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 UK Ltd. The
information provided in this document is for general purpose only and is subject to
change without prior notice. Sato UK Ltd. assumes no responsibilities for any errors
that may appear.
SATO XL400-410e Operator ManualPN 9001135APage 1-1
Unit 1: Introduction
ABOUT THIS MANUAL
This manual is laid out consistent with the product discussed and provides all of the information
required for general printer configuration, operation, troubleshooting, and maintenance. For
specialized programming, refer to the Programming Manual provided with the product.
Step-by-step maintenance instructions are provided with typical problems and solutions. Become
familiar with each section before installing and maintaining the printer.
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 unit 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 XL400-410e Operator ManualPN 9001135APage 1-2
Unit 1: Introduction
GENERAL DESCRIPTION
The XL400/410 “e” series printers are complete, high-performance labeling systems designed
specifically for printing labels and tags. All printer parameters are programmable using the front
panel controls and dip switches to provide printing of all popular bar codes and fonts styles and
sizes.
Ribbon Unwind SpindleRibbon Rewind Spindle
Top Housing Cover
Print Head Assembly
Adjustment Panel
Media Supply Spindle
Media Retaining Plate
Head Latch Lever
Operator PanelCutter Assembly
Figure 1-1a, Primary Components
Media Hold-Down
External Fuse
A/C Power Connector
Power Switch
Figure 1-1b, Primary Components
SATO XL400-410e Operator ManualPN 9001135APage 1-3
Unit 1: Introduction
CONTROL FEATURES
BUTTONS & SWITCHES
POWERTwo position on/off switch that controls power flow to the system.
START / STOPToggles the printer on/off line.
FEEDAllows feeding of one tag or label each time it is pressed. Is only
functional when the printer is off-line. Feeds one label when the
cutter is disabled. Feeds one label, cuts, and backfeeds when the
cutter is enabled.
CUTTER ON/OFFEnables or disables the cutter. Is only functional when the printer is
off-line.
EJECTFeeds out any printed media. If the cutter is enabled; it feeds, cuts,
and backfeeds. If cutter is disabled; it ejects, cuts, and backfeeds.
MEDIA TYPEAllows the selection of the applicable media to be printed.
DSW1 & DSW2Used to configure RS232 interface. Located behind access panel
inside the printer.
DSW3Is largely reserved. Located behind access panel inside the printer.
VR1
VR2
VR3
VR4
DARKNESS
CUT
POSITION
PRINT
POSITION
DISPLAY
Reference Label
DSW 1
DSW 2
DSW 3
PotentiometersDip Switches
Figure 1-2a, Control Features
SATO XL400-410e Operator ManualPN 9001135APage 1-4
Unit 1: Introduction
LED’s
SATO XL Printer
LCD Display
ON LINE
START
/STOP
CUTTER
FEEDEJECTMEDIA TYPE
ON/OFF
Function Keys
ERROR
Figure 1-2b, Control Features
CONNECTION PORTS
AC Power InputConnector permits 115V, 50/60 Hz supply via supplied cord.
