XL400e / XL410e Printers OPERATOR MANUAL PN 9001135C
SATO America, Inc. 10350A Nations Ford Road Charlotte, NC 28273 Main Phone: (704) 644.1650 Technical Support Hotline: (704) 644.1660 Technical Support Fax: (707) 644.1661 E-Mail: satosales@satoamerica.com techsupport@satoamerica.com www.satoamerica.com WARNING THE EQUIPMENT REFERENCED IN THIS DOCUMENT COMPLIES WITH THE REQUIREMENTS IN PART 15 OF FCC RULES FOR A CLASS B COMPUTING DEVICE. OPERATION OF THIS EQUIPMENT IN A RESIDENTIAL AREA MAY CAUSE UNACCEPTABLE INTERFERENCE TO RADIO AND TV RECEPTION.
TABLE OF CONTENTS INTRODUCTION About This Manual General Description Control Features 1-2 1-3 1-4 TECHNICAL DATA Physical Characteristics Enviromental Processing Print Sensing Media Character Font Capabilities Power Barcode Capabilities Interface Modules Regulatory Approvals 2-2 2-2 2-2 2-2 2-2 2-3 2-3 2-4 2-4 2-4 2-4 INSTALLATION Unpacking & Parts Identification Printer Installation Site Location Media Selection Media Loading Ribbon Loading Interface Selection RS232 Serial Interface IEEE1284 Parallel I
OPERATION Printer Configuration Dip Switch Panels Configuration Modes Normal Mode Test Print Mode Advanced Mode Default Settings Mode Flash Memory Download Mode User Download Mode Hex Dump Mode Card Mode Non-Standard Clear Mode Service Mode - Test Print Service Mode - Sensor Level Service Mode - Pitch Offset Service Mode - Cut Offset Service Mode - Backfeed Offset Service Mode - Counter Display Screen Identification Operational Adjustments Darkness, Cut Position, Print Position, Display Cutter Sensor Positi
MAINTENANCE Cleaning Procedures Replacement Procedures Fuse Print Head Ribbon Roller Adjustment Procedures Print Head Balance Print Head Alignment Pressure Roller Alignment Pressure Roller Balance Ribbon Guide Adjustment Ribbon Spindle Tensioning Pitch Sensor Adjustment (Label Gap & Center Hole Media) Pitch Sensor Adjustment (Eye-Mark Media) Pitch Sensor Adjustment (R-Corner) Pitch Sensor Adjustment (Side Hole Media) Jump Hole Sensor Adjustment Ribbon Sensor Adjustment Cutter Sensor Adjustment PN 9001135C
INTRODUCTION • • • SATO XL400-410e Operator Manual About This Manual General Description Control Features PN 9001135C Page 1-1
Unit 1: Introduction ABOUT THIS MANUAL This manual is laid out consistent with the product discussed and provides all of the information required for general printer configuration, operation, troubleshooting, and maintenance. For specialized programming, refer to the Programming Manual provided with the product. Step-by-step maintenance instructions are provided with typical problems and solutions. Become familiar with each section before installing and maintaining the printer.
Unit 1: Introduction GENERAL DESCRIPTION The XL400/410 “e” series printers are complete, high-performance labeling systems designed specifically for printing labels and tags. All printer parameters are programmable using the front panel controls and dip switches to provide printing of all popular bar codes and fonts styles and sizes.
Unit 1: Introduction CONTROL FEATURES BUTTONS & SWITCHES POWER START / STOP FEED CUTTER ON/OFF EJECT MEDIA TYPE DSW1 & DSW2 DSW3 Two position on/off switch that controls power flow to the system. Toggles the printer on/off line. Allows feeding of one tag or label each time it is pressed. Is only functional when the printer is off-line. Feeds one label when the cutter is disabled. Feeds one label, cuts, and backfeeds when the cutter is enabled. Enables or disables the cutter.
Unit 1: Introduction LED’s SATO XL Printer ERROR ON LINE START /STOP FEED LCD Display CUTTER ON/OFF EJECT MEDIA TYPE Function Keys Figure 1-2b, Control Features CONNECTION PORTS AC Power Input Interface Port Connector permits 115V, 50/60 Hz supply via supplied cord. Connector for interface harness. Must be connected for the printer to be operational. Acceptable interface types are: • • • • • Ext.
TECHNICAL DATA • • • • • • • • • • • SATO XL400-410e Operator Manual Physical Charcteristics Enviromental Power Processing Print Sensing Media Character Font Capabilities Barcode Capabilities Interface Modules Regulatory Approvals PN 9001135C Page 2-1
Unit 2: Technical Data PHYSICAL CHARACTERISTICS Width 19.6 Inches (302 mm) Height 11.50 Inches (294 mm) Depth 11.80 Inches (552 mm) Weight 30.80 Pounds (14.
