SATO M 5900RVe User Manual

M5900RVe

Direct Thermal Printer

OPERATOR MANUAL

PN 9001125A

SATO America, Inc.

10350A Nations Ford Road

Charlotte, NC 28273

Main Phone: [phone]

Technical Support Hotline: [phone]

Technical Support Fax: [phone]

E-Mail: [e-mail]

[e-mail]

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 1-2
General Description 1-3

Primary Components 1-3

Control Features 1-5

Switches 1-5
Connection Ports 1-5

TECHNICAL DATA

Physical Characteristics 2-2
Power 2-2
Enviromental 2-2
Print 2-2
Media 2-3
Sensing 2-2
Interface Modules 2-3
Processing 2-3
Character Font Capabilities 2-3
Barcode Capabilities 2-4
Regulatory Approvals 2-4

INSTALLATION

Unpacking & Parts Identification 3-2
Printer Installation 3-3

Site Location 3-3
Media Selection 3-3
Media Loading 3-3

Interface Selection 3-5

RS232 Serial Interface 3-5
IEEE1284 Parallel Interface 3-7
Universal Serial BUS (USB) Adapter 3-8
Local Area Network (LAN) Ethernet 3-8

802.11B Wireless 3-8
Receive Buffer 3-9
ACK/NAK Protocol 3-9

Accessories Installation 3-10

Interface Module 3-10

PN 9001125A

OPERATION

Printer Configuration 4-2

Dip Switch Panels 4-2

Configuration Modes 4-6

Normal Mode 4-6
Test Print Mode 4-7
Advanced Mode 4-8
Default Settings Mode 4-9
Flash Memory Download Mode 4-10
User Download Mode 4-12
Hex Dump Mode 4-13
Card Mode 4-14
Non-Standard Clear Mode 4-15
Service Mode 4-16
Counters Mode 4-17
Maintenance Mode 4-18
Screen Identification 4-19

Operational Adjustments 4-23

Print 4-23
Offset 4-23
Pitch 4-23
Print Reference Position 4-24
Sensor & Accessory Location 4-25

TROUBLESHOOTING

Error Signals 5-2
Troubleshooting Table 5-3
Troubleshooting Procedures 5-5

RS232 Serial Interface 5-5
Universal Serial Bus (USB) Interface 5-6
Parallel Interface 5-6
LAN Ethernet Interface 5-7

MAINTENANCE

Cleaning Procedures 6-2
Replacement Procedures 6-3

Fuse 6-4
Print Head 6-4
Interface Board 6-5

Adjustment Procedures 6-6

Print Head Balance 6-7
Print Head Alignment 6-8

PN 9001125A

INTRODUCTION

• About This Manual

• General Description

• Control Features

SATO M5900RVe Operator Manual PN 9001125A 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, 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.

This manual also incorporates the use of special information boxes. Examples of these boxes
and the type of information provided in each, are below.

WARNING: PROVIDES INFORMATION THAT, IF UNHEEDED, MAY
RESULT IN PRESONAL INJURY.

CAUTION: PROVIDES INFORMATION THAT, IF UNHEEDED, MAY

RESULT IN EQUIPMENT DAMAGE.

NOTE: Provides helpful hints to assist in performing the tasks at hand.

LCD DISPLAY: Provides the specific display that should be visible on
the LCD at that point.

A comprehensive Table Of Contents provided at the front of this manual facilitates rapid
movement within. The contents identify the different Units, Chapters, and Sections. Each
references the page number of their commencement.

The pages of this manual have embedded headers and footers to assist the user in identifying
his or her exact position within the manual. The header provides the section number followed by
its name. The footer identifies the product on the left, the manual’s part number in the center, and
the page number to the right side of the page.

Page enumeration is two-part with each separated by a hyphen. The first character set
references the Unit and the second identifies the page number. Page numbers begin with the
numeral (1) one at the commencement of a new unit and ascends sequentially.

SATO M5900RVe Operator Manual PN 9001125A Page 1-2

Unit 1: Introduction

GENERAL DESCRIPTION

The M5900RVe is a direct thermal, high performance printer capable of printing all popular bar
codes and twelve human readable fonts; providing an inventory of thousands of styles and sizes.
Its heavy metal construction is designed to deliver optimum performance in demanding
enviroments.

PRINT ASSEMBLY

TEAR BAR

PRINT HEAD

HEAD OPEN SWITCH

MEDIA RAMP

OPERATOR
PANEL

FRONT HOUSING COVER

LEFT HOUSING COVER

CENTER WALL

REAR HOUSING COVER

MEDIA SUPPORT ARM

PRINT HEAD LATCH

RIGHT LABEL GUIDE

PLATEN ROLLER

PRINTER FRAME

PRINTER CHASSIS

RIGHT HOUSING COVER

Figure 1-1a, Primary Components

SATO M5900RVe Operator Manual PN 9001125A Page 1-3

Unit 1: Introduction

INTERFACE BOARD

EXT INTERFACE

POWER SWITCH

MAIN FUSE

A/C CONNECTOR

MEMORY CARD

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MAIN CIRCUIT BOARD

PLATEN ROLLER PULLY

TIMING BELT

DRIVE MOTOR

POWER BOARD

Figure 1-1b, Primary Components

SATO M5900RVe Operator Manual PN 9001125A Page 1-4

Unit 1: Introduction

CONTROL FEATURES

SWITCHES

Power Switch Two position on/off switch that controls power flow to the system.
Line Key Toggles between on-line and off-line modes. When on-line, the

printer is ready to receive data from the host. Acts as a pause during
print by taking the printer off-line. Also used as a scroll-and-enter
interface for printer setup.

Feed Key Feeds one blank label through the printer when off-line. When the

printer is on-line, another copy of the last label will be printed. Also
used as a scroll-and-enter interface for printer setup.

DSW2 & DSW3 Sets operational parameters of printer.

DSW1 To configure optional RS232 communication card. Located on card.

CONNECTION PORTS

AC Power Input Connector permits 115V, 50/60 Hz supply via supplied cord.

Interface Port Connector for interface harness. Must be connected for the printer to

be operational. Acceptable interface types are:

• RS232C Serial I/F Module, DB-25

• IEEE1284 Parallel I/F Module, AMP 57-40360

• Universal Serial Bus Adapter

• Ethernet 10/100 BaseT I/F Module

• RS422/485 I/F Module, DB-9

Ext. Interface Port Connector for external control of print cycle. Also supplies power for

optional accessories - AMP 57-60140

Memory Card Slot Slot for the insertion of optional PCMCIA Memory Card

INTERFACE PORT

POWER

100V - 120V

I/F

EXT PORT

EXT.

POWER SWITCH

MAIN FUSE CONNECTION

AC POWER INPUT

LCD DISPLAY

LINE KEY

LINE FEED

OFFSET

PRINT PITCH

DSW2

FEED KEY

POTENTIOMETERS

DIP SWITCHES

DSW3

MEMORY CARD SLOT

FUSE T3.15A H 250V

Figure 1-2, Switches, Indicators, and Connection Ports

SATO M5900RVe Operator Manual PN 9001125A Page 1-5

Unit 1: Introduction

SATO M5900RVe Operator Manual PN 9001125A Page 1-6

TECHNICAL DATA

• Physical Charcteristics

•Power

• Enviromental

•Print

•Media

• Sensing

• Interface Modules

• Processing

• Character Font Capabilities

• Barcode Capabilities

• Regulatory Approvals

SATO M5900RVe Operator Manual PN 9001125A Page 2-1

Unit 2: Technical Data

PHYSICAL CHARACTERISTICS

Width 10.25 Inches (261 mm)

Height 11.25 Inches (285 mm)

Depth 12.75 Inches (322 mm)

Weight 22.75 Pounds (10.3 Kg) standard

POWER

Input Voltage 115/220 Volts AC +/- 10%, 50/60 Hertz +/-5%

Power Consumption 190 Volts/150 Watts Operating, 30 Volts/20 Watts Idle

ENVIRONMENTAL

Operating Temperature 41° to 104°F (5° to 40°C)

Storage Temperature 23° to 140°F (-5° to 60°C)

Storage Humidity 20 to 90% RH Non-Condensing

Operating Humidity 20 to 80% RH Non-Condensing

Electrostatic Discharge 8kV

PRINT

Method Direct Thermal

Speed (user selectable) 2, 3, 4, 5, 6 Inches Per Second

Print Module (dot size) .0049 Inches (.125 mm)

Resolution 203 Dots Per Inch (8 dpmm)

Maximum Print Width 4.4 Inches (112 mm)

Maximum Print Length 14.0 Inches (355 mm)

MEDIA

Width 1.5 to 5.0 Inches + .118 for paper backing (37-128 mm)

Length 1.0 to 14.0 Inches + .118 for paper backing (25-356 mm)

Type Die Cut Labels, Fan-Fold, Tag Stock or Continuous

Maximum Caliper .008 Inches (.21 mm)

Maximum Roll Diameter 6 Inches (152 mm), Wound face inward

Minimum Core Diameter 3 Inches (76 mm)

SENSING

Gap Fixed

Reflective Eye-Mark Fixed

Continuous Form Sensor not used.