Interface PortConnector for interface harness. Must be connected for the printer to
be operational. Acceptable interface types are:
•RS232C Serial I/F Module, DB-25
•Parallel
•Universal Serial Bus Adapter
•Ethernet 10/100 BaseT I/F Module
•RS422/485 I/F Module, DB-9
Ext. Interface PortConnector for external control of print cycle. Also supplies power for
optional accessories - AMP 57-60140
Memory Card SlotSlot for the insertion of optional PCMCIA Memory Card
Memory Card Slot
Seria l Interface Port
Interface Port
Accessory Port
Figure 1-3, Connection Ports
SATO XL400-410e Operator ManualPN 9001135APage 1-5
Unit 1: Introduction
SATO XL400-410e Operator ManualPN 9001135APage 1-6
TECHNICAL DATA
•Physical Charcteristics
•Enviromental
•Power
•Processing
•Print
•Sensing
•Media
•Character Font Capabilities
•Barcode Capabilities
•Interface Modules
•Regulatory Approvals
SATO XL400-410e Operator ManualPN 9001135APage 2-1
Unit 2: Technical Data
PHYSICAL CHARACTERISTICS
Width19.6 Inches (302 mm)
Height11.50 Inches (294 mm)
Depth11.80 Inches (552 mm)
Weight30.80 Pounds (14.0 Kg) standard
ENVIRONMENTAL
Operating Temperature41° to 104°F (5° to 40°C)
Storage Temperature0° to 104°F (-20° to 40°C)
Storage HumidityMax 90% RH, Non-Condensing
Operating Humidity15 to 85% RH, Non-Condensing
Electrostatic Discharge8kV
POWER
Input Voltage115/220 Volts AC +/- 10%, 50/60 Hertz +/-1%
Power Consumption150 Watts Operating
PROCESSING
CPU32 Bit RISC
FLash ROM2 Mega-Bytes
SDRAM16 Mega-Bytes
Receive Buffer2.95 Mega-Bytes
Memory ExpansionSee Options and Accessories
PRINT
MethodDirect Thermal / Thermal Transfer
Speed (user selectable)2, 3, 4, 5, 6 Inches Per Second
Print Module (dot size).0049 Inches (.125 mm)
ResolutionXL400e: 203 Dots Per Inch (8 dpmm)
XL410e: 305 Dots Per Inch (12 dpmm)
Maximum Print Width4.4 Inches (112 mm)
Maximum Print Length14.0 Inches (355 mm)
SENSING
GapFixed
Reflective Eye-MarkFixed
Continuous FormSensor not used.
SATO XL400-410e Operator ManualPN 9001135APage 2-2
Unit 2: Technical Data
MEDIA
Eye-Mark Label Dimensions
Gap Label Dimensions
Eye-Mark Tag
Side Hole Tag
Center Hole Tag
R-Corner Tag
Maximum Caliper.008 Inches (.21 mm)
Maximum Roll Diameter6 Inches (152 mm), Wound face inward
Minimum Core Diameter3 Inches (76 mm)
Width: 1.26 to 3.94 Inches (32-100mm)
Length: 1.00 to 9.45 Inches (25-240mm)
Width: 1.00 to 3.94 Inches (25-100mm)
Length: 0.63 to 9.33 Inches (16-237mm)
Width: 1.26 to 3.94 Inches (32-100mm)
Length: 1.00 to 9.45 Inches (25-240mm)
Width: 2.00 to 3.94 Inches (50-100mm)
Length: 1.00 to 9.45 Inches (25-240mm)
Width: 1.26 to 3.94 Inches (32-100mm)
Length: 1.00 to 9.45 Inches (25-240mm)
Width: 1.26 to 3.94 Inches (32-100mm)
Length: 1.00 to 9.45 Inches (25-240mm)
CHARACTER FONT CAPABILITIES
MATRIX FONTS
XCS Font24 dots W x 24 dots H (Care Symbol)
XCL Font36 dots W x 36 dots H (Care Symbol)
XU Font5 dots W x 9 dots H (Helvetica)
XS Font17 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)XL400e: 15 dots W x 22 dots H
XL410e: 22 dots W x 33 dots H
OB Font (OCR-B)XL400e: 20 dots W x 24 dots H
XL410e: 30 dots W x 36 dots H
AUTO SMOOTHING FONTS
XB48 dots W x 48 dots H (Univers Condensed Bold)
XL48 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,10 Font Variations
DOWNLOADABLE FONTS
True Type Fonts with Optional Memory Upgrade
CHARACTER CONTROL
Expansion up to 12 x in either the X or Y coordinates.
