SATO XL 400e, XL 410e User Manual

XL400e / XL410e
Printers
OPERATOR MANUAL
PN 9001135A
SATO UK Limited
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.
Valley Road, Harwich
Essex CO12 4RR
Fax: 01255 240111
Tech Support Hotline: 01255 252828
Email: techsupport@satouk.com
www.satouk.com
© Copyright 2005
SATO UK Limited
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.
TABLE OF CONTENTS
INTRODUCTION
About This Manual 1-2 General Description 1-3 Control Features 1-4
TECHNICAL DATA
Physical Characteristics 2-2 Enviromental 2-2 Power 2-2 Processing 2-2 Print 2-2 Sensing 2-2 Media 2-3 Character Font Capabilities 2-3 Barcode Capabilities 2-4 Interface Modules 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 3-4 Ribbon Loading 3-7
Interface Selection 3-12
RS232 Serial Interface 3-12 IEEE1284 Parallel Interface 3-14 Universal Serial BUS (USB) Adapter 3-15 Local Area Network (LAN) Ethernet 3-15
802.11B Wireless 3-15 Receive Buffer 3-16 ACK/NAK Protocol 3-16
Accessories Installation 3-17
PCMCIA Memory Upgrade 3-17 Stacker Unit 3-18
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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 - Test Print 4-16 Service Mode - Sensor Level 4-17 Service Mode - Pitch Offset 4-18 Service Mode - Cut Offset 4-19 Service Mode - Backfeed Offset 4-20 Service Mode - Counter Display 4-21 Screen Identification 4-22
Operational Adjustments 4-26
Darkness, Cut Position, Print Position, Display 4-26 Cutter Sensor Positioning 4-28 Operator Panel 4-29
Printing 4-30
Test Printing 4-30 Reloading Media 4-30 Powering Off 4-30
TROUBLESHOOTING
Error Signals 5-2 Printer Troubleshooting 5-3 Interface Troubleshooting 5-5
Parallel Interface 5-5 RS232 Serial Interface 5-5 LAN Ethernet Interface 5-6 Universal Serial Bus (USB) Interface 5-6
Performance Testing 5-7 Test Print Troubleshooting 5-9
Sensor Locations 5-12
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MAINTENANCE
Cleaning Procedures 6-2 Replacement Procedures 6-3
Fuse 6-3 Print Head 6-4 Ribbon Roller 6-5
Adjustment Procedures 6-6
Print Head Balance 6-7 Print Head Alignment 6-8 Pressure Roller Alignment 6-9 Pressure Roller Balance 6-10 Ribbon Guide Adjustment 6-11 Ribbon Spindle Tensioning 6-12 Pitch Sensor Adjustment (Label Gap & Center Hole Media) 6-13 Pitch Sensor Adjustment (Eye-Mark Media) 6-14 Pitch Sensor Adjustment (R-Corner) 6-16 Pitch Sensor Adjustment (Side Hole Media) 6-17 Jump Hole Sensor Adjustment 6-18 Ribbon Sensor Adjustment 6-19 Cutter Sensor Adjustment 6-20
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PN 9001135A