SATO M5900RVe Operator Manual PN 9001125A Page 2-2

Unit 2: Technical Data

INTERFACE MODULES

Parallel Port IEEE 1284 Standard

Serial Port RS232C (9600 to 57,6000 dps) Standard

RS422/485 (9600 to 57600 bps) Optional

Ready/Busy or X-On/X-Off Flow Control

Bi-Directional Status

Universal Serial Bus USB Adapter

Ethernet 10/100 Base T, 802.11B Wireless Wi-Fi

Data Transmission ASCII Format

PROCESSING

CPU 32 Bit RISC

FLash ROM 2 Mega-Bytes

SDRAM 16 Mega-Bytes

Receive Buffer 2.95 Mega-Bytes

Memory Expansion See Options and Accessories

CHARACTER FONT CAPABILITIES

MATRIX FONTS

U Font 5 dots W x 9 dots H

S Font 8 dots W x 15 dots H

M Font 13 dots W x 20 dots H

XU Font 5 dots W x 9 dots H (Helvetica)

XS Font 17 dots W x 17 dots H (Univers Condensed Bold)

XM Font 24 dots W x 24 dots H (Univers Condensed Bold)

OA Font (OCR-A)

OB Font (OCR-B)

AUTO SMOOTHING FONTS

WB 18 dots W x 30 dots H

WL 28 dots W x 52 dots H

XB 48 dots W x 48 dots H (Univers Condensed Bold)

XL 48 dots W x 48 dots H (Sans Serif)

VECTOR FONT

Proportional or Fixed Spacing

Font Size 50 x 50 dots to 999 x 999 dots

Helvetica, 10 Font Variations

AGFA RASTER FONTS

A Font CG Times, 8 to 72 pt.

SATO M5900RVe Operator Manual PN 9001125A Page 2-3

Unit 2: Technical Data

AGFA RASTER FONTS

B Font CG Triumvirate, 8 to 72 pt.

DOWNLOADABLE FONTS

Bit Mapped True Type Fonts with Utility Program

CHARACTER CONTROL

Expansion up to 12 x in either the X or Y coordinates.

Charcter Pitch Control

Line Space Control

Journal Print facility

0, 90, 180, and 270 Degree Rotation

BAR CODE CAPABILTIES

Linear Bar Codes Bookland (UPC/EAN Supplemental

EAN-8, EAN-13

CODABAR

Code 39
Code 93

Code 128

Interleaved 2 of 5

Industrial 2 of 5

Matrix 2 of 5

MSI

POSTNET

UCC/EAN-128

UPC-A and UPC-E

Two Dimemsional Data Matriix

Maxicode

PDF417

Micro PDF

Truncated PDF

QR Code

Ratios 1:2, 1:3, 2:5, User definable bar widths

Bar Height 4 to 999 dots, User progammable

Rotation 0, 90, 180, and 270 Degrees

Sequential Numbering Sequential numbering of both numerics and bar codes

Custom Characters RAM storage for special characters

Graphics Full dot addressable graphics, SATO Hex/Binary, .BMP or

.PCX formats

Form Overlay Form overlay for high-speed editing of complex formats

REGULATORY APPROVALS

Safety VCCI (Class B), EN 55022 (Class B), UL (CUL), TUV

SATO M5900RVe Operator Manual PN 9001125A Page 2-4

INSTALLATION

• Unpacking

• Parts Identification

• Printer Installation

• Interface Selection

• Accessories Installation

SATO M5900RVe Operator Manual PN 9001125A Page 3-1

Unit 3: Installation

UNPACKING & PARTS IDENTIFICATION

Unpack the printer as directed in the following procedure.

1 Place the shipping container (box) upright on a solid, flat surface.

2 Open the box, remove any loose items and the first layer of packing material.

3 Carefully lift the printer and accessories from the box and place them on a solid flat surface.

4 Remove the plastic covers from the printer and its accessories.

5 Inspect the printer and its accessories for visual physical damage.

6 Ensure the following components are present:

7 Report damaged property.

PACKED COMPONENTS

Printer

Power Cord

Operator Manual
Programming Manual

Software Disk

SATO M5900RVe Operator Manual PN 9001125A Page 3-2

Unit 3: Installation

PRINTER INSTALLATION

This chapter provides guidance on general printer setup and installation. The following chapter
provides instructions on how to selct 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

• Stationed within operational distance of the host computer based on interface specificaitons

MEDIA SELECTION

The size and type of the labels or tags to be printed should have been taken into consideration
before printer purchase. Ideally, the media width will be equal to, or just narrower than, the print
head. Using media that does not cover the print head, will allow the platen roller to tread on it and
wear it out. The edge of the media will also wear a groove in the platen roller which will effect
print quality.

After determining the width and length of the label or tag to be printed, and knowing the print
head width, order the media width of the print head and with the labels or tags oriented so that
the media’s space is optimized. The media should be wound with its labels on the inward.

MEDIA LOADING

1 Open the right housing cover, unlatch the print assembly, and open.

NOTE: Pull forward on the green handle marked “PULL”.

2 Suspend the media roll from the media support arm.

NOTE: A properly installed roll will be oriented so that the roll feeds from the
under side and its labels are located on the top side of the paper.

3 Adjust the media roll guide to prevent the media roll from travelling when being dispensed.

4 Feed the end of the media under the label guide and up the label ramp.

NOTE: The label guide is a black plastic arm that protrudes across the back
side of the label ramp.

5 Adjust the right label guide to a position so that label travel is prohibited.

NOTE: The right label guide is a green colored knob that adjusts laterally
across the back perimeter of the label ramp.

6 Lower and latch the print assembly.

SATO M5900RVe Operator Manual PN 9001125A Page 3-3

Unit 3: Installation

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Figure 3-1, Media Loading

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Figure 3-2, Fan-Fold Loading

SATO M5900RVe Operator Manual PN 9001125A Page 3-4

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

• 802.11B Wireless

Following the selection of the desired interface, proceed to the following unit for instructions on
how to Configure the printer for that interface type.

WARNING: NEVER CONNECT OR DISCONNECT INTERFACE CABLES
(OR USE A SWITCH BOX) WITH POWER APPLIED TO EITHER THE
HOST OR THE PRINTER. THIS MAY CAUSE DAMAGE TO THE
INTERFACE CIRCUITRY IN THE PRINTER/HOST AND IS NOT COVERED
BY WARRANTY.

NOTE: Some hosts monitor the Request-To-Send (RTS) signal (pin 4 of 25)

to determine if the printer is ready to receive data. Since the printer does not
generate this signal, the RTS line must be held true (high) in order to allow
communication. This can be performed by connecting the RTS pin to the
Clear-To-Send (CTS) signal (pin 5 of 25).

RS232 SERIAL INTERFACE

This High Speed Serial Interface is a Plug-In Interface Module that can be installed in the printer
by the user. The only difference between this interface and the TTL is their signal levels and
cable pinouts.

RS232C SPECIFICATIONS

Asynchronous ASCII Half-duplex communication

Bi-Directional Communication
Data Transmission Rate 9600, 19200, 38400, 57600 bps
Data Length 8 bit (selectable)
Stop Bit 1 bit (fixed)
Parity Bit ODD, EVEN, NONE (selectable)
Codes Used ASC II Character Codes, JIS Kanji Codes
Control Codes STX (02H), ETX (03H), ACK (06H), NAK (15H)
Connector Special
Cable Special
Signal Levels High = +5V to +12V, Low = -5V to -12V

SATO M5900RVe Operator Manual PN 9001125A Page 3-5

Unit 3: Installation

RS232C SERIAL INTERFACE SIGNALS

PIN DIRECTION SIGNAL DEFINITION

1 Reference FG (Frame Ground)
2 To Host TD (Transmit Data) - Data from the printer to the host computer. Sends X-On/

X-Off characters or status data (bi-directional protocols).
3 To Printer RD (Receive Data) - Data to the printer from the host computer.
4 To Host RTS (Request to Send) - Used with Ready/Busy flow control to indicate an

error condition. RTS is high and remains high unless the print head is open (in

this case, RTS would return to the high state after the print head is closed and

the printer is placed back on-line) or an error condition occurs during printing

(e.g., ribbon out, label out).
5 To Printer CTS (Clear to Send) - When this line is high, the printer assumes that data is

ready to be transmitted. The printer will not receive data when this line is low. If

this line is not being used, it should be tied high (to pin 4).
6 To Printer DSR (Data Set Ready) - When this line is high, the printer will be ready to

receive data. This line must be high before data is transmitted. If this line is not

being used, it should be tied high (to pin 20).
7 Reference SG (Signal Ground)

20 To Host DTR (Data Terminally Ready) - This signal applies to Ready/Busy flow control.

The printer is ready to receive data when this pin is high. It goes low when the

printer is off-line, either manually or due to an error condition, and while

printing in the single job buffer mode. It will also go low when the data in the

buffer reaches the buffer near full level.