Charcter Pitch & Line Space Control, Journal Print facility
0, 90, 180, and 270 Degree Rotation
SATO XL400-410e Operator ManualPN 9001135APage 2-3
Unit 2: Technical Data
BAR CODE CAPABILTIES
Linear Bar CodesBookland (UPC/EAN Supplemental
EAN-8, EAN-13
CODABAR
Code 39
Code 128
Interleaved 2 of 5
UCC/EAN-128
UPC-A and UPC-E
Two DimemsionalData Matrix
Maxicode
PDF417
Ratios1:2, 1:3, 2:5, User definable bar widths
Bar Height4 to 600 dots, User progammable
Rotation0, 90, 180, and 270 Degrees
Sequential NumberingSequential numbering of both numerics and bar codes
Custom CharactersRAM storage for special characters
GraphicsFull dot addressable graphics, SATO Hex/Binary, PCX formats
Form OverlayForm overlay for high-speed editing of complex formats
INTERFACE MODULES
Parallel PortIEEE 1284 Standard
Serial PortRS232C (9,600 to 19,200 dps) Standard
RS422/485 (9,600 to 57,600 bps) Optional
Universal Serial BusUSB Adapter
Ethernet802.11B Wireless
Data TransmissionASCII Format
REGULATORY APPROVALS
SafetyUL, CSA
RFI / EMIFCC Class A
SATO XL400-410e Operator ManualPN 9001135APage 2-4
INSTALLATION
•Unpacking
•Parts Identification
•Printer Installation
•Interface Selection
•Accessories Installation
SATO XL400-410e Operator ManualPN 9001135APage 3-1
Unit 3: Installation
UNPACKING & PARTS IDENTIFICATION
Place the shipping container upright on a solid, flat surface. Open the container and remove the
carboard cover and top foam inserts. Carefully lift the printer from the shipping container,
followed by the acccessory box, and place them on a solid flat surface. Remove the plastic wrap
from the printer and its accessories. Inspect the printer and its accessories for visual physical
damage and ensure all components are present and report damaged property. Retain the
shipping container, foam inserts, and plastic wrap in case future return is necessary.
Cardboard Cover
Top Foam Inserts
XL Printer
Accessory Box
Protective Wrap
Bottom Foam Inserts
Shipping Container
Figure 3-1, Unpacking and Parts Identification
SATO XL400-410e Operator ManualPN 9001135APage 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 select an interface for the host to communicate with the printer.
SITE LOCATION
•Stationed on a solid flat surface
•Stationed away from hazardous conditions
•Sufficient access space on all sides to premit access and opening of its covers.
•Stationed within operational distance of the host computer.
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 the
head and cause premature wear. 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 print surface inward.
3mm
3R
1R
5mm
3mm
3R
1R
2.6 Dia.
5mm
Sensor Positi on 2.5mm
Center Hole TagSide Hole TagR-Corner Tag
1.5mm
<3.75mm
2.5mm
1.5mm
3.0mm
14.0mm
3.0mm
3.0mm
3.0mm
14.0mm
Eye-Mark TagGap LabelEye-Mark Label
SATO XL400-410e Operator ManualPN 9001135APage 3-3
Unit 3: Installation
MEDIA LOADING
Perform the following steps to load media into the printer. This procedure covers only the
physical installation of media and is applicable regardless of the media type. Refer to the
Configuration unit for setup instructions.
1 Switch the printer power switch off and disconnect the power supply cord (Figure 3-3a).
2Open the top housing cover.
3Remove the media retaining plate from media supply spindle (Figure 3-3b).
4Insert media onto the media supply spindle followed by the media retaining plate.
5Release print head latch and hinged media hold-down (Figure 3-3c).
6Feed the media up the media ramp to its respective position (Figure 3-3d).
NOTE: Feed label media onto the platen roller. Tag media is to be fed onto
the feed roller.
7Loosen set screw and manually adjust paper guide inward until media is denied lateral
movement. Retighten set screw.
8Lower and latch media hold-down, print head assembly, and top cover (Figure 3-3e).
9Restore power and test print label (Figure 3-3f).
Top Housing Cover
Power Supply Cord
Power Switch
Figure 3-3a, Media Loading
SATO XL400-410e Operator ManualPN 9001135APage 3-4
Unit 3: Installation
Media Supply Spindle
Media
Media Retaining Plate
Figure 3-3b, Media Loading
Media Hold-Down
Print Head Latch
Figure 3-3c, Media Loading
SATO XL400-410e Operator ManualPN 9001135APage 3-5
Unit 3: Installation
Cutter Assembly
Media
Media Ramp
Set ScrewPaper Guide
Figure 3-3d, Media Loading
Top Housing Cover
Media Hold-DownPrint Head Assembly
Figure 3-3e, Media Loading
SATO XL400-410e Operator ManualPN 9001135APage 3-6
Unit 3: Installation
Label/Tag
Power Switch
Figure 3-3f, Media Loading
RIBBON LOADING
Perform the following steps to load the printer with ribbon. This procedure covers only the
physical installation of ribbon. Refer to the Configuration unit for setup instructions.
