err-105PD41

Honeywell PD41 error ERR-105: Troubleshooting Guide

The Honeywell PD41 error ERR-105 occurs when the printer's sensor system fails to identify media (labels) positioning. It is a common fault after changing label sizes or if adhesive residue has accumulated on the gap sensor. Solving this issue involves proper calibration and cleaning of the detection components.

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Common causes

  • 1Adhesive residue accumulation on the gap sensor.
  • 2Incorrect media type setting in software.
  • 3Physical misalignment of roll holders.
  • 4Sensor degradation due to high usage.

Solutions

Quick Diagnosis

The ERR-105 error usually pops up right after installing a new roll. If the status LED is blinking constantly, the printer is likely failing to detect the gap between labels correctly.

Step-by-Step Solution

  1. Open the cover and remove the labels and ribbon.
  2. Clean the gap sensor with a soft cloth lightly dampened with isopropyl alcohol.
  3. Ensure the label roll is correctly aligned and not shifted sideways.
  4. Run the calibration wizard from the front panel so the equipment scans the new media.

Prevention and Maintenance

Clean the printer sensors every time you change label rolls to prevent glue residue from interfering with detection. Keep the equipment in a dust-free environment.

When to Call a Technician

If after cleaning and calibrating, the sensor still fails to detect labels, the sensor might be physically damaged and require replacement.

Device Technical Data

  • Technology: Direct Thermal / Thermal Transfer
  • Speed: Up to 200 mm/s
  • Connectivity: Ethernet, RS-232, USB
  • Compatible Consumables: Industrial PD41 label roll series
  • Recommended Usage: Logistics and Warehousing
  • Official Drivers / Firmware

Steps to follow

  1. 1

    Sensor cleaning

    Use a swab with isopropyl alcohol to clean the gap sensor.

  2. 2

    Media adjustment

    Ensure the label roll is centered and side supports aren't too tight.

  3. 3

    Calibration

    Run media calibration from the printer menu so the sensor detects gaps correctly.

Frequently asked questions

This error means the printer fails to detect the media gap or mark during the calibration process.

No, the printer stops for safety reasons to prevent wasting expensive industrial label stock.

The PD41 supports various thermal media. Check your labels (gap, black mark, or continuous).

Clean sensors whenever you change label rolls to prevent adhesive residue buildup.