Unit 2: Technical Data MEDIA Eye-Mark Label Dimensions Width: 1.26 to 4.125 Inches (32-100mm) Length: 1.00 to 6.00 Inches (25-150mm) (w/ Stacker Unit) Gap Label Dimensions Width: 1.00 to 4.125 Inches (25-100mm) Length: 0.63 to 6.00 Inches (16-150mm) (w/ Stacker Unit) Eye-Mark Tag Width: 1.26 to 4.125 Inches (32-100mm) Length: 1.00 to 6.00 Inches (25-150mm) (w/ Stacker Unit) Side Hole Tag Width: 2.00 to 4.125 Inches (50-100mm) Length: 1.00 to 6.
Unit 2: Technical Data BAR CODE CAPABILTIES Linear Bar Codes Bookland (UPC/EAN Supplemental EAN-8, EAN-13 CODABAR Postnet Code 39 Code93 Code 128 Interleaved 2 of 5 UCC/EAN-128 UPC-A and UPC-E Two Dimemsional Data Matrix Maxicode QR Code PDF417 Ratios Bar Height Rotation Sequential Numbering Custom Characters Graphics Form Overlay 1:2, 1:3, 2:5, User definable bar widths 4 to 600 dots, User progammable 0, 90, 180, and 270 Degrees Sequential numbering of both numerics and bar codes RAM storage for spec
INSTALLATION • • • • • SATO XL400-410e Operator Manual Unpacking Parts Identification Printer Installation Interface Selection Accessories Installation PN 9001135C Page 3-1
Unit 3: Installation UNPACKING & PARTS IDENTIFICATION Place the shipping container upright on a solid, flat surface. Open the container and remove the carboard cover and top foam inserts. Carefully lift the printer from the shipping container, followed by the acccessory box, and place them on a solid flat surface. Remove the plastic wrap from the printer and its accessories. Inspect the printer and its accessories for visual physical damage and ensure all components are present and report damaged property.
Unit 3: Installation PRINTER INSTALLATION This chapter provides guidance on general printer setup and installation. The following chapter provides instructions on how to select an interface for the host to communicate with the printer. SITE LOCATION • Stationed on a solid flat surface • Stationed away from hazardous conditions • Sufficient access space on all sides to premit access and opening of its covers. • Stationed within operational distance of the host computer.
Unit 3: Installation MEDIA LOADING Perform the following steps to load media into the printer. This procedure covers only the physical installation of media and is applicable regardless of the media type. Refer to the Configuration unit for setup instructions. 1 Switch the printer power switch off and disconnect the power supply cord (Figure 3-3a). 2 Open the top housing cover. 3 Remove the media retaining plate from media supply spindle (Figure 3-3b).
Unit 3: Installation Media Supply Spindle Media Media Retaining Plate Figure 3-3b, Media Loading Media Hold-Down Print Head Latch Figure 3-3c, Media Loading SATO XL400-410e Operator Manual PN 9001135C Page 3-5
Unit 3: Installation Cutter Assembly Media Media Ramp Set Screw Paper Guide Figure 3-3d, Media Loading Top Housing Cover Print Head Assembly Media Hold-Down Figure 3-3e, Media Loading SATO XL400-410e Operator Manual PN 9001135C Page 3-6
Unit 3: Installation Label/Tag Power Switch Figure 3-3f, Media Loading RIBBON LOADING Perform the following steps to load the printer with ribbon. This procedure covers only the physical installation of ribbon. Refer to the Configuration unit for setup instructions. 1 Switch the printer power switch off and disconnect the power supply cord (Figure 3-4a). 2 Open the top housing cover. 3 Release the print head latch (Figure 3-4b).
Unit 3: Installation Top Housing Cover Power Switch Power Supply Cord Figure 3-4a, Ribbon Loading Ribbon Print Assembly Figure 3-4b, Ribbon Loading SATO XL400-410e Operator Manual PN 9001135C Page 3-8
Unit 3: Installation Ribbon Rewind Spindle Ribbon Unwind Spindle Ribbon Roll Ribbon Core Figure 3-4c, Ribbon Loading Ribbon Print Assembly Figure 3-4d, Ribbon Loading SATO XL400-410e Operator Manual PN 9001135C Page 3-9
Unit 3: Installation Ribbon Ribbon Core Figure 3-4e, Ribbon Loading Top Housing Cover Ribbon Print Head Latch Figure 3-4f, Ribbon Loading SATO XL400-410e Operator Manual PN 9001135C Page 3-10
Unit 3: Installation Label/Tag Power Switch Figure 3-4g, Ribbon Loading SATO XL400-410e Operator Manual PN 9001135C Page 3-11
Unit 3: Installation INTERFACE SELECTION This chapter presents the printer interface types and their specifications. These specifications include detailed information to assist in the selection of the most appropriate method for the printer to interface with the host. The four acceptable interface methods are: • RS232C Asynchronous Serial • IEEE1284 Parallel • Universal Serial Bus (USB) Adapter • Local Area network (LAN) Ethernet • 802.