NOTE: Pin assignments begin with one (1) in the upper right corner and
ascend to thirteen (13) in the upper left corner. Pin number fourteen (14)
picks up in the lower right corner and ascends to twenty-five (25) in the lower
left.

CABLE REQUIREMENTS

DB9 DB25 HOST CONNECTION DB9 PRINTER

1 1 FG (Frame Ground) Bi-Directional 1 FG (Frame Ground)
2 3 RD (Receive Data) To Host 2 TD (Transmit Data)
3 2 TD Transmit Data) To Printer 3 RD (Receive Data)
8 5 CTS (Clear To Send) To Printer DB9-6 4 RTS (Request to Send)
4 20 DTR (Data Temrinal Ready) To Printer DB9-4 6 DSR (Data Set Ready)
6 6 DSR* (Data Set Ready) To Host 9 DTR (Data Terminal Ready)
5 7 SG (Signal Ground) Bi-Directional 7 SG (Signal Ground)

* This connection at the host side of the interface would depend upon the pin that is being used as the
Ready/Busy signal by the driving software. Typically, on a PC, it would be either CTS (pin5) or DSR (pin

6) on a DB-25 connector.

SATO M5900RVe Operator Manual PN 9001125A Page 3-6

Unit 3: Installation

IEEE1284 PARALLEL INTERFACE

The parallel interface is a Plug-In 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. For this reason, an interface cable and host
interface conforming to the IEEE1284 specification must be present to fully utilize the speed
capabilities. This interface also operates bi-directionally and can report the status of the printer
back to the host.

SPECIFICATIONS

Printer Connector AMP 57-40360 DDK (or equivalent)
Cable Connector AMP 57-30360 DDK (or equivalent)
Cable IEEE1284 Parallel, 10 ft. (3 m) or less
Signal Level High = +2.4V to +5.0V, Low = 0V to -0.4V
Data Stream <ESC>A . . Job#1 . . <ESC>Z<ESC>A . . Job#n . . <ESC>Z

NOTE: Pin assignments begin with one (1) in the upper right corner and
descend to eighteen (18) in the upper left corner. Pin number nineteen (19)
picks up in the lower right corner and descends to thirty-six (36) in the lower
left.

IEEE 1284 PARALLEL INTERFACE PIN ASSIGNMENTS

PIN SIGNAL DIRECTION PIN SIGNAL DIRECTION

1 Strobe To Printer 19 Strobe Return Reference
2 Data 1 To Printer 20 Data 1 Return Reference
3 Data 2 To Printer 21 Data 2 Return Reference
4 Data 3 To Printer 22 Data 3 Return Reference
5 Data 4 To Printer 23 Data 4 Return Reference
6 Data 5 To Printer 24 Data 5 Return Reference
7 Data 6 To Printer 25 Data 6 Return Reference
8 Data 7 To Printer 26 Data 7 Return Reference

9 Data 8 To Printer 27 Data 8 Return Reference
10 ACK To Host 28 ACK Return Reference
11 Busy To Host 29 Busy Return Reference
12 Ptr Error To Host 30 PE Return Reference
13 Select To Host 31 INIT From Host
14 AutoFD1 To H os t 32 Fault To Host
15 Not Used 33 Not Used
16 Logic Gnd 34 Not Used
17 FG Frame Gnd 35 Not Used
18 +5V (z=24k ohm) To Host 36 SelectIn1 From Host

1 Signals required for ieee 1284 mode.

SATO M5900RVe Operator Manual PN 9001125A Page 3-7

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. Up to 127 devices may be
connected to a USB port using powered hubs.

SPECIFICATIONS

Printer Connector USB Type B Plug
Cable 10 feet (3 m) maximum
Host Windows 98 or above with USB Port
Power Supply BUS Power through cable
Power Consumption +5 V at 80 ma

LOCAL AREA NETWORK (LAN) ETHERNET

A Local Area Network (LAN) interface is an optional Plug-In Interface Module that can be
installed by the user. It requires a driver shipped with each printer that has the interface installed.
The driver that must be loaded on your PC and the PC must be configured to run one of the
supported network protocols using a 10/100BaseT LAN connection. Details for loading the LAN
driver are contained in the LAN Interface Manual that is shipped with each printer with a LAN
Optional interface installed.

SPECIFICATIONS

Connector RJ-45 Receptacle
Cable 10/100BaseT Category 5
Power Supply Powered from printer

802.11B WIRELESS

The wireless print server provides easy printer interface with 802.11b Wi-Fi compliant networks
free of wired connections. Each printer is shipped with an integrated driver and interface
installed. The driver must be loaded on your PC and the PC must be configured to run one of the
supported protocols.

80211B WIRELESS SPECIFICATIONS

Variable Data Rates 11, 5.5, 2 and 1 Mbps
Frequency Band 2.4 GHz ISM Band
Wired Equivalent Privacy 128 bit, 64 bit (compatible with 40bit), none
Sensitivity (typ, AAWGN, 8E-2 PER): -91dBm at 1Mbps, -88dBm at 2 Mdps,

-87dBm at 5.5Mbps, -84dBm at 11Mbps.
Range 100m indoors, 300m outdoors
Protocols TCP/IP, IPX/SPX, Direct Mode IPX/IP, DLC/LLC, NetBEUI,

NetBIOS/IP

SATO M5900RVe Operator Manual PN 9001125A Page 3-8

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.

The printer receives and prints one job at a time. If a print job exceeds the buffer size,
transmission will be rejected by the printer. Flow control protocols to throttle transmission are not
used. Error conditions that occur during the Print Data transmission will cause the printer to
return a NAK.

ACK/NAK PROTOCOL

Bi-Directional ACK/NAK protocol is used for error control. In a normal transmission sequence
when the transmission is received, the printer will return an ACK (06H) signifying that it was
received without a transmission error. After the transmission command structure has been
analyzed, a status byte is returned to the host. This status byte informs the host of the validity of
the command structure.

If the command structure is error free, the printer proceeds with the print operation. When the
print operation is completed, a Printer Status message is returned to the host. If an error was
detected during the initial transmission sequence, a NAK (15H) will be returned signalling to the
host that the received transmission contained errors and must be resent. If the returned Status
byte indicates a command structure error, the error must then be corrected before the print data
is resent to the printer.

A valid transmission to the printer must be bounded by an STX/ETX pair, with the STX (02H)
signifying the start of the Print Data and ending with an ETX (03H) signifying the end.

SATO M5900RVe Operator Manual PN 9001125A Page 3-9

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.

INTERFACE MODULE UPGRADE

The printer is typically ordered with a high-speed parallel interface board installed. However,
interface requirements sometimes change and an upgrade is desired. All of the interface boards
are installed within the same slot located in the rear of the printer with little or no difference in
installation methodology.

Simply remove the two screws (1) securing the existing interface board (2) to the printer (3).
Replace the exisiting board with the upgrade and secure with the two screws.

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Figure 3-3, Interface Board Upgrade

SATO M5900RVe Operator Manual PN 9001125A Page 3-10

OPERATION

• Printer Configuration

• Configuration Modes

• Operational Adjustments

SATO M5900RVe Operator Manual PN 9001125A Page 4-1

Unit 4: Operation

PRINTER CONFIGURATION

The printer may be configured for specific jobs via the interface panel located on the face of the
printer. The interface panel is comprised of two dip switch complexes, three potentiometers
(PRINT, OFFSET, PITCH), LINE and FEED keys. Each of these must be adjusted to fully
configure the printer. 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.

If a Serial Interface Card is being used, a dip switch panel (DSW1) located on the card, must be
configured in addition to DSW2 and DSW3. To configure DSW1, the card must be removed.
Refer to the Installation unit of this manual for instructions as required.

DIP SWITCH PANELS

The following tables provide guidance on the enabling/disabling of various printer functions and
features. Determine what features are applicable to your setup, or desired setup, and adjust their
respective dip switches as applicable.