INTRODUCTION

About This Manual
General Description
Control Features
SATO XL400-410e Operator Manual PN 9001135A Page 1-1
Unit 1: Introduction
ABOUT THIS MANUAL
This manual is laid out consistent with the product discussed and provides all of the information required for general printer configuration, operation, troubleshooting, and maintenance. For specialized programming, refer to the Programming Manual provided with the product.
Step-by-step maintenance instructions are provided with typical problems and solutions. Become familiar with each section before installing and maintaining the printer.
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 Manual PN 9001135A Page 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 Manual PN 9001135A Page 1-3
Unit 1: Introduction
CONTROL FEATURES
BUTTONS & SWITCHES
POWER Two position on/off switch that controls power flow to the system. START / STOP Toggles the printer on/off line.
FEED Allows feeding of one tag or label each time it is pressed. Is only
functional when the printer is off-line. Feeds one label when the cutter is disabled. Feeds one label, cuts, and backfeeds when the cutter is enabled.
CUTTER ON/OFF Enables or disables the cutter. Is only functional when the printer is
off-line.
EJECT Feeds out any printed media. If the cutter is enabled; it feeds, cuts,
and backfeeds. If cutter is disabled; it ejects, cuts, and backfeeds. MEDIA TYPE Allows the selection of the applicable media to be printed.
DSW1 & DSW2 Used to configure RS232 interface. Located behind access panel
inside the printer. DSW3 Is 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
Potentiometers Dip Switches
Figure 1-2a, Control Features
SATO XL400-410e Operator Manual PN 9001135A Page 1-4
Unit 1: Introduction
LED’s
SATO XL Printer
LCD Display
ON LINE
START /STOP
CUTTER
FEED EJECT MEDIA TYPE
ON/OFF
Function Keys
ERROR
Figure 1-2b, Control Features
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
Parallel
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
Memory Card Slot
Seria l Interface Port
Interface Port
Accessory Port
Figure 1-3, Connection Ports
SATO XL400-410e Operator Manual PN 9001135A Page 1-5
Unit 1: Introduction
SATO XL400-410e Operator Manual PN 9001135A Page 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 Manual PN 9001135A Page 2-1
Unit 2: Technical Data
PHYSICAL CHARACTERISTICS
Width 19.6 Inches (302 mm)
Height 11.50 Inches (294 mm)
Depth 11.80 Inches (552 mm)
Weight 30.80 Pounds (14.0 Kg) standard
ENVIRONMENTAL
Operating Temperature 41° to 104°F (5° to 40°C)
Storage Temperature 0° to 104°F (-20° to 40°C)
Storage Humidity Max 90% RH, Non-Condensing
Operating Humidity 15 to 85% RH, Non-Condensing
Electrostatic Discharge 8kV
POWER
Input Voltage 115/220 Volts AC +/- 10%, 50/60 Hertz +/-1%
Power Consumption 150 Watts Operating
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
PRINT
Method Direct Thermal / Thermal Transfer
Speed (user selectable) 2, 3, 4, 5, 6 Inches Per Second
Print Module (dot size) .0049 Inches (.125 mm)
Resolution XL400e: 203 Dots Per Inch (8 dpmm)
XL410e: 305 Dots Per Inch (12 dpmm)
Maximum Print Width 4.4 Inches (112 mm)
Maximum Print Length 14.0 Inches (355 mm)
SENSING
Gap Fixed
Reflective Eye-Mark Fixed
Continuous Form Sensor not used.
SATO XL400-410e Operator Manual PN 9001135A Page 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 Diameter 6 Inches (152 mm), Wound face inward
Minimum Core Diameter 3 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 Font 24 dots W x 24 dots H (Care Symbol)
XCL Font 36 dots W x 36 dots H (Care Symbol)
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) 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
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,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 Manual PN 9001135A Page 2-3
Unit 2: Technical Data
BAR CODE CAPABILTIES
Linear Bar Codes Bookland (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 Dimemsional Data Matrix
Maxicode
PDF417
Ratios 1:2, 1:3, 2:5, User definable bar widths
Bar Height 4 to 600 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, PCX formats
Form Overlay Form overlay for high-speed editing of complex formats
INTERFACE MODULES
Parallel Port IEEE 1284 Standard
Serial Port RS232C (9,600 to 19,200 dps) Standard
RS422/485 (9,600 to 57,600 bps) Optional
Universal Serial Bus USB Adapter
Ethernet 802.11B Wireless
Data Transmission ASCII Format
REGULATORY APPROVALS
Safety UL, CSA
RFI / EMI FCC Class A
SATO XL400-410e Operator Manual PN 9001135A Page 2-4