1 Switch the printer power switch off and disconnect the power supply cord (Figure 3-4a).
2Open the top housing cover.
3Release the print head latch (Figure 3-4b).
4Insert ribbon roll onto the ribbon unwind spindle to unwind counter-clockwise (Figure 3-4c).
5Insert a ribbon core onto the ribbon rewind spindle.
6Route the free end of the ribbon around the print assembly (Figure 3-4d).
7Tape the free end of the ribbon to the ribbon core (Figure 3-4e).
8Rotate the ribbon rewind spindle clockwise until several layers of ribbon are on the core.
9Lower the print head latch sandwiching the media and ribbon together (Figure 3-4f).
10 Close top housing cover.
11Restore power and test print label (Figure 3-4g).
SATO XL400-410e Operator ManualPN 9001135APage 3-7
Unit 3: Installation
Top Housing Cover
Power Switch
Power Supply Cord
Figure 3-4a, Ribbon Loading
Ribbon
Print Assembly
Figure 3-4b, Ribbon Loading
SATO XL400-410e Operator ManualPN 9001135APage 3-8
Unit 3: Installation
Ribbon Unwind SpindleRibbon Rewind Spindle
Ribbon Roll
Ribbon Core
Figure 3-4c, Ribbon Loading
Ribbon
Print Assembly
Figure 3-4d, Ribbon Loading
SATO XL400-410e Operator ManualPN 9001135APage 3-9
Unit 3: Installation
Ribbon
Ribbon Core
Figure 3-4e, Ribbon Loading
Print Head Latch
Top Housing Cover
Ribbon
Figure 3-4f, Ribbon Loading
SATO XL400-410e Operator ManualPN 9001135APage 3-10
Unit 3: Installation
Label/Tag
Power Switch
Figure 3-4g, Ribbon Loading
SATO XL400-410e Operator ManualPN 9001135APage 3-11
Unit 3: Installation
INTERFACE SELECTION
This chapter presents the printer interface types and their specifications. These specifications
include detailed information to assist in the selection of the most appropriate method for the
printer to interface with the host. The four acceptable interface methods are:
•RS232C Asynchronous Serial
•IEEE1284 Parallel
•Universal Serial Bus (USB) Adapter
•Local Area network (LAN) Ethernet
•802.11B Wireless
Following the selection of the desired interface, proceed to the next 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 ASCIIHalf-duplex communication
Bi-Directional Communication
Data Transmission Rate9600, 19200, 38400, 57600 bps
Data Length8 bit (selectable)
Stop Bit1 bit (fixed)
Parity BitODD, EVEN, NONE (selectable)
Codes UsedASC II Character Codes, JIS Kanji Codes
Control CodesSTX (02H), ETX (03H), ACK (06H), NAK (15H)
ConnectorSpecial
CableSpecial
Signal LevelsHigh = +5V to +12V, Low = -5V to -12V
SATO XL400-410e Operator ManualPN 9001135APage 3-12
Unit 3: Installation
RS232C SERIAL INTERFACE SIGNALS
PINDIRECTIONSIGNAL DEFINITION
1ReferenceFG (Frame Ground)
2To HostTD (Transmit Data) - Data from the printer to the host computer. Sends X-On/
X-Off characters or status data (bi-directional protocols).
3To PrinterRD (Receive Data) - Data to the printer from the host computer.
4To HostRTS (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).
5To PrinterCTS (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).
6To PrinterDSR (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).
7ReferenceSG (Signal Ground)
20To HostDTR (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
* 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 XL400-410e Operator ManualPN 9001135APage 3-13
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