Each dip switch panel is an eight switch complex. Each switch is of a two position on/off toggle
type with the On position always oriented upward. To set the switches, first power the unit off,
then position the dip switches as required. After placing the dip switches in the desired positions,
power the printer back on. The switch settings are read by the printer electronics during the
power up sequence. They will not become effective until the power is cycled.

NOTE: There are three dip switch panels and each are numbered
respectively. Each dip switch panel has eight switches that are also
numbered. Each of the following three tables represents a single dip
switch panel. The left column of each table identifies the switch
number and every column following that, provides settings
information.

CAUTION: NOT ALL OF THE SWITCHES WILL REQUIRE
ADJUSTMENT, CHANGE ONLY THOSE SWITCH SETTINGS
THAT ARE NECESSARY. LEAVE ALL OTHERS AT THEIR
DEFAULT POSITIONS.

SATO M5900RVe Operator Manual PN 9001125A Page 4-2

Unit 4: Operation

DSW1 DEFAULT SETTINGS

1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8

OFFOFFOFFOFFOFFOFFOFFOFF

DSW1 CONFIGURATION

1-1 Data BIt

1-2
1-3

1-4 Stop Bit

1-5
1-6

1-7
1-8

Parity

Baud Rate

Protocol

OFF 8 Data Bit

ON 7 Data Bit

1-2 1-3

ON ON Reserved

ON OFF Odd

OFF ON Even

OFF OFF None

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 Normal: 9600, High Speed: 9600

1-7 1-8

ON ON Status 4

ON OFF Status 3

OFF ON XOn / XOff

OFF OFF Ready / Busy

DSW1 FUNCTION DESCRIPTIONS

FUNCTION DESCRIPTION

Data Bit

Parity Selects the type of parity used for error detection.

Stop Bit Selects the number of stop bits to end each byte transmission.

Baud Rate Select the data rate (bps) for the RS232 port.

Protocol Selects the flow control and status reporting protocols.

SATO M5900RVe Operator Manual PN 9001125A Page 4-3

Sets the printer to receive either 7 or 8 bits of data for each byte
transmitted.

Unit 4: Operation

DSW2 DEFAULT SETTINGS

2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8

OFFOFFOFFOFFOFFOFFOFFOFF

DSW2 CONFIGURATION

DSW1 FUNCTION SETTING CONFIGURATION

2-1 Reserved

2-2 Media Sensor Selection

2-3 Head Check

2-4 Hex Dump

2-5 Multi-Job Receive Buffer

2-6 Firmware Download

2-7 Protocol Code

2-8 Operational Mode

DSW2 FUNCTION DESCRIPTIONS

OFF

ON

OFF Gap Sensor

ON Eye-Mark Sensor

OFF Head Check Disabled

ON Head Check Enabled

OFF Hex Dump Disabled.

ON Hex Dump Enabled

OFF Single Job Receive Buffer

ON Multi-Job Receive Buffer

OFF Disabled

ON Enabled

OFF Standard Protocol Mode

ON Non-Standard Protocol Mode

OFF Normal Operation

ON Emulation Mode for Original M5900

FUNCTION DESCRIPTION

Media Sensor Selection Selects between a Gap or Eye-Mark detector.

Head Check When enabled, will check for malfunctioning head elements.

Hex Dump Allows hexadecimal printing of all data received to the print buffer.

Multi-Job Receive Buffer

Firmware Download Places printer in mode for downloading software into flash ROM.

Protocol Code Selects the command codes used for protocol control.

Operational Mode Normal mode or for original M5900.

SATO M5900RVe Operator Manual PN 9001125A Page 4-4

Allows to continuously receive print jobs while compiling and printing
other jobs.

Unit 4: Operation

DSW3 DEFAULT SETTINGS

3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8

OFFOFFOFFOFFOFFOFFOFFOFF

DSW3 CONFIGURATION

3-1 3-2

OFF OFF Batch/Continuous

3-1
3-2

3-3 Label Sensor

3-4 Backfeed

3-5 Print Start Signal

3-6
3-7

3-8

Operating Mode

External Signal Type

Repeat Print via Ext

Signal

OFF ON Tear Off

ON OFF Cutter

ON ON Dispenser

OFF Sensor Used

ON Sensor Not Used

OFF Enabled

ON Disabled

OFF Disabled

ON Enabled

3-6 3-7

OFF OFF Type 4

OFF ON Type 3

ON OFF Type 2

ON ON Type 1

OFF Disabled

ON Enabled

DSW3 FUNCTION DESCRIPTIONS

FUNCTION DESCRIPTION

Operating Mode Batch/Continuous, Tear-Off, Cutter, Dispenser

Label Sensor

Back Feed

Print Start Signal

External Signal Refer to the Interface Specifications unit for information.

Repeat Print External Signal Allows an external device to repeat the print siquence.

SATO M5900RVe Operator Manual PN 9001125A Page 4-5

Enabled, detects the label’s edge and positions it automatically.
Disabled, it is under software control.

Enabled, positions the last printed label for dispensing and retracts
the media for printing the next.

Allows an external device to initiate a label print for synchronization
with the applicator. When on, the unit is in the Continuous print mode,
Backfeed is disabled and External Signals are ignored.

Unit 4: Operation

CONFIGURATION MODES

This chapter provides an overview of the various configuration modes of the operation menu. 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 front.

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.

NORMAL MODE

When a print job is received, the LCD will display the number of labels to be printed and will
numerically descend as each label is printed.

LINE

OFFLINE

000000

LINE

YES/NO

POWER = ON

ONLINE

QTY: 000000

Offline/User Mode

FEED

Feeds

blank label each

time is

pressed.

LINE

OFFLINE

000000

LINE

key changes
value. FEED key
moves from one

field to

another.

LINE & FEED

together

PRINT DARKNESS

1 2 3 4 5

PITCH OFFSET

+00mm

LINE

Cursor moves

each time LINE is

pressed.

FEED

PRINT SPEED

2 3 4 5 6

Cursor moves

each time LINE is

pressed.

FEED

FEED

Cursor moves

each time LINE

is pressed.

CANCEL PRINT JOB

YES NO

Figure 4-1, Normal Mode

SATO M5900RVe Operator Manual PN 9001125A Page 4-6

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

LINE

Scrolls thru

options each time

the LINE key is

pressed.

FEED

Continuously

prints test labels

of option

selected.

PRESS FEED KEY

TO STOP PRINTING

FEED

TEST PRINT MODE

BARCODE

TEST PRINT MODE

HEADCHECK

TEST PRINT MODE

MEMORY

TEST PRINT MODE

FACTORY

Discontinues

printing.

Scrolls thru

options each time

the LINE key is

pressed.

TEST PRINT SIZE

11CM

PRINT SIZE

SMALL LARGE

LINEFEED

Figure 4-2, Test Print Mode

SATO M5900RVe Operator Manual PN 9001125A Page 4-7

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.

LINE + POWER

Printer beeps.

ADVANCED MODE

FEED

Scroll

options each time

the FEED key is

pressed.

DARKNESS RANGE

A B

ZERO SLASH

YES NO

AUTO ONLINE

YES NO

PRINT OFFSET

V:+0000 H:+000

SET CALENDAR
YES NO

IGNORE CR/LF

YES NO

CHARACTER PITCH

PROP FIXED

LINE

LINE

LINE

LINE / FEED

Alternately

CALENDAR

00/00/00 00:00

LINE

LINE

LINE / FEED

Alternately

Scroll

FEED

options each time

keys are

pressed.

Figure 4-3, Advanced Mode

SATO M5900RVe Operator Manual PN 9001125A Page 4-8

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.

LINE + FEED +

POWER

Printer beeps.

DEFAULT SETTING

YES NO

Beeps

3 times and

returns default

settings.

DEFAULT SETTING

COMPLETED

LINE

Scrolls

options each time

the LINE key is

pressed.

Yes / No

POWER = OFFFEED

Figure 4-4, Default Settings Mode

SATO M5900RVe Operator Manual PN 9001125A Page 4-9

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. The printer return status is set between STX (02H) and ETX (03H), and
transferred in 3 bytes. Note that the return status for the font data transfer when storing font is 1
byte of ACK (06H). All status data transferred from the host are set between STX (02H) and ETX
(03H), and transferred in 3 bytes.

