SATO M-8490S User Manual

“S” Applicator

Print Engines

®

Operator and Technical

Reference Manual

M-8459S, M-8460S, M-8485S, M-8490S

PN 9001034 Rev. E SATO “S” Print Engines

SATO America, Inc.

545 Weddell Drive

Sunnyvale, CA 94089

Main Phone: [phone]

Tech Support Hotline: [phone]

Fax: [phone]

E-Mail: [e-mail]

© Copyright 1996, 1997, 1998

SATO America, Inc.

Warning: This equipment complies with the requirements in Part 15 of
FCC rules for a Class A computing device. Operation of this equipment in a
residential area may cause unacceptable interference to radio and TV
reception requiring the operator to take whatever steps are necessary to
correct the interference.

All rights reserved. No part of this document may be reproduced or issued
to third parties in any form whatsoever without the express permission of
SATO America, Inc. The materials in this document is provided for general
information and is subject to change without notice. SATO America, Inc.
assumes no responibilities for any errors that may appear.

SATO “S” Print Engines PN 9001034 Rev. E

M-8485S OPERATOR’S MANUAL

The Operator’s Manual for the “S” Print Engine Family contains basic information
about the printer such as setup, installation, cleaning and maintenance. It also
contains complete instructions on how to use the operator panel to configure the
printer. The following is a brief description of each section in this manual.

SECTION 1. PRINTER OVERVIEW

This section contains a discussion of the printer specifications and optional
features.

SECTION 2. INSTALLATION AND CONFIGURATION

This section contains instructions on how to unpack and set up the printer
and load the labels and ribbon.

SECTION 3. CONFIGURATION

This section contains information on using the operator panel and switch
panels to configure the printer.

PREFACE

SECTION 4. CLEANING AND MAINTENANCE

This section contains instructions on how to clean and maintain the printer.

SECTION 5. PROGRAMMING

This section introduces the “S” printer programming language. It contains the
commands that are used with the printer to produce labels with bar codes,
alphanumeric data and graphics.

SECTION 6. INTERFACE SPECIFICATIONS

This section contains the printer’s interface specifications, which include
detailed information on how to properly interface your printer to the host
system.

SECTION 7. TROUBLESHOOTING

This section contains troubleshooting procedures to follow in the event you
have printer problems.

SATO “S” Print Engines 9001034 Rev E Page - i

Preface

APPENDICES

APPENDIX A: Command Code Quick Reference

APPENDIX B: Bar Code Specifications

APPENDIX C: Custom Characters and Graphics

APPENDIX D: Optional Accessories

APPENDIX E: Custom Protocol Command Codes

Page - ii 9001034 Rev E SATO “S” Print Engines

TABLE OF CONTENTS

SECTION 1. PRINTER OVERVIEW

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

SECTION 2. INSTALLATION

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Component Names . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Media Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Loading Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Loading Label Stock . . . . . . . . . . . . . . . . . . . . . . . 2-7

Adjusting the Label Sensor . . . . . . . . . . . . . . . . . . . . . . 2-9

Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Dip Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

SECTION 3. CONFIGURATION

DIP Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Printer Adjustments (LCD Panel) . . . . . . . . . . . . . . . . . . . 3-5

Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

User Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Print Darkness . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Print Speed Adjustment . . . . . . . . . . . . . . . . . . . . 3-8

Pitch Offset and Direction . . . . . . . . . . . . . . . . . . . 3-8

Cancel Print Job . . . . . . . . . . . . . . . . . . . . . . . 3-9

Advanced Mode Settings and Adjustments . . . . . . . . . . . . 3-10

Zero slash Setting . . . . . . . . . . . . . . . . . . . . . . . 3-10

Auto Online Setting . . . . . . . . . . . . . . . . . . . . . . 3-10

Vertical Offset Setting . . . . . . . . . . . . . . . . . . . . . 3-10

Horizontal Offset and Direction . . . . . . . . . . . . . . . . 3-11

Sensor Threshold Level . . . . . . . . . . . . . . . . . . . . 3-13

Calendar Set . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Reset Counters . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Exit Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

User Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Hex Dump Diagnostic Labels . . . . . . . . . . . . . . . . . . . 3-23

Display Counter Values . . . . . . . . . . . . . . . . . . . . . . 3-23

SATO “S” Print Engines 9001034 Rev E Page - iii

Preface

SECTION 3. CLEANING AND MAINTENANCE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Adjusting the Print Quality . . . . . . . . . . . . . . . . . . . . . . 3-1

Cleaning the Print Head, Platen and Rollers . . . . . . . . . . . . . 3-2

Replacing the Print Head . . . . . . . . . . . . . . . . . . . . . . . 3-3

Cleaning the Sensors . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Replacing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

SECTION 4. PROGRAMMING

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

The SATO Programming Language . . . . . . . . . . . . . . . . . . 5-1

Selecting Protocol Control Codes . . . . . . . . . . . . . . . . . . . 5-2

Using Basic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

The M-8485S Print Area . . . . . . . . . . . . . . . . . . . . . . . 5-4

Rotated Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Command Default Settings . . . . . . . . . . . . . . . . . . . . . . 5-8

Command Code Page Reference . . . . . . . . . . . . . . . . . . . 5-9

Bar Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Bar Codes, Expansion . . . . . . . . . . . . . . . . . . . . . . . 5-16

Bar Codes, Variable Ratio . . . . . . . . . . . . . . . . . . . . . 5-17

Base Reference Point . . . . . . . . . . . . . . . . . . . . . . . 5-19

Characters, Custom Designed . . . . . . . . . . . . . . . . . . . 5-21

Character Expansion . . . . . . . . . . . . . . . . . . . . . . . 5-23

Character, Fixed Spacing . . . . . . . . . . . . . . . . . . . . . 5-25

Character Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Character, Proportional Spacing . . . . . . . . . . . . . . . . . 5-28

Clear Printer Memory and Buffers . . . . . . . . . . . . . . . . 5-29

Continuous Forms Printing . . . . . . . . . . . . . . . . . . . . 5-30

Copy Image Area . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Fonts, U, S, M, OA, OB, XU, XS and XM . . . . . . . . . . . . . 5-33

Fonts, Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Fonts, WB,WL, XB and XL . . . . . . . . . . . . . . . . . . . . 5-37

Form Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

Form Overlay Recall . . . . . . . . . . . . . . . . . . . . . . . 5-40

Form Overlay Store . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Graphics, Custom . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

Graphics, PCX . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Job ID Store . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

Journal Print . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Lines and Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