Unit 3: Installation RS232C SERIAL INTERFACE SIGNALS PIN DIRECTION 1 2 Reference To Host 3 4 To Printer To Host 5 To Printer 6 To Printer 7 20 Reference To Host SIGNAL DEFINITION FG (Frame Ground) TD (Transmit Data) - Data from the printer to the host computer. Sends X-On/ X-Off characters or status data (bi-directional protocols). RD (Receive Data) - Data to the printer from the host computer. RTS (Request to Send) - Used with Ready/Busy flow control to indicate an error condition.
Unit 3: Installation IEEE1284 PARALLEL INTERFACE The parallel interface is a Plug-In, bi-directional, Interface Module that can be installed by the user. It conforms to the IEEE1284 specification. It will automatically detect the IEEE1284 signals and operate in the high speed mode. If it does not detect the IEEE1284 signals, it will operate in the standard Centronics mode, which is significantly slower.
Unit 3: Installation UNIVERSAL SERIAL BUS (USB) ADAPTER The Universal Serial Bus (USB) interface is a Plug-In Interface Module that can be installed by the user. It requires a driver (shipped with each printer that has the interface installed) that must be loaded on your PC and the PC must be configured to support USB peripherals using Windows 98 or above. Details for loading the USB driver are contained in the USB Interface Manual that is shipped with each printer with a USB Optional interface installed.
Unit 3: Installation RECEIVE BUFFER The data stream is received from the host to the printer one job at a time. This allows the software program to maintain control of the job print queue so that it can move a high priority job in front of ones of lesser importance. A multiple job buffer allows the printer to continuously receive print jobs while compiling and printing other jobs at the same time. It acts much like a Print buffer to maximize the performance of the host and the printer.
Unit 3: Installation ACCESSORIES INSTALLATION In most instances, the printer is ordered with the desired accessories pre-installed. However, changes in printing conditions or requirements does warrant upgrades from time to time. This chapter of the manual covers the installation procedures of accessories that are deemed suitable for the owner/operator to perform. For all other accessory upgrades or installatins, contact the SATO Technical Support Dept.
Unit 3: Installation STACKER UNIT The XL Stacker Unit collects and stacks tags as they are printed and cut. Installation of the included alignment plate ensures proper spacing and alignment of the stacker with the printer. Connecting the stacker’s power cord to the Option port of the printer concludes installation. Adjust the unit for operation in accordance with the instructions provided with the product.
OPERATION • • • • SATO XL400-410e Operator Manual Printer Configuration Configuration Modes Operational Adjustments Printing PN 9001135C Page 4-1
Unit 4: Operation PRINTER CONFIGURATION The printer may be configured for specific jobs via the operator panel located on the right side of the printer and the interface panel comprised of three dip switch complexes and four potentiometers located within the printer’s interior. Each of these must be adjusted for full printer configuration. The first step is to set the dip switches to their proper positions and then proceed to the Configuration Modes and Operational Adjustments chapters to complete process.
Unit 4: Operation DSW1 DEFAULT SETTINGS 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 OFF OFF OFF OFF OFF OFF OFF OFF DSW1 CONFIGURATION 1-1 Data BIt 1-2 1-3 Parity 1-4 Baud Rate 1-7 1-8 Protocol 8 Data Bit ON 7 Data Bit 1-2 1-3 ON ON Reserved ON OFF Odd OFF ON Even OFF OFF None Stop Bit 1-5 1-6 OFF OFF 1 Stop Bit ON 2 Stop Bit 1-5 1-6 ON ON Normal: 2400, High Speed: 57600 ON OFF Normal: 4800, High Speed: 38400 OFF ON Normal: 19200, High Speed: 19200 OFF OFF
Unit 4: Operation DSW2 DEFAULT SETTINGS 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 OFF OFF OFF OFF OFF OFF OFF OFF DSW2 CONFIGURATION DSW2 FUNCTION SETTING 2-1 Print Mode 2-2 Reserved 2-3 Head Check 2-4 Hex Dump 2-5 Receive Buffer 2-6 Firmware Download 2-7 Protocol Code 2-8 Operational Mode CONFIGURATION OFF Thermal Transfer ON Direct Thermal OFF N/A ON N/A OFF Head Check Disabled ON Head Check Enabled OFF Hex Dump Disabled.