DOWNLOAD FONT REGISTRATION

STATUS DESCRIPTION ACSII HEX TRANSFER

Not Already Stored A 41 Printer to Host

Already Stored B 42 Printer to Host

Storage Area NG N 4E Printer to Host

Store Font 0 30 Host to Printer

Do Not Store Font 1 31 Host to Printer

Ready For Storage Status O 4F Printer to Host

Font Storage Completed Normally E 45 Printer to Host

Font Storage Cancelled S 53 Printer to Host

Font Storage Completed Abnormally Z 5A Printer to Host

DOWNLOAD FONT DELETION

STATUS DESCRIPTION ACSII HEX TRANSFER

Not Already Stored A 41 Printer to Host

Already Stored B 42 Printer to Host

Delete Font 0 30 Host to Printer

Do Not Delete Font 1 31 Host to Printer

Font Deletion Completed Normally E 45 Printer to Host

Font Deletion Cancelled S 53 Printer to Host

Font Storage Completed Abnormally Z 5A Printer to Host

DOWNLOAD FONT INFORMATION AQUISTION

STATUS DESCRIPTION ACSII HEX TRANSFER

Not Already Stored A 41 Printer to Host

Already Stored B 42 Printer to Host

Font Information Transferred OK 0 30 Host to Printer

Number of Transferred Data 000000-999999 6 bytes w/30-39 Printer to Host

Font Information Font Info Data + Font Data Info Printer to Host

SATO M5900RVe Operator Manual PN 9001125A Page 4-10

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 = ON

Printer beeps.

FLASH DOWNLOAD

READY

Download Data.

XXXXXX DOWNLOAD

DOWNLOADING

Printer

downloads

data.

XXXXXX DOWNLOAD

COMPLETE

POWER = OFF
DSW2-6 = OFF

Figure 4-5, Flash Memory Download Mode

SATO M5900RVe Operator Manual PN 9001125A Page 4-11

Unit 4: Operation

USER DOWNLOAD MODE

This download feature allows the operator to download print jobs to the printer. 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

LINE + POWER

Printer beeps.

USER DOWNLOAD

PRESS LINE KEY

LINE

USER DOWNLOAD

WAITING

Download Data

USER DOWNLOAD

DOWNLOADING

Printer

downloads

data.

USER DOWNLOAD

COMPLETE

FEED
POWER = OFF
DSW2-7 = OFF

Figure 4-6, User Download Mode

SATO M5900RVe Operator Manual PN 9001125A Page 4-12

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 ON

ONLINE

QTY: 000000

Create and print

A label.

LINE

OFFLINE

000000

DSW2-4 = ON

LINE

ONLINE

QTY: 000000

POWER = OFF

DSW2-4 = ON

POWER = ON

and transmit data.

ONLINE

QTY: 000000

Receive Buffer

is printed in

hexadecimal

format.

DSW2-4 = OFF
POWER = OFF

and ON again.

Printer returns
to normal print

mode.

FEED

Label printed

of print buf fer in

hexadecimal

format.

Figure 4-7, Hex Dump Mode

SATO M5900RVe Operator Manual PN 9001125A Page 4-13

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.

LINE + POWER

MEM SELECT(CC1)

CARD MEMORY

Printer beeps.

CARD->MEMORYCOPY

TRUETYPEFONT Y/N

ADVANCED MODE

LINE

CARD MODE

LINE & FEED

Alternately

Printer

processes each

time the FEED key

is pressed.

CARD->MEMORYCOPY

SATOFONT Y/N

CARD->MEMORYCOPY

ALL Y/N

MEMORY->CARDCOPY

ALL <0MB> Y/N

CARD->MEMORYCOPY

PROGRAM Y/N

MEMORY->CARDCOPY

PROGRAM Y/N

CARD FORMAT

YES NO

MEMORY FORMAT

YES NO

Figure 4-8, Card Mode

SATO M5900RVe Operator Manual PN 9001125A Page 4-14

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
LINE + FEED

+ POWER

Printer emits

I long and

3 short
beeps.

ALT. PROTOCOL

DEFAULT COMPLETE

POWER = OFF
DSW2-7 = OFF

Figure 4-9, Non-Standard Clear Mode

SATO M5900RVe Operator Manual PN 9001125A Page 4-15

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.

LINE + POWER

GAP x.x V

INPUT x.xV

Printer beeps.

AUTO ONLINE FEED

YES NO

ADVANCED MODE

LINE twice

SERVICE MODE

LINE & FEED

Alternately

Printer

processes each

time the FEED key

is pressed.

FEED ON ERROR

YES NO

REPRINT W/FEED

YES NO

FORWARD/BACKWARD

DISTANCE DEFAULT

EXT PIN9 SELECT

MODE1 MODE2

EURO CODE

xx

SELECT LANGUAGE

ENGLISH

PRIORITY SETTING
COMMAND LCD

IEEE1284

ACK SIGNAL 00.5

LINE

FORWARD/BACKWARD

DISTANCE 000MM

Figure 4-10, Service Mode

SATO M5900RVe Operator Manual PN 9001125A Page 4-16

Unit 4: Operation

COUNTERS MODE

The Counters Mode allows integrated cycle counters to be reset for various components and
accessories.

LINE + POWER

COUNTERS

HD DSP CUT LIFE

Printer beeps.

ADVANCED MODE

LINE

three times

COUNTERS MODE

LINE & FEED

Alternately

Printer

processes each

time the FEED key

is pressed.

HEAD COUNTER

x.xM

HEAD COUNTER CLEAR

YES NO

DISPENSE COUNTER

0.0M

DSP COUNT CLEAR

YES NO

CUT COUNTER

0

CUT COUNT CLEAR

YES NO

LIFE COUNTER

0.0M

Figure 4-11, Counters Mode

SATO M5900RVe Operator Manual PN 9001125A Page 4-17

Unit 4: Operation

MAINTENANCE MODE

The Maintenance Mode encompasses the Factory and All Clear Modes.

DSW2-4 = ON

LINE + FEED

+ POWER

Printer beeps.

MAINTENANCE MODE
DIPSW2-4 ON->OFF

LINE/FEED

Alternately

Scrolls

When LINE is

pressed.

Processes and
advances when

FEED is

pressed.

COUNTER CLEAR

COUNTER EEPROM

FEED

ALL CLEAR

DSW2-4 = OFF

FACTORY MODE

LINE

ALL CLEAR MODE

LINE

PRINT SIZE

SMALL LARGE

TEST PRINT

PRESS FEED KEY

FEED

Printer

beeps three

times.

FEED

XXXXXXX ALLCLEAR

COMPLETED

LINE/FEED

Alternately

Scrolls

When LINE is

pressed.

Processes and

advances when

FEED is

pressed.

XXXXXXX ALLCLEAR

YES NO

Figure 12, Maintenance Mode

SATO M5900RVe Operator Manual PN 9001125A Page 4-18

Unit 4: Operation

ADVANCED MODE

MENU DESCRIPTION

DARKNESS RANGE Affects the print darkness via the heat range of the print head.

Option A has a higher heat range than option B. Option B is
preferable if the print job requires large print coverageon the
label to prevent excessive heat buildup and damage to the
head. This option works in conjunction with the print darkness
menu in the Normal Mode.

ZERO SLASH Determines if a zero will be printed with or without a slash.

When the YES option is chosen, all applicable fonts will be
affected. This setting may also be controlled via software
commands.

AUTO ONLINE Determines the mode in which the printer powers up. If the YES

option is selected, the printer will power up in the online mode
and ready to print. If the NO option is selected, the printer will
power up in the offline mode and will require to manually be
brought online.

PRINT OFFSET Allows the vertical and horizontal offset adjustment. This is

distance the print image is offset from the label’s edge. The
vertical offset moves the image forward or backward on the
label while the horizontal offset moves the image laterally.

SET CALENDAR Displays only if the option is installed. This feature permits the

printing of the date and time of print occurance onto the label. If
the YES option is selected, a secondary menu will display for
date and time entry.

IGNORE CR/LF The YES option sets the printer to delete all carriage return and

line feed commands in the data stream. The NO option the
default.

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. Conversely, proportional
printing accomidates printing to the width of each printed
character.

CARD MODE

MENU DESCRIPTION

MEM SELECT(CC1)
CARD MEMORY

CARD->MEMORYCOPY
TRUE TYPE FONT

SATO M5900RVe Operator Manual PN 9001125A Page 4-19

Establishes the media of the first drive. The default value is on
the card. LINE key moves the cursor and the FEED key selects
the option. LINE key moves the cursor and the FEED key
selects the option.

Allows the copying of True Type Font in Flash ROM. LINE key
moves the cursor and the FEED key selects the option.

Unit 4: Operation

MENU DESCRIPTION

CARD MODE

CARD->MEMORYCOPY
SATO FONT

CARD->MEMORYCOPY
ALL

MEMORY->CARDCOPY
ALL

CARD->MEMORYCOPY
PROGRAM

MEMORY->CARDCOPY
PROGRAM Y/N

CARD FORMAT Allows formatting of the memory card and to clear all internal

MEMORY FORMAT Allows formatting of Flash ROM memory. LINE key moves the

START Initiates the copying or formatting activity. LINE key moves the

COPYING Displays that the copying or formatting activity is underway.