Line Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

Off-Line/Pause . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

Postnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

Print Darkness . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

Print Length, Expanded . . . . . . . . . . . . . . . . . . . . . . 5-53

Print Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

Print Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

Print Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

Page - iv 9001034 Rev E SATO “S” Print Engines

Preface

Repeat Label . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

Replace Data (Partial Edit) . . . . . . . . . . . . . . . . . . . . 5-60

Reverse Image . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

Rotate, Fixed Base Reference Point . . . . . . . . . . . . . . . . 5-66

Rotate, Moving Base Reference Point . . . . . . . . . . . . . . . 5-64

Sequential Numbering . . . . . . . . . . . . . . . . . . . . . . 5-68

Start/Stop Label . . . . . . . . . . . . . . . . . . . . . . . . . 5-70

Calendar Option Commands . . . . . . . . . . . . . . . . . . . 5-71

Calendar Increment . . . . . . . . . . . . . . . . . . . . . . 5-72

Calendar Print . . . . . . . . . . . . . . . . . . . . . . . . 5-74

Calendar Set . . . . . . . . . . . . . . . . . . . . . . . . . 5-76

Memory Card Option Commands . . . . . . . . . . . . . . . . . 5-77

Clear Card Memory . . . . . . . . . . . . . . . . . . . . . . 5-78

Expand Memory Area . . . . . . . . . . . . . . . . . . . . . 5-79

Fonts, TrueType Recall . . . . . . . . . . . . . . . . . . . . 5-81

Fonts, TrueType Store . . . . . . . . . . . . . . . . . . . . 5-82

Format/Field Recall . . . . . . . . . . . . . . . . . . . . . . 5-83

Format/Field Store . . . . . . . . . . . . . . . . . . . . . . 5-84

Graphics, Custom Recall . . . . . . . . . . . . . . . . . . . 5-85

Graphics, Custom Store . . . . . . . . . . . . . . . . . . . . 5-86

Graphics, PCX Recall . . . . . . . . . . . . . . . . . . . . . 5-88

Graphics, PCX Store . . . . . . . . . . . . . . . . . . . . . . 5-89

Initialize . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90

Slot Select . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91

Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92

Custom Protocol Command Codes Download . . . . . . . . . . . 5-93

Two-Dimensional Symbols . . . . . . . . . . . . . . . . . . . . 5-95

Data Matrix, Data Format . . . . . . . . . . . . . . . . . . . 5-96

Data Matrix, Print Data . . . . . . . . . . . . . . . . . . . . 5-98

Dat Matrix, Sequential Numbering . . . . . . . . . . . . . . 5-99

Maxicode . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101

PDF417 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103

SECTION 5. INTERFACE SPECIFICATIONS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Interface Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

The Receive Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Single Job Buffer . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Multi Job Buffer . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

RS232C Serial Interface . . . . . . . . . . . . . . . . . . . . . . . 6-3

General Specifications . . . . . . . . . . . . . . . . . . . . . . 6-3

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . 6-3

Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Ready/Busy Flow Control . . . . . . . . . . . . . . . . . . . . . 6-4

X-On/X-Off Flow Control . . . . . . . . . . . . . . . . . . . . . 6-5

Bi-Directional Communications . . . . . . . . . . . . . . . . . . 6-6

Centronics Parallel Interface . . . . . . . . . . . . . . . . . . . . . 6-9

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . 6-9

Accessory (EXT) Connector . . . . . . . . . . . . . . . . . . . . . . 6-10

Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

External Output Signals . . . . . . . . . . . . . . . . . . . . . . 6-11

SATO “S” Print Engines 9001034 Rev E Page - v

Preface

SECTION 6. TROUBLESHOOTING

Initial Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Using the Centronics (Parallel) Interface . . . . . . . . . . . . . . . 7-1

Using the RS232C (Serial) Interface . . . . . . . . . . . . . . . . . 7-3

Error Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

APPENDICES

APPENDIX A: Command Code Quick Reference

APPENDIX B: Bar Code Specifications

Bar Code Symbologies . . . . . . . . . . . . . . . . . . . . . . B-1

Codabar . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Code 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Interleaved Two of Five (I 2/5) . . . . . . . . . . . . . . . . B-4

UPC-A/EAN-13 . . . . . . . . . . . . . . . . . . . . . . . . B-5

EAN-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Industrial Two of Five . . . . . . . . . . . . . . . . . . . . B-8

Matrix Two of Five . . . . . . . . . . . . . . . . . . . . . . B-9

Code 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

MSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

Code 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

UPC-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13

Bookland (UPC/EAN Supplements) . . . . . . . . . . . . . B-14

UCC-128 . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15

Postnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-17

Data Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . B-18

Maxicode . . . . . . . . . . . . . . . . . . . . . . . . . . . B-20

PDF417 . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21

Code 128 Character Table . . . . . . . . . . . . . . . . . . B-22

APPENDIX C: Custom Characters and Graphics

Custom Designed Character Example . . . . . . . . . . . . . . . C-1

Custom Graphics Example . . . . . . . . . . . . . . . . . . . . C-4

PCX Graphics Example . . . . . . . . . . . . . . . . . . . . . . C-8

APPENDIX D: Optional Accessories

PCMCIA Memory Cards . . . . . . . . . . . . . . . . . . . . . . D-1

Calendar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Top Mounted Reflective Sensor . . . . . . . . . . . . . . . . . . D-3

APPENDIX E: Custom Protocol Command Codes

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Download Command Structure . . . . . . . . . . . . . . . . . . E-1

Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Download Procedure . . . . . . . . . . . . . . . . . . . . . . . E-2

Page - vi 9001034 Rev E SATO “S” Print Engines

INTRODUCTION

The SATO “S” Print Engines are designed to be integrated into high-performance
on-site labeling systems. All printer parameters are user programmable using the
front panel controls and the DIP switches. All popular bar codes and 13
human-readable fonts, including a vector font, are resident in memory providing
literally thousands of type styles and sizes.

