SATO XL400e User manual

PN 9001135A
XL400e / XL410e
Printers
OPERATOR MANUAL

SATO UK Limited
Valley Road, Harwich
Essex CO12 4RR
Tel: [phone]
Fax: [phone]
Tech Support Hotline: [phone]
Email: [email protected]
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.

PN 9001135A
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

PN 9001135A
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

PN 9001135A
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

PN 9001135A

SATO XL400-410e Operator Manual PN 9001135A Page 1-1
INTRODUCTION
• About This Manual
• General Description
• Control Features

Unit 1: Introduction
SATO XL400-410e Operator Manual PN 9001135A Page 1-2
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.
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.
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.

Unit 1: Introduction
SATO XL400-410e Operator Manual PN 9001135A Page 1-3
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.
Figure 1-1a, Primary Components
Figure 1-1b, Primary Components
Media Supply Spindle
Ribbon Unwind SpindleRibbon Rewind Spindle
Media Retaining Plate
Head Latch Lever
Operator PanelCutter Assembly
Print Head Assembly
Top Housing Cover
Adjustment Panel
Media Hold-Down
A/C Power Connector
Power Switch
External Fuse

Unit 1: Introduction
SATO XL400-410e Operator Manual PN 9001135A Page 1-4
CONTROL FEATURES
Figure 1-2a, 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.
VR4
VR3
VR2
VR1 DSW 1
DSW 2
DSW 3
DARKNESS
CUT
POSITION
PRINT
POSITION
DISPLAY
Potentiometers Dip Switches
Reference Label

Unit 1: Introduction
SATO XL400-410e Operator Manual PN 9001135A Page 1-5
Figure 1-2b, Control Features
Figure 1-3, Connection Ports
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
LCD Display
ON LINE
START
/STOP FEED EJECT MEDIA TYPE
ERROR
CUTTER
ON/OFF
LED’s
Function Keys
SATO XL Printer
Accessory Port
Serial Interface Port
Memory Card Slot
Interface Port

Unit 1: Introduction
SATO XL400-410e Operator Manual PN 9001135A Page 1-6

SATO XL400-410e Operator Manual PN 9001135A Page 2-1
TECHNICAL DATA
• Physical Charcteristics
• Enviromental
•Power
• Processing
•Print
• Sensing
•Media
• Character Font Capabilities
• Barcode Capabilities
• Interface Modules
• Regulatory Approvals

Unit 2: Technical Data
SATO XL400-410e Operator Manual PN 9001135A Page 2-2
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.

Unit 2: Technical Data
SATO XL400-410e Operator Manual PN 9001135A Page 2-3
MEDIA
Eye-Mark Label Dimensions Width: 1.26 to 3.94 Inches (32-100mm)
Length: 1.00 to 9.45 Inches (25-240mm)
Gap Label Dimensions Width: 1.00 to 3.94 Inches (25-100mm)
Length: 0.63 to 9.33 Inches (16-237mm)
Eye-Mark Tag Width: 1.26 to 3.94 Inches (32-100mm)
Length: 1.00 to 9.45 Inches (25-240mm)
Side Hole Tag Width: 2.00 to 3.94 Inches (50-100mm)
Length: 1.00 to 9.45 Inches (25-240mm)
Center Hole Tag Width: 1.26 to 3.94 Inches (32-100mm)
Length: 1.00 to 9.45 Inches (25-240mm)
R-Corner Tag Width: 1.26 to 3.94 Inches (32-100mm)
Length: 1.00 to 9.45 Inches (25-240mm)
Maximum Caliper .008 Inches (.21 mm)
Maximum Roll Diameter 6 Inches (152 mm), Wound face inward
Minimum Core Diameter 3 Inches (76 mm)
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

Unit 2: Technical Data
SATO XL400-410e Operator Manual PN 9001135A Page 2-4
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 3-1
INSTALLATION
• Unpacking
• Parts Identification
• Printer Installation
• Interface Selection
• Accessories Installation

Unit 3: Installation
SATO XL400-410e Operator Manual PN 9001135A Page 3-2
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.
Figure 3-1, Unpacking and Parts Identification
Top Foam Inserts
Cardboard Cover
XL Printer
Accessory Box
Shipping Container
Bottom Foam Inserts
Protective Wrap

Unit 3: Installation
SATO XL400-410e Operator Manual PN 9001135A Page 3-3
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.
Center Hole Tag Side Hole Tag R-Corner Tag
Eye-Mark Tag Gap Label Eye-Mark Label
5mm
3R
1R
26Dia
3mm
5mm
3R
1R
2.6 Dia.
3mm
2.5mm
<3.75mm
Sensor Position 2.5mm
3.0mm
14.0mm
1.5mm
3.0mm
3.0mm
14.0mm
1.5mm
3.0mm

Unit 3: Installation
SATO XL400-410e Operator Manual PN 9001135A Page 3-4
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).
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).
Figure 3-3a, Media Loading
NOTE: Feed label media onto the platen roller. Tag media is to be fed onto
the feed roller.
Top Housing Cover
Power Supply Cord
Power Switch