Unit 4: Operation DSW3 DEFAULT SETTINGS 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 OFF OFF OFF OFF OFF OFF OFF OFF DSW3 CONFIGURATION DSW1 FUNCTION SETTING 3-1 N/A 3-2 Pitch Size Check 3-3 N/A 3-4 N/A 3-5 N/A 3-6 N/A 3-7 N/A 3-8 N/A CONFIGURATION OFF Reserved ON Reserved OFF Disabled ON Enabled OFF Reserved ON Reserved OFF Reserved ON Reserved OFF Reserved ON Reserved OFF Reserved ON Reserved OFF Reserved ON Reserved OFF Reserved ON Reserved DSW3 FUN
Unit 4: Operation CONFIGURATION MODES With exception of the Power switch located on the back side of the printer, all of the following configuration activities are performed via the use of the operator panel located on the printer’s right side and the adjustment panel located within the printer’s interior. Many settings may also be controlled via software commands. In the case of conflict between the software and control panel settings, the printer will always use the last entered valid setting.
Unit 4: Operation TEST PRINT MODE This mode allows the operator to print test labels for troubleshooting and for verification of configuration settings. FEED + POWER Printer beeps TEST PRINT MODE CONFIGURATION START/STOP to scroll. TEST PRINT MODE BARCODE TEST PRINT MODE HEADCHECK TEST PRINT MODE MEMORY TEST PRINT MODE FACTORY FEED To select. FEED To select. PRINT SIZE LARGE SMALL PRINT SIZE 03CM START/STOP to scroll. FEED to select. Printing completes. Printing commences.
Unit 4: Operation ADVANCED MODE The Advanced Mode is provided to make basic printer operational adjustments. Typically, once these adjustments or settings have been made, they will not require additional address unless a new job is downloaded. The following table identifies the menus of the Advanced Mode and their purpose. START/STOP + POWER Printer beeps ADVANCED MODE START/STOP CARD MODE Refer to that chart. FEED CHARACTER PITCH PROP FIXED START/STOP to scroll. FEED to select.
Unit 4: Operation DEFAULT SETTINGS MODE When the sequences have been completed, the printer automatically returns to its default gap or eye-mark settings. The default settings are those programmed settings of the factory prior to delivery. START/STOP + FEED + POWER Printer beeps. DEFAULT SETTING YES NO START/STOP to scroll. FEED to select. FEED Yes / No POWER = OFF Beeps 3 times and returns default settings.
Unit 4: Operation FLASH MEMORY DOWNLOAD MODE A Flash ROM internally stores and deletes font data and custom designed character data. The storage capacity for custom characters is 95 for each type of 16 x 16, 22 x 22, and 24 x 24 dots. There are four transmission protocols for font download: (1) Download Font Storage, (2) Download Font Deletion, (3) Download Font Information Aquisition, (4) Storage CustomDesigned Character.
Unit 4: Operation STORAGE OF CUSTOM DESIGNED CHARACTER STATUS DESCRIPTION ACSII HEX TRANSFER Storage Ready Status O 4F Printer to Host Storage Completed Normally E 45 Printer to Host Storage Completed Abnormally Z 5A Host to Printer DSW2-6 = ON POWER DOWNLOAD WAITING DSW2-6 = OFF POWER = OFF Send data. xxxxxxx DOWNLOAD START >>>>>>> END Printer begins receiving data. xxxxxxx DOWNLOAD COMPLETED More than 3 seconds transpires.
Unit 4: Operation USER DOWNLOAD MODE This download feature allows the operator to download to the printer, the configuration command codes found in the Programming Reference. When downloading is complete, the LCD screen will return to the original display after three seconds. If an error occurs, a DOWNLOAD ERROR will display and identify the reason. DSW2-7 = ON START/STOP + POWER Printer beeps. USER DOWNLOAD START/STOP USER DOWNLOAD WAITING Send data from host.
Unit 4: Operation HEX DUMP MODE The contents of the print buffer and the data received before it is placed into the print buffer may be examined through the use of the Hex Dump Mode. Each line of the printed data is inumerated in the first column, the second column contains the data in hexadecimal format, and the right column contains the same data in ASCII format. Print Buffer/Receive Buffer POWER = OFF DSW2-4 = ON POWER = ON ONLINE 000000 POWER = ON and transmit data.
Unit 4: Operation CARD MODE This configuration mode is used for configuring the Flash ROM and/or PCMCIA interface cards. The following table identifies the menus of the Card Mode and their purpose. The flow chart after, sequences the operator, printer, and host interface activities. START/STOP + POWER Printer beeps. ADVANCED MODE MEMORY->CARDCOPY ALL <0MB> Y/N START/STOP START/STOP START/STOP to scroll. FEED to select.
Unit 4: Operation NON-STANDARD CLEAR MODE Returns non standard protocol code to the default value. The default values are STX (7B), ETX (7D), ESC (5E), ENQ (40), NUL (7E), CAN (21), OFFLINE (5D). Follow the sequences in th flow chart below to perform this function. DSW2-7 = ON START/STOP + FEED + POWER Printer emits I long and 3 short beeps. ALT.
