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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. The materials in this document is provided for general information and is subject to change without notice. SATO assumes no...
TABLE OF CONTENTS OVERVIEW 1.1 General Specifications..................1-2 1.2 Character Fonts....................1-4 1.3 Bar Codes......................1-5 1.4 Physical Characteristics ..................1-6 1.5 Optional Accessories..................1-7 INSTALLATION 2.1 Unpacking and Parts Identification ..............2-2 2.2 Setting Up The Printer ..................2-3 2.3 Printer Components..................2-4 2.4 The Operator Panel ..................2-6 2.5 Tilting The Operation Panel................2-7 2.6 Media Types Supported ..................2-8 2.7 Media Specifications..................2-10...
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TROUBLESHOOTING 6.1 Initial Checklist....................6-1 6.2 Using the Centronics (Parallel) Interface............6-1 6.3 Using the RS232C (SERIAL) Interface............6-3 OPTIONAL ACCESSORIES 7.1 Introduction......................7-1 7.2 Label Rewinder....................7-1 7.3 PCMCIA Memory Cards ..................7-2 7.4 Stacker ......................7-4 7.5 Calendar ......................7-6...
Section 1: Introduction OVERVIEW Thank you for your investment in this SATO printer product. This Operator’s Manual contains basic information about the installation, setup, configuration, operation and maintenance of the printer. A total of seven topics are covered herein, and organized as follows:...
Section 1: Introduction 1.1 GENERAL SPECIFICATIONS The SATO XL400/410 “e” series printers of Thermal Transfer Printers are complete, high-performance labeling systems designed specifically for printing tags and labels. All printer parameters are programmable using the front panel controls and DIP switches.
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Section 1: Introduction 1.1 GENERAL SPECIFICATIONS (CONT’D) SPECIFICATION XL400e XL410e CONTROLS AND SIGNALS On-Line LED Green Cutter Green Error LED LCD Panel 2 Line x 16 Character Start/Stop Switch Rear Feed Switch Front Panel Cutter Front Panel Eject Front Panel...
Section 1: Introduction 1.2 CHARACTER FONTS SPECIFICATION XL400e XL410e MATRIX FONTS (5 dots W x 9 dots H) Helvetica XU Font (17 dots W x 17 dots H) Univers Condensed Bold XS Font (24 dots W x 24 dots H) Univers Condensed Bold...
Sequential numbering of both numerics and bar codes Sequential Numbering Custom Characters RAM storage for special characters Graphics Full dot addressable graphics, SATO Hex/Binary or PCX formats Form overlay for high-speed editing of complex formats Form Overlay XL400/410e Operator’s Manual...
Section 1: Introduction 1.5 OPTIONAL ACCESSORIES Accessory Description Memory Expansion Two slots for PCMCIA Memory Cards (up to 2MB each) that 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.
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Section 1: Introduction This page has been left blank intentionally. Page 1-8 XL400/410e Operator’s Manual...
Section 2: Installation INSTALLATION This section assists you in unpacking and installing the printer from the shipping container. You will also be guided through a familiarization tour of the main parts and controls. The following information is provided: • Unpacking and Parts Identification •...
SECTION 2: INSTALLATION 2.1 UNPACKING AND PARTS IDENTIFICATION When unpacking the printer, take note of the following: • The box should stay right-side up. • Lift the printer out of the box carefully. • Remove the plastic covering from the printer. •...
Section 2: Installation 2.2 SETTING UP THE PRINTER Consider the following when setting up the printer: • Locate a solid, flat surface with adequate room to set the printer. If a Cutter/Stacker is to be used with the printer, make sure there is adequate room for the unit. The printer cover swings upward and back, so make sure there is enough clearance for the cover to swing open.
SECTION 2: INSTALLATION 2.4 THE OPERATOR PANEL CUTTER ON/OFF INDICATOR ON LINE INDICATOR ERROR LED START/ LCD DISPLAY STOP FEED CUTTER OF/OFF EJECT MEDIA TYPE The XL Operator Panel consists of three LED indicators and five key switches. The switches are used to set the printer operating parameters.
