Even Selections: Even, odd, none The parity of the printer must match the parity of the host for accurate communications to take place. Select the parity that matches the one being used by the host. STOP BITS Setting Stop Bits Press the RIGHT or LEFT BLACK OVAL key to display other choices.
Press Display Shows Action/Explanation NETWORK ID Setting Network ID Press the LEFT BLACK OVAL key to move to the next digit position, press the RIGHT BLACK OVAL 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 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 RIGHT or LEFT BLACK OVAL key to display other choices. Default: ZPL II Selections: ZPL II, ZPL The printer will remain 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 62 Display Shows Action/Explanation BACKFEED Backfeed Sequence Press the RIGHT or LEFT BLACK OVAL 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.
Press Display Shows Action/Explanation HEAD TEST COUNT Setting the Head Test Count Press the LEFT BLACK OVAL key to move to the next digit position, press the RIGHT BLACK OVAL key to change the value of the digit. Default: 0000 (disables the test) Range: 0000 to 9999 The printer periodically performs a test of the printhead functionality, called a “printhead test” or “head test.” This parameter establishes how many labels are printed between these internal tests.
Press Display Shows APPLICATOR PORT Action/Explanation Setting the Applicator Port Press the RIGHT or LEFT BLACK OVAL key to display other choices. Default: Off Selections: Off, mode 1, mode 2, mode 3, mode 4 Determines the action of the verifier port. • Off: The applicator port is off. • Mode 1: Asserts the ~END_PRINT signal low while the printer is moving the label forward. • Mode 2: Asserts the ~END_PRINT signal high while the printer is moving the label forward.
Press Display Shows Action/Explanation LCD ADJUST LCD Display Adjustment Press the LEFT BLACK OVAL key to decrease the value (reduce brightness), press the RIGHT BLACK OVAL key to increase the value (increase brightness). Range: 00 to 19 This parameter allows you to adjust the brightness of your display if your display is difficult to read. FORMAT CONVERT Format Convert Press the RIGHT or LEFT BLACK OVAL key to display other choices.
Press Display Shows Action/Explanation IP RESOLUTION* IP Resolution Press the RIGHT or LEFT BLACK OVAL key to display other choices. Default: Dynamic Selections: Dynamic, permanent 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 Protocols Press the RIGHT or LEFT BLACK OVAL key to display other choices.
Press Display Shows LANGUAGE Action/Explanation Selecting the Display Language Press the RIGHT or LEFT BLACK OVAL key to display other choices. Default: English Selections: English, Spanish, French, German, Italian, Norwegian, Portuguese, Swedish, Danish, Spanish 2, Dutch, Finnish, Custom This parameter allows you to change the language used on the front panel display. RFID Test Press the left oval key to select the QUICK test or the right oval key to select the SLOW test.
Press Display Shows Action/Explanation You are now back at the first parameter in the configuration sequence. DARKNESS 68 NOTE: If you pressed the NEXT/SAVE key but are through programming the printer configuration, you may press the SETUP/EXIT key and continue with the “SAVE SETTINGS” function. SAVE SETTINGS Save Settings Press the RIGHT or LEFT BLACK OVAL key to display other choices. Default: Permanent Selections: Permanent, temporary, cancel, load defaults, load last save.
Routine Care and Adjustment Cleaning The following table provides a brief cleaning schedule. Specific cleaning procedures are provided on the following pages.
Cleaning the Exterior 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. Cleaning the Interior 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 and the printhead. Figure 25 Cleaning the Sensors 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 25, Figure 6 on page 15, and Figure 7 on page 16.
Cleaning the Snap Plate Clean the snap plate to remove label adhesive or a label that has adhered to the underside of the snap plate. Refer to Figure 26. 1. Carefully push the tabs on the snap plate towards the rear of the printer and gently lift up on the snap plate. CAUTION: Use care to not bend, twist, or otherwise deform the tabs! 2. Remove the snap plate from the printer. 3. Clean the snap plate with cleaning solvent and a soft cloth. Refer to Figure 27. 4.
Figure 26 Figure 27 Zebra R-140 User’s Guide 73
Cleaning the Cutter Module (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 will remove 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.