The Operator’s Manual will help you understand the basic operations of the printer
such as setup, installation, configuration, cleaning and maintenance.

The following information is presented in this section:

SECTION 1.

PRINTER OVERVIEW

• General Printer Specifications

• Optional Accessories

SATO "S" Print Engines 9001034 Rev. E Page 1-1

SPECIFICATIONS

SPECIFICATION M-8485S M-8460S M-8490S M-8459S

PRINT

Method Direct or Thermal Transfer Direct Only

Section 1. Printer Overview

Speed (User Selectable) 4 to 10 ips

100 to 250 mm/s

Print Module (Dot Size) .0049 in.

.125 mm

Resolution 203 dpi

8 dpmm

Maximum Print Width 5.0 in.

128 mm

1024 dots

Maximum Print Length
Expanded Print Length

Maximum Print Length
with 2MB Memory Card

49.2 in.

1249 mm

4 to 8 ips

100 to 200 mm/s

6.0 in.

152 mm

1216 dots

7 in. (178) mm

14 in. (356 mm)

4 to 8 ips

100 to 200 mm/s

.0033 in.
.083 mm

305 dpi

12 dpmm

4.4 in.

112 mm

1344 dots

32.8 in.

833 mm

2 to 5 ips

50 to 125 mm/s

.0049 in.
.125 mm

203 dpi

8 dpmm

4.4 in.

112 mm

896 dots

49.2 in.

1249 mm

MEDIA

Minimum Width 1.0 in. (25 mm) 2.0 in. (53 mm) 1.0 in. (25 mm) 1.0 in. (25 mm)
Minimum Length
Maximum Width 5.25 in

(1)

.25 in. (6 mm) .25 in. (6 mm) .25 in. (6 mm) .25 in. (6 mm)

134 mm

6.5 in.

165 mm

5.25 in.

134 mm

5.25 in

134 mm
Type Die Cut Labels, Fan-Fold or Continuous
Maximum Caliper .010 in. (.25 mm)
Max Unwind torque 8.8 lbs (4 Kg) with 5 in. wide labels
Backing Paper Rewind

400 g or less

Tension

LABEL SENSING

See-Thru for labels or tags Adjustable
Reflective Eye-Mark Fixed

RIBBON

Maximum Width 5.25 in.

134 mm

6.5 in.

165 mm

5.25 in.

134 mm
Length 1968 ft (600 M) N/A
Thickness 4.5 micron, Face-In Wind N/A

All specifications subject to change withoutnotice.

(1) Minimum label length at print speeds greater than 6 ips is 1.0 in.

N/A

Page 1-2 9001034 Rev. E SATO "S" Print Engines

Section 1. Printer Overview Page 1-3

SPECIFICATION ALL

CONTROLS AND SIGNALS

On-Line LED
Power LED
Label LED
Ribbon (Not used on M-8459S) LED
Error LED
LCD Panel 2 Line x 16 Character
On/Off-Line Switch Front Panel
Label Feed Switch Front Panel
Power On/Off Switch Front Panel

POTENTIOMETER ADJUSTMENTS

Print Darkness Inside Panel
Pitch Inside Panel
Offset Inside Panel
Display Front Panel

INTERFACE CONNECTIONS

Parallel Centronics Compatible Standard
Serial RS232C (2400 to 19.2K bps) Standard

RS422/485 (2400 to 19.2K bps) Optional

Serial Protocol Hardware Flow Control (Ready/Busy)

Software Flow Control (X-On/X-Off)

Bi-directional (ENQ/Response)

Data Transmission ASCII Format

PROCESSING

CPU 32 Bit RISC
ROM 1M byte (4M bit x 2)
DRAM 2 MByte

All specifications subject to change without notice.