COMPLETED Displays that the copying or formatting activity is complete.

CARD COPY/FORMAT
ERROR

CARD ID ERROR Displays when the incorrect card has been selected. The FEED

Allows the copying of SATO Font in Flash ROM. LINE key
moves the cursor and the FEED key selects the option.

Allows the copying of the entire card contents into Flash ROM.
LINE key moves the cursor and the FEED key selects the
option.

Allows the copying of the entire contents of the Flash ROM or
firmware. A 4MB card or greater is required. An error occurs if
an insufficient memory card is used.

Allows corying of Firmware program. Can overwrite the
Firmware program card in program ROM. A program card is
created by copying to the memory card of the Firmware
mentioned later.

Allows copying of the Firmware program in the memory card. A
2MB card or greater is required. LINE key moves the cursor and
the FEED key selects the option.

contents. LINE key moves the cursor and the FEED key selects
the option.

cursor and the FEED key selects the option.

cursor and the FEED key selects the option.

After 3 seconds of display, returns to the original screen.

Displays if the copying or formatting activity incuured an error
and could not complete. The FEED key returns the display to
the original screen.

key returns the display to the original screen.

SERVICE MODE

MENU DESCRIPTION

GAP x.xV
INPUT x.xV

AUTO ONLINE FEED
YES NO

SATO M5900RVe Operator Manual PN 9001125A Page 4-20

Sets slice level. Sets the slice level at intervals of 0-3.2V. When
the value is set at 0, auto setting is done through the firmware
software. LINE key moves the cursor and the FEED key selects
the option.

Sets the default feed. Sets whether to automatically feed paper
in ONLINE mode after startup. The defualt position is NO: do
not feed paper. LINE key moves the cursor and the FEED key
selects the option.

Unit 4: Operation

MENU DESCRIPTION

SERVICE MODE

REPRINT W/FEED
YES NO

FORWARD/BACKFEED
DISTANCE DEFAULT

EXT PIN9 SELECT
MODE1 MODE2

EURO CODE Sets Euro Code. Selects the assigned code of the Euro mark.

SELECT LANGUAGE Sets the language to be displayed on the LCD screen. There

PRIORITY SETTING
COMMAND LCD

IGNORE CAN/DLE
YES NO

IEEE1284
ACK SIGNAL 00.5

Sets reprint of previous labels. Prints one page of the previously
printed contents by pressing the FEED key during ONLINE. The
default value is NO: do not reprint. LINE key moves the cursor
and the FEED key selects the option.

Sets the peel-off paper feed distance. The paper feed/backfeed
may be set from 0-255mm. The actual Feed/Backfeed distance
is equivalent to VR value + Paper Feed quantity. LINE key
moves the cursor and the FEED key selects the option.

Switches to external signal (9 pins) output mode. LINE key
moves the cursor and the FEED key selects the option.

The default value is D5 (HEX). LINE key moves the cursor and
the FEED key selects the option.

are eight language options available. LINE key moves the
cursor and the FEED key selects the option.

Sets priority of commands. Sets software commands as being
invalid in regards to print darkness, print speed, and base
reference point id LCD is selected. The default value is
COMMAND: conned settings are valid. LINE key moves the
cursor and the FEED key selects the option.

Sets 1 byte command as being valid or invalid. Displays only
when status 4 is selected. A NO value equals: Invalid.

Sets to ACK signal width of the IEEE1284. Displays only when
the IEEE1284 board is installed. The default value is 0.5.

COUNTERS MODE

MENU DESCRIPTION

COUNTERS
HD DSP CUT LIFE

HEAD COUNTER

0.0M

HEAD COUNT CLEAR
YES NO

DSP COUNTER

0.0M

DSP COUNT CLEAR
YES NO

CUT COUNTER

0.0M

SATO M5900RVe Operator Manual PN 9001125A Page 4-21

Selects the counter category: Print head, Dispenser, Cutter, Life
Cycle. LINE key moves the cursor and the FEED key selects
the option.

Print Head counter display. Displays the quantity of times the
print head has cycled.

Offers the option to reset the counter to zero. The default value
is NO. LINE key moves the cursor and the FEED key selects
the option.

Dispenser counter display. Displays the quantity of times the
dispenser has cycled.

Offers the option to reset the counter to zero. The default value
is NO. LINE key moves the cursor and the FEED key selects
the option.

Cutter counter display. Displays the quantity of times the cutter
has cycled.

Unit 4: Operation

MENU DESCRIPTION

COUNTERS MODE

CUT COUNT CLEAR
YES NO

LIFE COUNTER

0.0M

Offers the option to reset the counter to zero. The default value
is NO. LINE key moves the cursor and the FEED key selects
the option.

Printer life counter display. Displays the quantity of times the
printer has cycled.

MAINTENANCE MODE

MENU DESCRIPTION

COUNTER CLEAR Selects the counter to clear. The options are None, All, Print

Head, Cutter, and Dispenser. The default value is NONE: Do
not clear. LINE key moves the cursor and the FEED key selects
the option.

PRINT SIZE
SMALL LARGE

TEST PRINT
PRESS FEEDKEY

ALL CLEAR
COUNTER EEPROM

XXXXXXX ALLCLEAR
YES NO

XXXXXXX ALLCLEAR
COMPLETED

Sets the print size for the test print.

Starts the test print. Test printing is started by pressing the
FEED key. Press the FEED key again to cease printing.

Selects the mode to clear. The options are the counters (print
head, dispenser, cutter) or the EEPROM (setup information).
LINE key moves the cursor and the FEED key selects the
option.

Confirms the all clear option chosen and allows the option of
continuing/discontinuing with the clear process. LINE key
moves the cursor and the FEED key selects the option.

Confirms that the all clear function was initiated and completed.

SATO M5900RVe Operator Manual PN 9001125A Page 4-22

Unit 4: Operation

OPERATIONAL ADJUSTMENTS

These operational adjustments are for fine tuning the printer as necessary following the
configuration process and are largely confined to the three potentiometers located on the
operator panel. Refer to the table below for their function.

POTENTIOMETER DESCRIPTION/PROCEDURE

PRINT Is used to adjust the darkness or lightness of the printed image

and should be used in conjunction with the configuration
adjustments. Make course adjustments there and then fine tune
here. If unable to achieve the desired setting here, the course
adjustment must be reset.

Adjust this potentiometer as labels are being printed. Allow two
labels to be printed for each adjustment to ensure a desired
setting.

OFFSET The offset adjustment is used to reposition the media for

printing following advancement for dispensing or cutting. A label
is printed, it is fed forward for dispense, the printer retracts the
remaining media (offset) to print the next label. To preform this
adjustment:

1. Power On the printer.

2. Press the LINE key to place printer offline.

3. Press the FEED key to feed a blank label.

4. Adjust the OFFSET potentiometer.

5. Press the FEED key to feed another label.

6. Repeat steps 3 and 4 until properly adjusted.

7. Press the LINE key to bring the printer back online.

PITCH Is to be used in conjunction with the configuration adjustments.

Make course adjustments there and then fine tune here. If
unable to achieve the desired setting here, the course
adjustment must be reset. Adjust this potentiometer as labels
are being printed. Allow two labels to be printed for each
adjustment to ensure a desired setting.

Adjustment of the PITCH potentiometer will affect the print
offset postion. Thusly, if using a dispenser or cutter, adjust the
Offset first and then the Pitch.

NOTE: The two Figures that follow are provided to identify
reference positions to assist in the operational adjustment
process.

SATO M5900RVe Operator Manual PN 9001125A Page 4-23

Unit 4: Operation

Standard Cutter Position

EYE-MARK

LABEL

LABEL

LABEL GAP

Standard Print, Cut,
Peel Off, Tear Off Positions

LABEL

Standard Cutter Position

PAPER FEED DIRECTION

LABEL

TAG EYE-MARK

Standard Cutter Position

Figure 4-13, Print Refernece Position

Standard Print,
Peel Off, Tear Off Positions

Standard Print Position

SATO M5900RVe Operator Manual PN 9001125A Page 4-24

Unit 4: Operation

Cutter

Peel

Off

20.0mm

11.0mm

Tear

Off

10.0mm

Platen

39.0mm

Progess Direction

Eye Mark

Gap

25mm

8mm

Figure 4-14, Sensor & Accessory Locations

SATO M5900RVe Operator Manual PN 9001125A Page 4-25

Unit 4: Operation

SATO M5900RVe Operator Manual PN 9001125A Page 4-26

TROUBLESHOOTING

• Error Signals

• Troubleshooting Table

• Troubleshooting Procedures

SATO M5900RVe Operator Manual PN 9001125A Page 5-1

Unit 5: Troubleshooting

ERROR SIGNALS

LCD MESSAGE BEEP ERROR CONDITION TO CLEAR

MACHINE ERROR 1 long Machine Error

Defective main board

EEPROM ERROR 1 long EEPROM read/write error Cycle power on/off. Reload. Replace.