4. Snap the fuse holder back into position. 5. Reconnect the power cord. If the new fuse fails right away, the printer has an internal component failure and must be repaired.
Adjustments Toggle Positioning Both toggles should be positioned so that they provide even pressure on the media. The toggles are positioned by sliding them to the desired location. On media too narrow to accommodate both toggles, position one toggle over the center of the media and decrease the pressure on the unused toggle. NOTE: Make sure that the toggle pressure is even across the width of the media. Otherwise, the media and/or ribbon may “drift.
Printhead Pressure Adjustment This adjustment may be necessary if printing is too light on one side or if thick media is used. Refer to Figure 30. 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 2.4"/61 mm per second by running the PAUSE key self test (see page 89). 3. While printing labels, lower the darkness setting until a gray level of printing is seen. 4.
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Troubleshooting LED Error Conditions and Warnings Error Condition Ribbon Out Problem Solution In thermal transfer mode, the ribbon is not loaded or loaded incorrectly. Load the ribbon correctly. See “Ribbon Loading” on page 43. In thermal transfer mode, the ribbon sensor is not sensing correctly loaded ribbon. Perform the media and ribbon sensor calibration (see page 21).
Error Condition Head Open Problem The printhead is not fully closed. Solution Close the printhead. Error Condition Head Element Bad Problem Solution If the failed elements impact your printing application, One or more of the printhead elements replace the printhead. To override this error, disable have failed the printhead element test. the head test count feature on the front panel by defaulting the value to “0000.” See page 63. Warning Ribbon In Problem The ribbon is loaded.
Warning Head Cold Problem The printhead is under temperature. 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 Cutter Jammed Problem Cutter blade is in the media path. Solution Turn off the printer power and unplug the printer. Inspect the cutter module for debris and clean as needed following the cleaning instructions on page 74.
Print Quality Problems General Print Quality Issues Problem Solution You are using an incorrect media and Consult your authorized Zebra reseller/distributor for ribbon combination for your application. 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.
Wrinkled Ribbon Problem Solution The ribbon is not loaded correctly. Load the ribbon correctly. See “Ribbon Loading” on page 43. The darkness setting is incorrect. Set the darkness to the lowest possible setting for good print quality. See “Darkness” on page 50. Set the pressure to the minimum required for good Incorrect printhead pressure or balance. print quality. See “Printhead Pressure Adjustment” on page 77. The media is not feeding correctly. It is “walking” from side to side.
A label format was sent to the printer. Several labels print, then the printer skips, misplaces, misses, or distorts the image on the label. 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 26 for requirements.
RFID Symptoms Problem RFID tags not programming (general). RFID VOID label is printed. Diagnosis Solution Printer not set-up properly Print a Configuration label (Cancel Key Self Test) to verify RFID version. Run an RFID Self Test (through the Front Panel). Make note of Error Messages and refer to that symptom in this table. Check if supported RFID media is loaded properly. Reload media. Verify tag type is properly selected in ZPLII and/or through front panel.
Problem NO TAG Error Message (Continued) Diagnosis Solution Tags have metal/aluminum in them. Confirm that the tags meet requirements (i.e. no metal/ aluminum in them) Reload with proper tags. ZPL II giving insufficient amount of retries. Increase the number of retries in the ZPL II commands. Tag is bad. Load new tags. Retry printing label. PK TIMEOUT Error Message An attempt was made to communicate to the internal hardware, but timed out. Cycle power and try printing label again.
Printer Diagnostics Power-On Self Test A power-on self test (POST) is performed automatically each time the printer is turned on. During this test sequence, the front panel lights and liquid crystal display monitor the progress of the POST. If the printer fails any of these tests, the word “FAILED” will be 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 31 (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. See the sample printout in Figure 32. 1. Turn off the printer. 2. Press and hold the PAUSE key while turning on the power. n n n n n n The initial self test prints 15 labels at 2.4"/61 mm per second per second, then automatically pauses the printer. Each time the PAUSE key is pressed, an additional 15 labels print.
FEED Key Self Test See Figure 33. 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. Look at 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 50 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 will be 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 59. A typical printout from this test is shown in Figure 34.