Unit 4: Operation SERVICE MODE Allows the programming of various dimensional settings and the language used. Refer to the table below for an explaination of each menu encountered. The following flow chart provides configuration sequence. DSW2-4 = ON START/STOP + FEED + POWER Printer beeps DSW2-4 = OFF SERVICE MODE DIPSW2-4 ON->OFF FEED to select. SERVICE MODE TEST PRINT PRINT SIZE SMALL FEED COUNTER CLEAR ALL COUNTER CLEAR NONE LARGE START/STOP to scroll. FEED to select.
Unit 4: Operation DSW2-4 = ON START/STOP + FEED + POWER SERVICE MODE SENSOR LEVEL START/STOP FEED Printer beeps GAP INPUT [ x.x V ] [ x.x V ] SERVICE MODE DIPSW2-4 ON->OFF PAPER SENSOR JUMP HOLE START/STOP to scroll. FEED to select. [x] FEED DSW2-4 = OFF SERVICE MODE TEST PRINT Refer to Service Mode Chart A START/STOP EYE INPUT [ x.x V ] [ x.x V ] CUTTER SENSOR CENTER HOLE START/STOP to scroll. FEED to select.
Unit 4: Operation DSW2-4 = ON START/STOP + FEED + POWER SERVICE MODE PITCH OFFSET START/STOP Printer beeps FEED SERVICE MODE DIPSW2-4 ON->OFF DSW2-4 = OFF PITCH OFFSET CENTER HOLE START/STOP to scroll.
Unit 4: Operation DSW2-4 = ON START/STOP + FEED + POWER Printer beeps SERVICE MODE DIPSW2-4 ON->OFF Refer to Service Mode Chart A DSW2-4 = OFF SERVICE MODE TEST PRINT SERVICE MODE CUT OFFSET START/STOP FEED CUT OFFSET CENTER HOLE SERVICE MODE SENSOR LEVEL FEED START/STOP Refer to Service Mode Chart C +00 START/STOP to scroll.
Unit 4: Operation DSW2-4 = ON START/STOP + FEED + POWER Printer beeps SERVICE MODE DIPSW2-4 ON->OFF Refer to Service Mode Chart A DSW2-4 = OFF SERVICE MODE TEST PRINT SERVICE MODE BACKFEED OFFSET START/STOP FEED BACKFEED OFFSET CENTER HOLE +00 START/STOP to scroll.
Unit 4: Operation DSW2-4 = ON START/STOP + FEED + POWER Printer beeps SERVICE MODE COUNTER DISPLAY SERVICE MODE DIPSW2-4 ON->OFF START/STOP FEED DSW2-4 = OFF COUNTER LIFE Refer to Service Mode Chart A SERVICE MODE TEST PRINT START/STOP to scroll. START/STOP Refer to Service Mode Chart B X.X M SERVICE MODE SENSOR LEVEL COUNTER HEAD X.X M COUNTER CUT X.
Unit 4: Operation NORMAL MODE MENU DESCRIPTION NORMAL MODE Basic print functions. ONLINE 000000 Receives data and can issue a label. Displays the countdown number and the count-up number in the lower region on the LCD. 00000000 CENTER HOLE 000000 00000000 Center Hole is the factory default media. If another media has been selected, that will be displayed. The countdown and count-up quantites is also displayed.
Unit 4: Operation ADVANCED MODE MENU DESCRIPTION ADVANCED MODE Menu allows configuration of printer features that typically do not require change. CHARACTER PITCH The PROP option allows proportional pitch and the FIXED option is without. The FIXED option sets printing so that each font occupies the same amunt of lateral space regardless of a given character width. For example, the character “i” would occupy the same space laterally as the character “s” even though the “s” is obviously wider.
Unit 4: Operation CARD MODE MENU DESCRIPTION CARD MODE Menu allows configuration of the memory card. MEM SELECT(CC1) CARD MEMORY Establishes the media of the first drive. The default value is on the card. START/STOP key moves the cursor and the FEED key selects the option. CARD->MEMORYCOPY ALL Y/N Allows the copying of the entire card contents into Flash ROM. START/STOP key moves the cursor and the FEED key selects the option.
Unit 4: Operation SERVICE MODE MENU DESCRIPTION SERVICE MODE Menu allows configuration media type. COUNTER CLEAR NONE PRINT SIZE SMALL LARGE Selects the counter to clear. The options are None, All, Print Head, Cutter, and Dispenser. The default value is NONE: Do not clear. START/STOP key moves the cursor and the FEED key selects the option. Sets the print size for the test print. START/STOP key moves the cursor and the FEED key selects the option. PRINT SIZE 3CM Sets the width of test print media.