HEAD ERROR 3 short Print Head is damaged Replace print head then cycle power.

SENSOR ERROR 3 short Media meandering

Incorrect adjustment
Incorrcet sensor selection
Defective sensor

CARD R/W ERROR 1 long Card not installed

Invalid number
Incorrect format
Write protected

CARD LOW BATTERY 1 long Memory card battery low Replace battery and cycle power.

CARD NO BATTERY 1 long No battery inside card. Install battery.

HEAD OPEN 3 short Print head is open Latch print head.

PARITY ERROR 3 short Incorrect adjustment

Incorrect cable connection

OVERRUN ERROR 3 short Incorrect parameter

Incorrect cable connection

Cycle power on/off. If the former doesn’t
work, replace board.

Check media guides.
Cycle power and check adjustment.
Check sensor selection.
Replace sensor.

Install and cycle power.
Verify, correct.
Format card and cycle power.
Corrrect.

Reformat & register card.

Ensure correct settings.
Ensure correct connection.

Ensure correct settings.
Ensure correct connection (Null Modem).

FRAMING ERROR 3 short Incorrect parameter

Incorrect cable connection

BUFFER OVER 3 short Buffer overflow

Near full signal is ignored

PAPER END 3 short Media stock exhausted

Meandering media
Incorrect sensor adjustment

MEDIA ERROR 3 short Incorrect media type

Incorrect signal.
Defective sensor

CUTTER ERROR 3 short Cutter is jammed

Incorrect signal
Defective cutter unit

DOWNLOAD ERROR 3 short Read/Write error

No download domain

CARD COPY/FORMAT

ERROR

3 short Read/Write copying error

Card not installed
No copy domain

Ensure correct settings.
Ensure correct connection (Null Modem).

Ensure correct settings.
Cycle power on/off.

Replenish media.
Adjust media guides.
Adjust sensor, open/close head lever.

Ensure correct media stock.
Open/Close head lever.
Replace sensor.

Clean and cycle power.
Cycle power.
Replace cutter unit.

Ensure no errors in download file.
Ensure download file isn’t too large.

Ensure no errors in copy file.
Ensure card is present.
Ensure copying file isn’t too large.

SATO M5900RVe Operator Manual PN 9001125A Page 5-2

Unit 5: 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. Align print head as required.

Excessive print speed. Reduce print speed setting.

UNEVEN PRINT DARKNESS

Unbalanced print head. Ensure correct balance.

Worn platen roller. Replace platen roller as required.

Dirty print head. Clean as necessary.

SMEARED PRINT IMAGES

Poor label quality. Use high quality label stock.

Foreign material on print head and platen
roller.

Foreign material on labels. Use high quality label stock.

Excessive print head energy. Adjust darkness control.

Excessive print speed. Adjust as speed as required.

Excessive head pressure. Adjust head balance.

Clean print head and platen roller.

NO LABEL MOVEMENT

Loose timing belt. Ensure motor mount screws are tight, belt properly tensioned.

Incorrect label pitch sensor selected. Select the correct label sensor type.

No voltage output. Replace fuse on main circuit board. Test power supply and

replace as required.

Drive motor not operating. Ensure wiring harness connection. Replace as necessary.

Defective main board. Troubleshoot board and replacee as nwecessary.

NO PRINTED IMAGE

Print head is disconnected. Ensure print head wiring harness is connected on each end.

SATO M5900RVe Operator Manual PN 9001125A Page 5-3

Unit 5: Troubleshooting

NO PRINTED IMAGE

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. Ensure not defective.

Incorrectly positioned display potentiom­eter.

Defective power supply. Troubleshoot and replace components as necessary.

Adjust as required.

MEANDERING MEDIA

Incorrectly loaded media. Ensure correct loading.

Improperly adjusted media guides. Adjust as required.

Unbalanced print head. Adjust as required.

Worn or improperly adjusted platen roller. Adjust. Replace as required.

PRINTER CREATES A BLANK LABEL

Data input error. Ensure correct data stream.

Improper media selected. Ensure correct media is in use.

Disconnected print head. Cycle off power and ensure proper connection.

Defective print head. Replace print head as required.

Defective main board. Replace main board as required.

INCORRECT LABEL POSITIONING

Incorrect sensor selection. Ensure the correct sensor is selected.

Improper sensor adjustment. Adjust as required.

Incorrect media in use. Ensure the correct media is being used.

Data input error. Ensure correct data stream.

SATO M5900RVe Operator Manual PN 9001125A Page 5-4

Unit 5: Troubleshooting

TROUBLESHOOTING PROCEDURES

The procedures below provide in depth instructions on symptom analysis of specific
components. If it is suspected that the problem lies within one of these components, refer to the
relative instructions.

CAUTION: NEVER CONNECT OR DISCONNECT INTERFACE CABLES
(OR USE A SWITCH BOX) WITH POWER APPLIED TO EITHER THE
PRINTER OR THE HOST. THIS MAY CAUSE DAMAGE TO THE
INTERFACE CIRCUITRY AND IS NOT COVERED BY WARRANTY.

RS232 SERIAL INTERFACE

• Ensure the serial cable is thoroughly connected to the PC and the printer.

• Ensure the serial cable is not defective.

• Ensure that a Null Modem Cable with correct Pin-out specifications is being used.

• Ensure the specified RS232 Interface Module is installed.

• Ensure the data stream is correct; all letters of command codes are in upper case and without
spaces. Carriage Returns are also not acceptable in line fields.

• Ensure the Baud rate, Parity, Data Bits, and Stop Bits are consistent with that of computer.
Print a Configuration Test Label to determine the RS232 settings.

• Ensure the printer is receiving from the computer using a Receive Buffer Hex Dump. The
printer will print (only once) a hexadecimal dump of everything it has received from the host
computer. Each hexadecimal character represents a character the printer received. Analyze
and troubleshoot the data stream.

NOTE: A small label may produce a large amount of data when printed in
Hex Dump.

While checking the hex dump printout, look for OD

H OAH (carriage return and line feed) char-

acters throughout. The command string should be continuous. CR or LF characters are not
allowed between the start command (<ESC>A) and the stop command (<ESC>Z). If Basic is
being used, it may be adding these characters automatically as the line wraps. Adding a
width statement to your program can help suppress these extra OD

H OAH characters by

expanding the line length up to 255 characters.

If not programming in BASIC, check to see if the equivalent statement in the language exists
to suppress extra carriage returns and line feeds from data being sent to the printer. The data
stream must be one complete line going to the printer.

SATO M5900RVe Operator Manual PN 9001125A Page 5-5

Unit 5: Troubleshooting

UNIVERSAL SERIAL BUS (USB) INTERFACE

If nothing prints during a test print, verify the device drivers have been successively installed by
performing the following:

1. Click on Start, Settings, and then Control Panel.

2. Click on System within the new window.

3. Click on the Device Manager tab.

4. Ensure that the View Device By Type is checked.

5. Scroll down to SATO-USB Device and ensure that errors do not exist. Reinstall as required.

6. Reboot the PC and the printer.

7. Contact Microsoft technical support for further assistance as required.

PARALLEL INTERFACE

• Ensure the printer cable is thoroughly connected to the PC and the printer.

• Ensure the printer cable is connected to the correct ports on each end.

• Ensure the printer cable (IEEE1284) meets specifications. The computer may not be able to
communicate correctly otherwise.

• Ensure the Interface Module is installed.

• Ensure the data stream is correct, all letters of command codes are in upper case, and
without spaces.

• Ensure protocol codes are set for standard or non-standard and that they are consistent with
the data stream.

• Ensure the printer is receiving from the computer using a Receive Buffer Hex Dump. Refer to
that procedure for instructions. The printer will print (only once) a hexadecimal dump of
everything it has received from the host computer. Each hexadecimal character represents a
character the printer received. Analyze and troubleshoot the data stream.

NOTE: A small label may produce a large amount of data when printed in
Hex Dump.

While checking the hex dump printout, look for OD

H OAH (carriage return and line feed) char-

acters throughout. The command string should be continuous. CR or LF characters are not
allowed between the start command (<ESC>A) and the stop command (<ESC>Z). If Basic is
being used, it may be adding these characters automatically as the line wraps. Adding a
width statement to your program can help suppress these extra OD

H OAH characters by

expanding the line length up to 255 characters.