INSTALLATION

Unpacking
Parts Identification
Printer Installation
Interface Selection
Accessories Installation
SATO XL400-410e Operator Manual PN 9001135A Page 3-1
Unit 3: Installation
UNPACKING & PARTS IDENTIFICATION
Place the shipping container upright on a solid, flat surface. Open the container and remove the carboard cover and top foam inserts. Carefully lift the printer from the shipping container, followed by the acccessory box, and place them on a solid flat surface. Remove the plastic wrap from the printer and its accessories. Inspect the printer and its accessories for visual physical damage and ensure all components are present and report damaged property. 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 Manual PN 9001135A 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 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 Tag Side Hole Tag R-Corner Tag
1.5mm
<3.75mm
2.5mm
1.5mm
3.0mm
14.0mm
3.0mm
3.0mm
3.0mm
14.0mm
Eye-Mark Tag Gap Label Eye-Mark Label
SATO XL400-410e Operator Manual PN 9001135A Page 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).
2 Open the top housing cover.
3 Remove the media retaining plate from media supply spindle (Figure 3-3b).
4 Insert media onto the media supply spindle followed by the media retaining plate.
5 Release print head latch and hinged media hold-down (Figure 3-3c).
6 Feed 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.
7 Loosen set screw and manually adjust paper guide inward until media is denied lateral
movement. Retighten set screw.
8 Lower and latch media hold-down, print head assembly, and top cover (Figure 3-3e).
9 Restore 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 Manual PN 9001135A Page 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 Manual PN 9001135A Page 3-5
Unit 3: Installation
Cutter Assembly
Media
Media Ramp
Set Screw Paper Guide
Figure 3-3d, Media Loading
Top Housing Cover
Media Hold-DownPrint Head Assembly
Figure 3-3e, Media Loading
SATO XL400-410e Operator Manual PN 9001135A Page 3-6
Unit 3: Installation
Label/Tag
Power Switch
Figure 3-3f, Media Loading
RIBBON LOADING
Perform the following steps to load the printer with ribbon. This procedure covers only the physical installation of ribbon. Refer to the Configuration unit for setup instructions.
1 Switch the printer power switch off and disconnect the power supply cord (Figure 3-4a).
2 Open the top housing cover.
3 Release the print head latch (Figure 3-4b).
4 Insert ribbon roll onto the ribbon unwind spindle to unwind counter-clockwise (Figure 3-4c).
5 Insert a ribbon core onto the ribbon rewind spindle.
6 Route the free end of the ribbon around the print assembly (Figure 3-4d).
7 Tape the free end of the ribbon to the ribbon core (Figure 3-4e).
8 Rotate the ribbon rewind spindle clockwise until several layers of ribbon are on the core.
9 Lower the print head latch sandwiching the media and ribbon together (Figure 3-4f).
10 Close top housing cover.
11 Restore power and test print label (Figure 3-4g).
SATO XL400-410e Operator Manual PN 9001135A Page 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 Manual PN 9001135A Page 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 Manual PN 9001135A Page 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 Manual PN 9001135A Page 3-10
Unit 3: Installation
Label/Tag
Power Switch
Figure 3-4g, Ribbon Loading
SATO XL400-410e Operator Manual PN 9001135A Page 3-11
Unit 3: Installation
INTERFACE SELECTION
This chapter presents the printer interface types and their specifications. These specifications include detailed information to assist in the selection of the most appropriate method for the printer to interface with the host. The four acceptable interface methods are:
RS232C Asynchronous Serial
IEEE1284 Parallel
Universal Serial Bus (USB) Adapter
Local Area network (LAN) Ethernet
802.11B 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 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 XL400-410e Operator Manual PN 9001135A Page 3-12
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.
113
1425
Figure 3-5, Serial Connector Pin Asignments
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 Terminal 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 XL400-410e Operator Manual PN 9001135A Page 3-13
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