Unit 4: Operation OPERATIONAL ADJUSTMENTS These operational adjustments are for fine tuning the printer as necessary following the configuration process and are confined to the three potentiometers located on the adjustment panel in addition to the operator panel. Refer to the table below for their function. POTENTIOMETER DARKNESS (VR1) DESCRIPTION/PROCEDURE Is used to adjust the darkness or lightness of the printed image and should be used in conjunction with the configuration adjustments.
Unit 4: Operation Reference Label VR1 VR2 VR3 VR4 DARKNESS CUT POSITION PRINT POSITION DISPLAY DSW 1 DSW 2 DSW 3 VR1 VR2 VR3 VR4 Figure 4-11, Adjustment Panel SATO XL400-410e Operator Manual PN 9001135C Page 4-27
Unit 4: Operation CUTTER SENSOR POSITIONING The cutter assembly has dual adjustable sensors and is designed to permit lateral movement of the sensor assembly to accomdate multiple media types. To position the sensor, loosen its set screw and move the sensor assembly along the incremented scale to the correct position so that it aligns with its reference mark on the media and then retighten the set screw. Then select which of the dual sensors is also applicable to the media of use.
Unit 4: Operation OPERATOR PANEL The operator panel may be used at two different angles. The normal angle is flush with the surface of the printer. Pressing against the upper portion of the panel causes it to tilt backwards to allow better viewing under certain situations. To release the panel from the tilted angle, move the release button located above the panel to the right.
Unit 4: Operation PRINTING At this point, both the printer and the operator should be ready to print labels or tags. One can begin by commencing production or by printing a test label first. To begin production, simply use the operator panel as directed in the Introduction unit of this manual. TEST PRINTING A test label is designed to assist in the identification of print problems. Refer to the Troubleshooting unit of this manual for instructions on printing a test label.
TROUBLESHOOTING • • • • • • SATO XL400-410e Operator Manual Error Signals Printer Troubleshooting InterfaceTroubleshooting Performance Testing Test Print Troubleshooting Sensor Locations PN 9001135C Page 5-1
Unit 5: Troubleshooting ERROR SIGNALS This unit coorelates the three types of error signals with probable causes and problem resolution. Three types error signals are: LED, LCD Message, and an audible beep. ERROR SIGNAL TABLE LED LCD MESSAGE BEEP Error on MACHINE ERROR 1 long Cycle power off/on. Replace board. Error on EEPROM ERROR 1 long Cycle power off/on. Replace board. Error on HEAD ERROR 3 short Replace print head. Cycle power off/on.
Unit 5: Troubleshooting PRINTER TROUBLESHOOTING TROUBLESHOOTING TABLE IMAGE VOIDS Damaged print head. Replace print head. Damaged electronics. Replace circuit board. Damaged or worn platen roller. Replace platen roller. Vertical line in printed image. Dirty or defective print head. LIGHT PRINT IMAGES Low print head energy/darkness. Adjust darkness control. Low print head pressure. Adjust head balance. Foreign material on print head. Clean print head and platen roller. Poor head alignment.
Unit 5: Troubleshooting NO PRINTED IMAGE Print head is disconnected. Ensure print head wiring harness is connected on each end. No voltage output. Test power supply and replace as necessary. Damaged print head. Replace print head. Damaged electronics. Replace circuit board. Interface problems. Check. Refer to relative instructions below. Data input error. Ensure correct data stream. LCD FIELD ILLUMINATED BUT WITHOUT WORDS OR NO DISPLAY AT ALL Power cable issues. Ensure properly connected.
Unit 5: Troubleshooting INTERFACE TROUBLESHOOTING This unit provides a checklist for the various interface types. Locate the checklist relative to the interface used and perform each of the troubleshooting tasks until the problem has been isolated. PARALLEL INTERFACE CHK TROUBLESHOOTING STEP Ensure the interface module is correctly installed. Run self-test to verify. Ensure the printer cable is connected to the appropriate LPT port on the host computer.
Unit 5: Troubleshooting LAN EHTERNET INTERFACE CHK TROUBLESHOOTING STEP Ensure the interface has been correctly configured. Wait two minutes and run self-test to verify. If a test label does not print, there ma y be a hardware problem. Ensure the serial cable meets specifications and is correctly connected at each end. Ensure the cable and its ports are not defective. Ensure that a faulty print server or other protocol related senarios are not creating a queue setup issue.
Unit 5: Troubleshooting PERFORMANCE TESTING This unit explains how to troubleshoot circuitry and adjust sensors using a multimeter. These activities may be performed with or without test module assistance in conjunction with the multimeter. MULTIMETER WITH TEST MODULE The SATO Test Module is is a purchase option designed and sold by SATO America to assist in troubleshooting SATO Printers.
Unit 5: Troubleshooting TEST CHART MODULE DIAL CONNECTOR PIN 1A FUNCTION This test connector pin is used as the ground post. 2A 0 3A Used to determine voltage of components that require between +4.8 and +5.2 VDC to properly function. 1 4A Used to determine voltage of components that require between +11.4 and +12.6 VDC to properly function. 2 5A Used to determine voltage of components that require between -11.4 and -12.6 VDC to properly function.