If not programming in BASIC, check to see if the equivalent statement in language exists to
suppress extra carriage returns and line feeds from data being sent to the printer. The data
stream must be one complete line going to the printer.

SATO M5900RVe Operator Manual PN 9001125A Page 5-6

Unit 5: Troubleshooting

LAN ETHERNET INTERFACE

• If the printer does not come up ready: Ensure the printer is powered on, all cables are
connected, and the printer is on-line. If possible, connect a terminal to the serial port and
observe for a boot prompt indicating the print server firmware has not been loaded properly. If
reloading does not correct the problem, try pressing switch 1 for more than 10 seconds. If the
problem persists, the product may be defective.

• If the printer comes up ready but will not print: There is a problem with the interface
between the server and the printer, network connection or cabling, or a queue setup flaw. The
queue setup flaw could be the result of a faulty print server setup or other protocol-related
scenarios. Systematically perform checks and tests to isolate the cause.

The interface between the printer and server may be checked by waiting approximately two
minutes after the printer is powered on and then run a self-test label. If a self-test label does
not print, there could be a hardware problem. Double check the cable connections. In some
rare cases, disabling NBUF with the command SET PORT P1 NBUF DISABLED will solve
the problem.

If connecting to a 10baseT network, verify that the OK LED is illuminated. If the appropriate
LED’s are not on, there is a possibility of a defective cable or connector. Try connecting a
different cable, port, or device to observe the results.

If using a repeater or hub, ensure that SQE is turned off at the hub (this is the default setting
for most hubs). Also, test the hub or repeater by trying the print server on a different port.

If using a bridge or router located between the print server and the host computer, ensure
that the device is setup to allow the print server to send and receive data from the host. For
example, a bridge can only be set up allow certain types of Ethernet addresses to pass
through (a process known as filtering). Such a bridge must be configured to allow print server
addresses. Likewise, a router can be set up to only pass certain protocols. Ensure that the
desired protocol can be passed through to the print server. In the case of routers, also ensure
that the protocol is routable (LAT, NetBEUI, and DLC/LLC are not routable.

Ensure that an illegal operation such as printing a label larger than the printer can handle is
not being attempted.

Check the protocol troubleshooting sections provided with the Ethernet Interface Module for
additional causes of intermittent printer problems.

• Experiencing intermittent printing problems: Excessive NetWare polling may be a big cause
of intermittent problems. Ensure that only the needed NetWare file servers have been
enabled (do a SHOW NETWARE command from the print server console to see the enabled
file servers). If V3.21 or earlier versions of firmware is in use, ensure that NetWare polling is
disabled by using the console command SET NETWARE RANGE 0. If Netware is not in use,
disable NEtWare entirely with the command SET NETWARE DISABLED.

Check the individual troubleshooting sections provided with the Ethernet Plug-In Interface
Module for additional causes of intermittent printer problems.

SATO M5900RVe Operator Manual PN 9001125A Page 5-7

Unit 5: Troubleshooting

SATO M5900RVe Operator Manual PN 9001125A Page 5-8

MAINTENANCE

• Cleaning Procedures

• Replacement Procedures

• Adjustment Procedures

SATO M5900RVe Operator Manual PN 9001125A 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. To remove residue, apply SATO Solvent or
isopropyl alcohol to a clean cotton swab and gently wipe the entire surface of the print head and
platen roller until clean.

It is recommended that the printer be cleaned after the printing of every two rolls of labels.

WARNING: DISCONNECT POWER SUPPLY TO THE PRINTER AND
ALLOW TO COOL TO ROOM TEMPERATURE PRIOR TO CLEANING.

WARNING: EXERSIZE CARE WHEN CLEANING TO PREVENT
PERSONAL INJURY. THE TEAR BAR HAS A VERY SHARP EDGE.

CAUTION: IF USING A PNEUMATIC BLOWER TO REMOVE DEBRIS

FROM THE PRINTER, EXERSIZE CARE TO PREVENT PRINT HEAD
DAMAGE.

Figure 6-1, Cleaning

SATO M5900RVe Operator Manual PN 9001125A Page 6-2

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.

1 Switch off the printer and disconnect the power supply cord.

2 Unscrew fuse cap (1, Figure 6-2) from the fuse connector located on the printer back side.

3 Withdraw cap (1) along with fuse (2) and inspect for damage.

4 Insert replacement fuse (2) into cap (1) and screw into the fuse connector.

5 Restore power.

2

1

Figure 6-2, Fuse Replacement

SATO M5900RVe Operator Manual PN 9001125A Page 6-3

Unit 6: Maintenance

PRINT HEAD REPLACEMENT

If the print head becomes damaged or wears out, it can be easily removed and replaced without
having to make critical adjustments. Before replacing the print head, check the head counter
values by printing a test pattern.

1 Switch off the printer and disconnect the power supply cord.

2 Open the right housing cover and unlatch print head assembly (1, Figure 6-3).

3 Pry lever guard (2) free from print assembly (1).

4 Remove screw (3) to release defective print head (4) and tear bar (5).

5 Disconnect the wiring harness from defective print head (4) and lift away.

6 Apply tear bar (5) to replacement print head (4) and secure to print assembly (1) using

screw (3).

CAUTION: EXCERSIZE CARE WHEN INSTALLING THE REPLACEMENT
PRINT HEAD TO PREVENT DAMAGE TO ITS ELEMENTS.

NOTE: A properly installed tear bar will be oriented so that it folds down in
front of the print head andd is parallel with the print assembly.

7 Reattach lever guard (2) to print assembly (1).

8 Clear the print head counter. Refer to the relative procedure for instructions if required.

9 Reconnect power supply cord, test cycle, and close right housing cover.

2

3

5

1

4

Figure 6-3, Print Head Replacement

SATO M5900RVe Operator Manual PN 9001125A Page 6-4

Unit 6: Maintenance

INTERFACE BOARD REPLACEMENT

1 Switch off the printer and disconnect the power supply cord.

2 Remove two screws (1, Figure 6-4) securing interface board (2) to the exterior of rear

housing cover (3).

3 Withdraw defective interface board (2) from the printer.

4 Insert replacement interface board (2) through the housing slot to connect with the main

circuit board.

5 Secure interface board (2) to the rear housing cover (3) using two screws (1).

6 Reconnect power supply cord and test cycle.

2

D

D

R

R

A

A

O

O

B

B

S

S

R

R

+

+

4

4

8

8

2

2

1

1

E

E

E

E

E

E

I

I

1

3

Figure 6-4, Interface Board Replacement

SATO M5900RVe Operator Manual PN 9001125A Page 6-5

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.

This chapter provides instructions on the performance of those activities that are mechanical in
nature and are responsive to maintenance activities. The table below provides common print
defects and their relative cause.

PRINT DEFECTS RELATIVE PROCEDURE

Print becomes lighter or darker from one side to the other.
This condition is repetitive from label to label.

Voids in the overall print image that is repetitive from label to
label.

A visible path on the label where print image is missing. The
path will change somewhat from label to label.

The scales at the lower left and right sides are not equal
distances from the labels lower edge.

The lines are not sharp. Print Darkness Adjustment

The image is too light or dark. Print Darkness Adjustment

Bar code label has a sharp line where print is missing. Print Darkness Adjustment

The printed position is too far in one direction or another. Print Position Adjustment

Print Head Balance Adjustment

Print Darkness Adjustment

Print Position Alignment
Platen Roller Adjustment

Print Position Alignment

Offset Label Stop Position

SATO M5900RVe Operator Manual PN 9001125A Page 6-6

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.

1 Open the right housing cover to access the print assembly (1, Figure 6-5).

2 Begin the continuous printing of labels.

3 Slightly loosen set screw (2) and slightly adjust eccentric nut (3) until the negative

characteristics are corrected.

4 Hold eccentric nut (3) in position while retightening set screw (2).

5 Close the right housing cover to conceal print assembly (1).

3

2

1

Figure 6-5, Print Head Balance Adjustment

SATO M5900RVe Operator Manual PN 9001125A Page 6-7

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 right housing cover to access and open the print assembly (1, Figure 6-6).

3 Detach lever guard (2), loosen two set screws (3), and one mounting screw (4).

4 Manipulate print head assembly (5) so that it is parallel with platen roller (6).

5 Secure mounting screw (4), two set screws (3), and attach lever guard (2).

6 Close the right housing cover and restore power.

1

5

2

4

3

6

1

Figure 6-6, Print Head Alignment

SATO M5900RVe Operator Manual PN 9001125A Page 6-8