SATO "S" Print Engines 9001034 Rev. E Page 1-3

Section 1. Printer Overview

SPECIFICATION M-8485S/M-8459S/M-8460S M-8490S

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 Wx 17 dots H) Univers Condensed Bold
XM Font (24 dots W x 24 dots H) Univers Condensed Bold
OA Font (15 dots W x 22 dots H) OCR-A (22 dots W x 33 dots H) OCR A
OB Font 20 dots W x 24 dots H) OCR-B (30 dots W x 36 dots H) OCR B

AUTO SMOOTHING FONTS

WB WB Font (18 dots W x 30 dots H)
WL WL Font (28 dot W x 52 dots H)
XB XB Font (48 dots W x 48 dots H) Univers Condensed Bold
XL XL Font (48 dot 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

DOWNLOADABLE FONTS

TrueType Fonts with Optional Memory Card

CHARACTER CONTROL

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

Character Pitch control

Line Space control

Journal Print facility

0°, 90°, 180° and 270° Rotation

All specifications subject to change without notice.

Page 1-4 9001034 Rev. E SATO "S" Print Engines

Section 1. Printer Overview Page 1-5

SPECIFICATION ALL

SYMBOLOGIES

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

Data Matrix

Maxicode

PDF417

Ratios 1:2, 1:3, 2:5 User definable bar widths
Bar Height 4 to 600 dots, User programmable
Rotation 0°, 90°, 180°and 270°

OTHER FEATURES

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 or .PCX formats
Form Overlay Form overlay for high-speed editing of complex formats.

All specifications subject to change without notice.

SATO "S" Print Engines 9001034 Rev. E Page 1-5

Section 1. Printer Overview

SPECIFICATION M-8485S/M-8459S/M-8490S M-8460S

DIMENSIONS

Wide 9.65 in. (245 mm)
Deep 16.1 in. (408 mm) 17.9 in.

455 mm

High 11.8 in. (300 mm)

WEIGHT 25.0 lbs (11.34 Kg) 27.5 lbs

12.5 Kg

POWER REQUIREMENTS

Voltage

100 - 115 V (±10 %)

220V (±10 %)

50/60 Hz (±1%)

Power Consumption 50W Idle

700W Operating

ENVIRONMENTAL

Operating Temperature 41° to 104°F (5° to 40°C)
Storage Temperature -0° to 104°F (-20° to 40°C)
Operating Humidity 15-85 % RH, non-condensing
Storage Humidity Max 90% RH, non-condensing
Electrostatic Discharge 8KV

REGULATORY APPROVALS

Safety UL, CSA, CE
RFI/EMI FCC Class A

All specifications subject to change without notice.

(1) CE approval on M-8460S only

(1)

Page 1-6 9001034 Rev. E SATO "S" Print Engines

Section 1. Printer Overview Page 1-7

ACCESSORY M-8485S/M-8459S/M-8490S M-8460S

MEMORY EXPANSION Two slots for PCMCIA Memory Cards (up to 2MB each). Can be used

for Graphic File storage, print buffer expansion, format storage and
downloaded TrueType fonts.

CALENDAR An internally mounted Date/Time clock that can be used to date/time

stamp labels at the time of printing.

FACE-OUT LABEL SENSOR Top-mounted sensor for reflective Eye-Marks

printed on the face of the label.

All specifications subject to change without notice.

N/A

SATO "S" Print Engines 9001034 Rev. E Page 1-7

This page left intentionally blank.

Section 1. Printer Overview

Page 1-8 9001034 Rev. E SATO "S" Print Engines

INTRODUCTION

This section of the manual has been written to help you install the SATO “S” print
engine modules and to get started as quickly as possible.

It is recommend to read each chapter in this manual before the installation or the use
of the print modules.

INSTALLATION

Careful consideration must be given when selecting the location of the printer,
especially to environmental considerations. To obtain optimum results from the SATO
“S” print module, always try to avoid operation locations influenced by:

SECTION 2.

INSTALLATION

• Direct or bright sunlight, as this will make the label sensor less responsive

and may cause the label to be sensed incorrectly.

• Locations which have extremes of temperature, as this can create electrical

problems on the circuits within the printer.

• The installed location of the printer should ideally be in areas free from

dust, humidity and sudden vibrations.