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Specifications NOTE: Printer specifications are subject to change without notice. Media Handling n n Tear-off mode: Labels are produced in strips. Peel-off mode: Labels are dispensed and peeled from the liner as needed. n Cutter mode: Labels are printed and individually cut. n Rewind mode: Labels are rewound internally.
Zebra Programming Language (ZPL II®) n n n n n n n n n n Downloadable graphics, scalable and bitmap fonts, and label formats Object copying between memory areas (RAM, memory card, and internal FLASH) Code Page 850 character set Adjustable print cache Data compression Automatic virtual input buffer management Automatic memory allocation Format inversion Mirror image printing Four-position field rotation (0º, 90º, 180º, and 270º) n n n n n n n n n n Slew command Programmable quantity with print, paus
General Specifications General Specifications R-140 Height 15.5" 393.7 mm Width 11.15" 283.2 mm Depth 19.5" 495.3 mm Weight (without options) 55 lb General (auto adjusting) Electrical Printing PAUSE test label at Power consumption slowest speed Printer idle Compliance Temperature Relative humidity 25 kg 90-264 VAC; 48-62 Hz 180 W 19 W Complies with FCC class “A” and Canadian Doc. class “A” rules. Carries the CE mark of compliance.
Printing Specifications Printing Specifications R-140 Resolution 203 dots/inch (8 dots/mm) Dot size (width x length) First dot location from inside media edge 0.0049” x 0.0049” (.125 x .125 mm) 0.10" ± .035" (2.5 mm ± .89 mm) Maximum print width Noncontinuous printing Print length (max.) 5.
Media Specifications Media Specifications Minimum label length* Standard Tear-off 0.7" (18 mm) Peel-off 0.5" (13 mm) Cutter 1.5" (38 mm) Rewind 0.25" (6 mm) Smart Media (RFID) Total media width (label + liner, if any) Minimum 1.57” (40 mm) 3.0” (76 mm) Maximum 5.51” (140 mm) 5.51” (140 mm) Total thickness (includes liner, if any) Minimum 0.003” (0.076 mm) 0.003” (0.076 mm) Maximum 0.012” (0.305 mm) 0.010” (0.254 mm) excluding IC Chip Cutter maximum full-width media thickness .
Power Line Cord Specifications n The overall length must be less than 9.8 feet (3.0 meters). n It must be rated for at least 5 A, 250 V. n n 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 35. 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 36.
Appendix Printer Interface Technical Information RS-232/RS-422/RS-485 Serial Data Port 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.
RS-232 connector (DTE) rear panel DB-25S +5 V F1 1 Amp 1 FG (frame ground) 2 TXD (transmit data) output 3 RXD (receive data) input 4 RTS (request to send) output 6 DSR (data set ready) input 7 SG (signal ground) 9 +5 VDC source 20 DTR (data terminal ready) output Figure 37 RS-232 Interconnections The printer is configured as Data Terminal Equipment (DTE). Figure 37 illustrates the internal connections of the printer’s RS-232 connector.
DB-25P connector to printer DB-9S connector to computer DCD FG RXD TXD TXD DTR RXD SG RTS DSR DSR RTS SG CTS DTR RI Figure 38 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 39 illustrates the connections required for this cable.
Male DB-25 to printer Frame ground 1 Signal ground ref. 11 Data input B(-) 13 14 Data output B(-) Data input A(+) Data output A(+) 16 19 Figure 40 RS-422/RS-485 Interconnections The printer may be connected to a host by either an RS-422 or an RS-485 interface. The DB-25 connector on the rear of the printer uses specific pins for this purpose. Figure 40 illustrates the required cable wiring for interconnecting to the printer’s DB-25 connector.
Parallel Data Port 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 in response to a “Printer Status Request” command is sent through the RS-232 serial port. However, if the host has a properly configured IEEE-1284 parallel port that is recognized by the printer, status information will be returned through the parallel port.