Section 2: Installation 2.5 TILTING THE OPERATION PANEL The panel can be used at two angles. The normal angle is flush with the surface of the printer. Pushing the panel causes it to tilt backwards to allow better viewing under certain situations. To release the panel from the tilted angle, press the release button above the panel, inside the printer.
SECTION 2: INSTALLATION 2.6 MEDIA TYPES SUPPORTED SIDE NOTCH TAG CUT LINE Center-Hole Tag without notch Center-Hole Tag with Side Notch (set printer for Center Hole) (set printer for Center Hole) OUTSIDE EDGE OUTSIDE EDGE Side-Hole Tag without notch Side-Hole Tag with Side Notch (set printer for Side Hole) (set printer for Side Hole) Page 2-8...
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Section 2: Installation 2.6 MEDIA TYPES SUPPORTED R-Corner Specifications (set printer for R-Corner Tag) X: = 3.75 mm minimum Y: = 2.0 mm minimum, 3 mm maximum Z: = Center of Notch Width = 2.5 mm I-Mark Specifications (set printer for I-Mark Tag or Label) I-MARK LABEL GAP XL400/410e Operator’s Manual...
SECTION 2: INSTALLATION 2.6 MEDIA TYPES SUPPORTED Label Gap Specifications (set printer for Label Gap) X: = 3.75 mm minimum Y: = 2.0 mm minimum, 3 mm maximum Z: = Center of Notch Width = 2.5 mm 2.7 MEDIA SPECIFICATIONS Media Type Minimum Size Maximum Size...
SECTION 2: INSTALLATION 2.9 LOADING TAGS AND LABELS Lift up the Cover and turn the printer ON. COVER POWER SWITCH Remove the Media Retaining Plate and place the media roll on the Media Supply Spindle. Replace the Media Retaining Plate to secure the roll in place. Note: The media should come off the bottom of the roll (wound face-in).
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Section 2: Installation 2.9 LOADING TAGS AND LABELS (CONT’D) Lift up the print head by rotating the Head Release Lever to the rear of the printer. Release the Media Hold Down by pushing and lifting the lever underneath the green tab marked “PUSH”. MEDIA HOLD- DOWN...
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SECTION 2: INSTALLATION 2.9 LOADING TAGS AND LABELS (CONT’D) Close the Media Hold-Down by pushing down on the green tab marked “PUSH” and lock it in place. Rotate the Head Lock Lever toward the front of the printer until the print head latches in place. COVER MEDIA HOLD-...
Section 2: Installation 2.10 LOADING THE RIBBON Turn the power off and life up the Cover. COVER POWER SWITCH Unlatch the print head by rotating the Head Lock Lever toward the rear of the printer. It will automatically retract to the open position. HEAD LOCK LEVER XL400/410e Operator’s Manual...
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SECTION 2: INSTALLATION 2.10 LOADING THE RIBBON (CONT’D) Place the ribbon on the Ribbon Unwind Shaft, making sure the ribbon unwind direction is as shown). Place an empty ribbon core one the Ribbon Rewind Shaft. RIBBON UNWIND RIBBON REWIND RIBBON RIBBON CORE Route the ribbon as shown.
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Section 2: Installation 2.10 LOADING THE RIBBON (CONT’D) Make sure the media is fed into the printer with the leading edge underneath the print head. Latch the print head in the down position by rotating the Head Latch. COVER HEAD LOCK LEVER Turn ON the printer.
SECTION 2: INSTALLATION 2.11 CUT SENSOR ADJUSTMENT These adjustments are for R-Corner Tag (Side-Notch), Center-Hole and Edge-Hole tags only. Lift up the cover. The Cut Sensors are located on an adjustable assembly that must be correctly positioned for the type of media used. They must be adjusted correctly even though the Cutter is disabled.
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Section 2: Installation 2.11 CUT SENSOR ADJUSTMENT (CONT’D) The scale used depends upon the type of media selected (i.e. R-Corner, Center- Hole or Side-Hole). The setting corresponds to the width of the media (i.e., if you are using center hole tags that are 80mm wide, the notch should be set at the 80mm mark of the black scale).