CONSUMABLES

Always use SATO carbon ribbons or equivalent in the thermal transfer models. The
use of incorrect materials may cause malfunctions of the printer and void the
warranty.

SATO “S” Print Engines 9001034 Rev. E Page 2-1

Section 2. Installation

DIMENSIONS

Note: The exact position of components may vary depending on model.

Width: 10.4 inches 265 mm
Depth:

Depth M-8460S Only:

16.06 inches 417 mm

17.8 inches 452 mm

Height: 11.8 inches 303 mm

0.4"

M-8460S

8.9"

227 mm

7.08"

180 mm

10 mm

9.65"

245 mm

8.8"

223 mm

11.8"

300 mm

11.8"

300 mm

10.4"

265 mm

4.6"

117.5 mm

235 mm

16.1"

408 mm

117.5 mm

9.25"

M-8460S

17.9"

452 mm

4.6"

10.4"

265 mm

Page 2-2 9001034 Rev. E SATO “S” Print Engines

COMPONENT NAMES

DIP Switch Panel

Ribbon Motion

Sensor

Cover Open

Switch

Section 2. Installation

Label and Ribbon
Loading Diagram

Operation Panel

Ribbon Rewind

Head Open

Switch

Ribbon Unwind

Label Hold Down

Label Edge Guide

Head Pressure

Adjust

M-8460S/M-8485S/M-8490S

Nip Roller

Latch

Platen Roller

Print Head

Head Latch

M-8459S Only

SATO “S” Print Engines 9001034 Rev. E Page 2-3

Section 2. Installation

REAR PANEL

AC Fuse

Serial I/F
Connector

Parallel I/F
Connector

Memory Card
Slot Cover

AC Input
Connector

EXT Connector

Power On/Off Switch: To turn power On or Off
Operation Panel To set up the various configurations and to display

dispensing quantity and the various alarms. The
details of these are described on page 3-5

Adjustment Panel Potentiometers (inside label compartment) to make

setup adjustments. The details of these are described
on page 3-19.

AC Input Connector To input 115V 50/60 Hz. Use the power cable provided.
AC Fuse To protect the machine from abnormal power input.

Type 15A/250V.

Serial I/F Connector Connects to the RS-232C serial port of the host.

Parallel I/F Connector Connects to the Centronics parallel port of the host.

EXT Connector This is an external signal connector for interfacing with

the label applicator system.

Memory Card Connectors for Optional PCMCIA Memory Cards.

Page 2-4 9001034 Rev. E SATO “S” Print Engines

SWITCHES AND SENSORS

Cover Open Switch: The print head mechanism cover is fitted with a micro

Ribbon Motion Sensor: The sensor will react to the carbon ribbon unwind

Head Open Switch: When the print head is opened, this switch is activated

Label Sensor: This sensor unit contains two sensors for both label

Section 2. Installation

switch. When the cover is opened, this switch is
activated and the printer will stop printing.

when approximately 46 feet of ribbon remain. This
sensor is a motion detector that signals the printer
when the ribbon supply is turning. This sensor is used
for both the ribbon end and ribbon near end sensing.

Note: The M-8459S Direct Thermal print engine does
not use a Ribbon Motion Sensor.

and the printer will stop printing.

gap and Eye-mark sensing.

SATO “S” Print Engines 9001034 Rev. E Page 2-5

Section 2. Installation

MEDIA LOADING

Ribbon Loading (not applicable for the M-8459S)

1. Open the print head by rotating the Head
Latch until the head releases. It is
spring-loaded in the open position.

2. Place a new ribbon roll on the Ribbon
Unwind Spindle and push it onto the
spindle as far as it will go. Make sure the
ribbon wil unwind from the top of the
roll. Note that all SATO ribbons are
wound face-in (the ink or dull side faces
toward the inside of the roll).

3. Place an empty ribbon core on the Ribbon
Wind Spindle and push it onto the
spindle as far as it will go.

New Ribbon

Empty Core

4. Unwind the clear ribbon leader until about
12 inches of leader/ribbon are off the roll.

5. Route the ribbon as shown in the Ribbon
Routing Diagram on the inside of the
cover.

6. Tape the end of the ribbon leader to the
empty core so that it will underneath the
core and over the top (see diagram on
inside of cover).