Unit 5: Troubleshooting TEST PRINT TROUBLESHOOTING Chapter provides instruction on special printing to identify and resolve specific print problems. HEX DUMP Allows the operator to determine if there were problems in the downloading of data. TEST LABEL Allows the operator to identify specific problems regarding mechanical performance and setup. HEX DUMP MODE The contents of the print buffer can be examined using the Hex Dump Mode. In the left column, each line of data received is numbered.
Unit 5: Troubleshooting TEST LABEL PRINTING The test label is designed to assist in the identification of print problems. Follow the flow chart provided below to perform this activity. FEED + POWER Printer beeps TEST PRINT MODE CONFIGURATION START/STOP to scroll. TEST PRINT MODE BARCODE TEST PRINT MODE HEADCHECK TEST PRINT MODE MEMORY TEST PRINT MODE FACTORY FEED To select. FEED To select. PRINT SIZE LARGE SMALL PRINT SIZE 03CM START/STOP to scroll. FEED to select. Printing completes.
Unit 5: Troubleshooting Compare this scale on each side to ensure the print is evenly spaced horizontally. Visually inspect these rows for voids indicating defective head elements. SAMPLE TEST LABEL Label Contents Will Vary Depending on Test Label Type. Displays the dip switch settings at the time of print. Line sharpness is determined by print speed and darkness. D S W 1 N O N E D S W 2 D S W 3 Clear line in print indicates the ribbon was wrinkled during printing.
Unit 5: Troubleshooting SENSOR LOCATIONS This chapter provides a diagram identifying the locations of the printer’s various sensors. Refer to the diagram provided below.
MAINTENANCE • • • SATO XL400-410e Operator Manual Cleaning Procedures Replacement Procedures Adjustment Procedures PN 9001135C Page 6-1
Unit 6: Maintenance CLEANING PROCEDURES Cleaning of the printer is a necessary maintenance activity to ensure print quality and long printer life. There are two basic types of cleaning involved; the removal of loose debris and the removal of residue. Use a soft cloth and/or a pneumatic blower to remove debris from the printer. This process should be performed prior to the removal of residue.
Unit 6: Maintenance REPLACEMENT PROCEDURES The printer contains replaceable components and sub-assemblies. This chapter contains stepby-step instructions for the removal and replacement of those primary components and subassemblies that are subject to wear or damage. FUSE REPLACEMENT The printer has three fuses; one is externally accessible and is wired to the power supply while the other two are located internally and directly connected to the main circuit board.
Unit 6: Maintenance PRINT HEAD REPLACEMENT If the print head becomes damaged or wears out, it can be easily replaecd using a screwdriver. Critical adjustments are not required because the print head is a subassembly mounted to a permanent, factory adjusted mechanism. 1 Switch off the printer and disconnect the power supply cord. 2 Open the top housing cover 3 Unlatch the print head and remove the ribbon stock. 4 Relatch the print head and remove one mounting screw securing the defective print head.
Unit 6: Maintenance RIBBON ROLLER REPLACEMENT The ribbon roller is a high wear component due to the ribbon medium treading on its surface. The ribbon roller is the only roller approved for replacement by the operator. For all other roller replacements, contact a service representative. NOTE: Observe and remember the sequence and orientation of tribbon roller components as dismantling to facilitate installation of the replacement. 1 Switch off the printer and disconnect the power supply cord.
Unit 6: Maintenance ADJUSTMENT PROCEDURES To maintain optimum performance and print quality, periodically mechanical adjustments will have to be made. These adjustments are typically required following the replacment of a component. Other adjustments may be required due to variations in media size or quality and due to different print image denseness. Instructions relative to those conditions are not covered here. Refer to the Installation and Operation units for those relative instructions.
Unit 6: Maintenance PRINT HEAD BALANCE ADJUSTMENT If the print head balance is out of adjustment, the printed image will be darker on side of the label than the other and the media stock will be proned to want to travel in the direction of least resistance. The adjustment of print head pressure on the label is subjective. One will know when balance is achived by the disappearance of prevailing negative characteristics. To adjust print head balance, perform the following procedure.
Unit 6: Maintenance PRINT HEAD ALIGNMENT Print head position has a direct impact on print quality. An improperly aligned print head will cause the print to be inconsistent across the label. The following procedure will provide guidance on print head alignment. 1 Remove power and disconnect the power supply cord. 2 Open the top housing cover to access and open the print assembly. 3 Remove ribbon stock as applicable. 4 Loosen the two set screws and one mounting screw.