ZPL II Commands for RFID ^WT – Write Tag The format for the ^WT instruction is: ^WTb,r,m,w,s where ^WT = Write Tag command b = Block Number Default value: 0 Other values: 1 to n, where n is the maximum number of blocks for the tag NOTE: This is the starting block number. If the user sends more than a block of data it will overflow into the next block. If the user overflows the block and subsequent blocks cause errors (write protects, beyond range, etc.
w = Write protect Default value: 0 (NOT write protected) Other value: 1 (Write protect) s = Special mode Reserved ^RT – Read Tag The format for the ^RT instruction is: ^RT#,b,n,f,r,m,s where ^RT = Read Tag command # = Number to be assigned to the Field Default value: 0 Other Values: 1 to 9999 b = Starting Block Number Default value: 0 Other values: 1 to n, where n is the maximum number of blocks for the tag n = Number of blocks to read Default value: 1 Other values: 2 to n, where n is maximum number of blo
f = Format Default value: 0 ASCII Other values: 1 Hexadecimal r = Retries Default value: 0 Other values: 1 to 10, number of retries m = motion Default value: 0 (Feed label after writing) Other value: 1 a feed) (No Feed after writing, other ZPL may cause s = Reserved Default value: 0 Example: This example reads a block from a tag, and prints it on a label: ^XA ^FO20,120^A0N,60^FN1^FS ^FO20,100^A0N,20^FN2^FS ^RT1,7,3,0,5,0,0^FS ^RT2,2,2,0,5,0,0^FS ^XZ The tag type is set by the front panel or by the ^RS com
The second ^RT command string at block 2, reads two blocks of data in ASCII format. It retries up to 5 times. The data read will go into the ^FN2 location of the format. NOTE: The data can be sent back to the host via the ^HV command.
The unique ID will be read from the tag and available to print or return to the host computer.
Sample ZPL II Label Formats ZPL II ® is Zebra Technologies Corporation’s Zebra Programming Language 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 four sample label formats for you to begin experimenting with. It is not intended as an introduction to ZPL II.
Format 1: Simple Text and a Barcode Line # Type this label format 1. ^XA 2. ^LH30,30 3. ^FO20,10^AD^FDZEBRA^FS 4. ^FO20,60^B3N,Y,20,N^FDAAA001 5. ^XZ You’ll get this printout 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”.
Format 3: Using a Serialized Data Field Line # Type this label format 1. ^XA 2. ^LH30,30 3. ^FO20,10^AD^FDZEBRA^FS 4. ^FO20,60^B3,,40,^FDAAA001^FS 5. ^FO20,180^AF^SNSERIAL NUMBER 00000000111,1,Y^FS 6. ^PQ10 7. ^XZ You’ll get this printout Ten labels will print. The first (top) and last (bottom) are shown here. Line #1-3: (See 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.
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Index Basic . . . . . . . . . . . . . . . . . 19 Complete. . . . . . . . . . . . . . . 50 Continuous media . . . . . . . . . . . . 11 A Adjustments Media sensor position . . . . . . . . 77 Printhead pressure . . . . . . . . . . 77 Toggle positioning . . . . . . . . . . 76 B Bar codes . . . . . . . . . . . . . . . . 94 Black mark media sensor . . . . . . . . 16 D Damage, reporting . . . . . . . . . . . . 3 Data specifications. . . . . . . . . . . . 25 F FEED key and PAUSE key self test. . .
Loading the ribbon . . . . . . . . . . . 43 Lower media sensor adjustment . . . . . 16 Lubrication . . . . . . . . . . . . . . . 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 32 38 34 31 Media loading, fanfold . . . . . . . . . 40 Media loading, roll . . . . . . . . . . . 31 Media requirements . . . . . . . . . . . . 4 Media sensors Black mark. . . . . . . . . . . . . . 16 Transmissive . . . . . . . . . . . . . 14 Media sensors, positioning . . . . . . .
Ribbon requirements . . . . . . . . . . . 4 Ribbon specifications . . . . . . . . . . 96 Unpacking and inspection . . . . . . . . 3 Upper media sensor adjustment . . . . . 15 S Self tests CANCEL key . . . . . . . . Communications diagnostics FEED key . . . . . . . . . . FEED key and PAUSE key . PAUSE key . . . . . . . . . Power-on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 91 90 91 89 87 Serial port technical information . . . . 99 Software configuration . . . . . . . .
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