7. Manually wind approximately three turns
of ribbon on the core.

8. Inspect the ribbon to make sure it is not
folded over or excessively wrinkled as it
passes over the print head.

9. If labels are already loaded, close and latch
the print head.

Page 2-6 9001034 Rev. E SATO “S” Print Engines

Loading the Label Stock

1. Open the print head by rotating the Head
Latch until the head releases. It is
spring-loaded in the open position.

2. Unlatch the Label Hold Down by lifting up
on the latch. It is spring-loaded in the
open position.

3. Pull the Label Edge Guide all the way out.

4. Remove approximately 18 inches of labels
from the backing liner.

5. Route the label liner under the Label Hold
Down and under the print head and out
the front of the printer.

6. Pull the liner through the printer until the
first label is positioned under the Label
Hold Down.

Label Edge

Guide

Section 2. Installation

Label Hold Down

7. Push the labels in until they contact the
inside edge of the printer, then position
the Label Edge Guide until it lightly
contacts the outside edge of the label
liner.

8. Close and latch the Label Hold Down and
Print Head.

9. Release the Nip Roller Hold Down by
rotating the Nip Roller Latch tab
clockwise. The Nip Roller Hold Downwill
swing down.

10. Route the liner over the peel bar and
back between the Nip Roller Hold Down
and the Nip Roller.

11. Pull the liner tight. Close the Nip Roller
Hold Down by pushing upward until it
latches in place. Make sure the Nip
Roller Latch is securely engaged.

Label Hold Down

Closed

Labels

Note: Always check that the backing paper
is taut between Platen Roller and Nip Roller.

Nip Roller

Latch

SATO “S” Print Engines 9001034 Rev. E Page 2-7

Nip Roller

Hold Down

Label

Liner

Peel

Bar

Section 2. Installation

12. Power the printer on and press the Feed key. It should feed labels until the first
label is peeled and ready for application.

Page 2-8 9001034 Rev. E SATO “S” Print Engines

ADJUSTING THE LABEL SENSOR

The “S” printers can position labels using either a label gap (transmissive) or an
Eye-Mark (reflective) sensor. The sensor used is selected by DSW2-2 (page 3-2). The
gap sensor position can be adjusted over a limited range. In addition, the signals from
the sensors can be adjusted using the LCD panel (page 3-13) to compensate for
different liner opacities and/or Eye-Mark reflectance values.

Inside Frame

Section 2. Installation

Print Head

Inside Label Edge

Gap Sensor Adjustment

Non-Printable Area

Minimum Length = 0.5" (12 mm)

Maximum Width

Maximum Print Width

Eye-Mark on Back Side of Liner

Minimum Width = 0.25" (6 mm)

M-8459S M-8460S M-8485S M-8490S

Max Label Width

(includes liner)

Max Print Width 4.4" (112 mm) 6.0" (152 mm) 5.0" (128 mm) 4.4" (112 mm)

Gap Sensor

Adjustment Range

Non-Print Area 0.12" (3 mm) 0.12" or 0.25"

SATO “S” Print Engines 9001034 Rev. E Page 2-9

5.27" (134 mm) 6.5 “ (165 mm) 5.27" (134 mm) 5.27" (134 mm)

0.5" to 2.67"

14 mm to 68 mm

0.5" to 3.25"

14 mm to 82 mm

3 mm or 6.5 mm

0.5" to 2.67"

14 mm to 68 mm

0.12" (3 mm) 0.12" (3 mm)

0.5" to 2.67"

14 mm to 68 mm)

Section 2. Installation

ADJUSTING SENSOR POSITION

The label gap (transmissive) sensor can be positioned over a limited (see table on
page 2-9). The movable sensor assembly is mounted on the Label Hold Down and is
held in position by two screws. To adjust the position of the sensor, both screws must
be loosened and the sensor moved to the desired position in the slot, and then the
screws retightened. Adjustments to compensate for different liner opacity is done
with the LCD panel (see page 3-13).