Unit 6: Maintenance PRESSURE ROLLER ALIGNMENT The pressure roller works in conjunction with the feed roller, sandwiching the loaded media between the two. It is the drive-coupled feed roller that advances the media forward to the platen roller. The pressure roller is an idle one. For proper media tracking the two rollers must be parallel and possess proportionate pressure from one end to the other. Tracking is the direction the media is incline to take.
Unit 6: Maintenance PRESSURE ROLLER BALANCE The pressure roller works in conjunction with the feed roller, sandwiching the loaded media between the two. It is the drive-coupled feed roller that advances the media forward to the platen roller. The pressure roller is an idle one. For proper media tracking the two rollers must be perfectly parallel and possess proportionate pressure from one end to the other. Tracking is the direction the media is inclined to take.
Unit 6: Maintenance RIBBON GUIDE ADJUSTMENT If the print ribbon is not spread smoothly over the print head when it makes contact with the media, print voids will occur at the point of the ribbon fold. Typically, this is the result of the axis of one of the following not being perfectly parallel: ribbon spindle, ribbon roller, print head, or ribbon guide. The purpose of the adjustable ribbon guide is to compensate for the axis deviations of the other three.
Unit 6: Maintenance RIBBON SPINDLE TENSIONING The printer has two ribbon spindles; one to supply ribbon medium from the rear of the printer past the print head to the spindle closest to the front for the purpose of rewinding the used medium. The rewind spindle is coupled to the drive train and draws the ribbon medium forward incrementally with the print media (label/tag) comparable with gearing ratios. For proper function, the spindles must be individually adjusted with the correct drag.
Unit 6: Maintenance PITCH SENSOR ADJUSTMENT (LABEL GAP & CENTER HOLE MEDIA) This sensor adjustment regulates penetrating ability for media referencing. Penetration modification is performed via two potentiometers that is part of the potentiometer complex located behind the access panel on the left side of the printer. To establish penetration, upper and lower voltage levels must be set and the difference between the two voltage levels should be maximized for optimum performance.
Unit 6: Maintenance PITCH SENSOR ADJUSTMENT (EYE-MARK MEDIA) This sensor adjustment regulates penetrating ability for media referencing. Penetration modification is performed via two potentiometers that is part of the potentiometer complex located behind the access panel on the left side of the printer. To establish penetration, upper and lower voltage levels must be set and the difference between the two voltage levels should be maximized for optimum performance.
Unit 6: Maintenance VR3 VR8 VR9 VR4 VR2 VR1 VR11 VR10 VR12 VR5 VR6 VR7 Identification TP1 TP4 1A 2A 3A 0 Test Panel 8 4A 1 5A 7 2 Test Module Dial 6A 1B 6 3 5 4 2B 3B 4B Connect ground probe here GND SIG Connect positive probe here 5B 6B Figure 6-11, Test Module & Sensor Potentiometers 6A 1A 6B 1B Figure 6-12, Test Connector SATO XL400-410e Operator Manual PN 9001135C Page 6-15
Unit 6: Maintenance PITCH SENSOR ADJUSTMENT (R-CORNER MEDIA) This sensor adjustment regulates penetrating ability for media referencing. Penetration modification is performed via two potentiometers that is part of the potentiometer complex located behind the access panel on the left side of the printer. To establish penetration, upper and lower voltage levels must be set and the difference between the two voltage levels should be maximized for optimum performance.
Unit 6: Maintenance PITCH SENSOR ADJUSTMENT (SIDE HOLE MEDIA) This sensor adjustment regulates penetrating ability for media referencing. Penetration modification is performed via two potentiometers that is part of the potentiometer complex located behind the access panel on the left side of the printer. To establish penetration, upper and lower voltage levels must be set and the difference between the two voltage levels should be maximized for optimum performance.
Unit 6: Maintenance JUMP HOLE SENSOR ADJUSTMENT This sensor adjustment regulates penetrating ability for media referencing. Penetration modification is performed via two potentiometers that is part of the potentiometer complex located behind the access panel on the left side of the printer. To establish penetration, upper and lower voltage levels must be set and the difference between the two voltage levels should be maximized for optimum performance.
Unit 6: Maintenance RIBBON SENSOR ADJUSTMENT This sensor adjustment regulates penetrating ability for ribbon feed. Penetration modification is performed via a potentiometer that is part of the potentiometer complex located behind the access panel on the left side of the printer. To establish the penetration level, upper and lower limits must be set. These activities require the use of a multimeter and may be perfomed with or without the assistance of the SATO Test Module.
Unit 6: Maintenance CUTTER SENSOR ADJUSTMENT This sensor adjustment regulates penetrating ability for the cutter sensor. Penetration modification is performed via a potentiometer that is part of the cutter assembly. To establish the penetration level, upper and lower limits must be set. These activities require the use of a multimeter. NOTE: Refer to the CUTTER REFERENCE CHART table below for the assigned connector pins, the potentiometer to be adjusted, and the desired multimeter voltage values.