Sensor Adjust

Slot

Print Head

(shown open)

Sensor Position

Screws

Page 2-10 9001034 Rev. E SATO “S” Print Engines

OPERATION PANEL

Section 2. Installation

Power On/Off

Switch

LCD Display

Operation Panel

LCD Display 2 Line x 16 Character display.
LABEL LED Illuminated when label is out.
RIBBON LED Illuminated when ribbon is out.

Not used on the M-8459S

Control Switches

& Indicators

ERROR LED Illuminated when errors have occurred.
ON-LINE LED Illuminated when printer is On-Line.

LINE Key: Switches the printer On-Line or Off-Line. It can also be

used as a Pause function key to stop label during the
printing process.

FEED Key To feed one blank label.
DISPLAY Potentiometer for adjusting the contrast of the LCD

SATO “S” Print Engines 9001034 Rev. E Page 2-11

Section 2. Installation

DIP SWITCH PANEL

The DIP Switch panel is located inside the cover and contains three 8-position DIP
switches and three adjustment potentiometers. Adjustment procedures for these are
listed in Section 3: Configuration.

DIP Switches

Potentiomenter

Page 2-12 9001034 Rev. E SATO “S” Print Engines

SECTION 3.

CONFIGURATION

PRINTER DIP SWITCH CONFIGURATION

DIP Switch Panels

There are three DIP switches (DSW1, DSW2 and DSW3). These are located inside the
cover. These switches can be used to set:

• RS232C transmit/receive parameters

• Thermal transfer or direct thermal mode

• Label sensor enable/disable

• Head check mode

• Hex dump mode

• Receive buffer size

• Operation mode

Each switch is an eight section toggle switch. The ON position is always to the top. To
set the switches, first power the unit Off, then position the DIP switches. Finally, after
placing the 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.

RS232 Transmit/Receive Setting

Data Bit Selection (DSW1-1). This switch sets the printer to receive either 7 or 8

bit data bits for each byte transmitted.

DSW1

DSW1-1 SETTING

Off 8 data bits
On 7 data bits

ON

OFF

12345678

Parity Selection (DSW1-2, DSW1-3). These switches select the type of parity
used for error detection.

DSW1-2 DSW1-3 SETTING

Off Off No Parity
Off On Even
On Off Odd
On On Not Used

ON

OFF

12345678

DSW1

SATO “S” Print Engines 9001034 Rev E Page 3-1

Section 3. Configuration

Stop Bit Selection (DSW1-4). Selects the number of stop bits to end each byte

transmission.

DSW1-4 SETTING

Baud Rate Selection (DSW1-5, DSW1-6). Selects the data rate (bps) for the

RS232 port.

DSW1-5 DSW1-6 SETTING

Off Off 9600
Off On 19200
On Off 4800
On On 2400

Protocol Selection (DSW1-7, DSW1-8). Selects the flow control and status

reporting protocols. See Section 5: Interface Specifications for more information.

Off 1 Stop Bit
On 2 Stop Bits

DSW1

ON

OFF

12345678

DSW1

ON

OFF

12345678

DSW1-7 DSW1-8 SETTING

Off Off Rdy/Bsy
Off On Xon/Xoff
On Off Bi-Com
On On Not Used

ON

OFF

12345678

DSW1

Printer Set Up

Print Mode Selection (DSW2-1). Selects between direct thermal printing on

thermally sensitive paper and thermal transfer printing using a ribbon. Note: This
switch is not used on the M-8459S.

DSW2-1 SETTING

Off Therm Xfr
On Direct Therm

ON

OFF

12345678

DSW2

Sensor Type Selection (DSW2-2). Selects between the use of a label gap or a

reflective Eye-Mark detector. See page 2-9 for the location of these sensors.

DSW2-2 SETTING

Off Gap
On Eye-Mark

ON

OFF

12345678

DSW2

Head Check Selection (DSW2-3). When selected, the printer will check for head

elements that are electrically malfunctioning.

DSW2

DSW2-3 SETTING

Off Disabled
On Enabled

Page 3-2 9001034 Rev E SATO “S” Print Engines

ON

OFF

12345678