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SECTION 2: INSTALLATION 2.11 CUT SENSOR ADJUSTMENT (CONT’D) After adjusting the Cutter Sensor Assembly, tighten the Sensor Adjustment Thumbscrew and close the Cover. COVER SENSOR ADJUSTMENT THUMBSCREW After adjusting the Cutter Sensor, make sure you: • Have the media and ribbon loaded correctly. •...
Section 2: Installation 2.12 TURNING THE PRINTER ON/OFF TOTAL NUMBER OF LABELS PRINTED. WILL INCREMENT FOR LABEL PRINTED SINCE THE LAST TIME THE PRINTER WAS TURNED ON. TOTAL NUMBER OF LABELS PRINTED. WILL INCREMENT FOR LABEL PRINTED SINCE THE LAST TIME THE PRINTER WAS TURNED ON.
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SECTION 2: INSTALLATION 2.12 TURNING THE PRINTER ON/OFF Replenishing the Tag Supply When replenishing the tag/label supply with the same type and size, it is not necessary to power the printer off. The printer will automatically position the new media to the correct position. •...
Section 3: Configuration CONFIGURATION The configuration settings for the XL Series printers are set in two ways. The first is via three DIP switches (DSW1, DSW2 and DSW3) located under the cover. The other is using the Operator Panel LCD Display. CONTROL PANEL COVER CONTROL PANEL FUSE...
Section 3: Configuration 3.1 PRINTER DIP SWITCH CONFIGURATION DIP Switch Panels Three DIP switches (DSW1, DSW2 and DSW3) are located underneath an access panel inside the printer. These switches can be used to set: • RS232C transmit/receive parameters • Thermal transfer or direct thermal mode •...
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Section 3: Configuration 3.1 PRINTER DIP SWITCH CONFIGURATION (CONT’D) Stop Bit Selection (DSW1-4): Selects the number of Stop bits to end each byte’s transmission. DSW1 DSW1-4 Setting 1 Stop Bit 2 Stop Bits Baud Rate Selection (DSW1-5, DSW1-6): Selects the data rate (bps) for the RS232 port. DSW1 DSW1-5 DSW1-8...
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Section 3: Configuration 3.1 PRINTER DIP SWITCH CONFIGURATION (CONT’D) Receive Buffer Selection (DSW2-5): Selects the operating mode of the receive buffer. See Section 5: Interface Specifications for more information.. DSW2 DSW2-5 Setting Single Job Multi Job Reserved (DSW2-6): Reserved for future use. Protocol Code Selection (DSW2-7): Selects the command codes used for protocol control.
Slash Slash Once the default operation is completed, a “SATO DEFAULT COMPLETED” message will be displayed on the LCD panel or a single “beep” will be heard if the printer does not have an LCD panel. The printer should be turned off while this message is being displayed (or after the “beep”...
Section 3: Configuration 3.3 PRINTER ADJUSTMENTS The LCD Panel on the XL400e and XL410e is used by the operator when manually entering printer configuration settings. Many of the settings can also be controlled via software commands, and in the case of conflict between software and control panel settings, the printer will always use the last valid setting.
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000000 POWER + FEED center hole tag User Mode 000000 000000 POWER + START/STOP center hole tag Load SATO Default Settings POWER + START/STOP 000000 000000 center hole tag Dnload User’s own Protocol Codes 000000 000000 POWER + MEDIA TYPE + FEED...
Section 3: Configuration 3.4 USER MODE The LCD Panel on the XL400e and XL410e is used by the operator when manually entering printer configuration settings. Many of the settings can also be controlled via software commands, and in the case of conflict between software and control panel settings, the printer will always use the last valid setting.
There are three SPEED settings on the XL410 (4 ips, 5 ips and 6 ips) and four on the XL400e (5 ips, 6 ips, 7 ips and 8 ips). They are listed on the bottom line of the display. The current setting is indicated by an underline cursor under one of the speed settings.
Section 3: Configuration 7. The underline cursor is now positioned under the least significant digit of the H offset setting. The horizontal offset will increase each time the START/STOP key is pressed. If the START/ STOP key is pressed and held down, the value will count up rapidly. 8.
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Section 3: Configuration 3.5 SERVICE MODE A Service Mode is provided to make adjustments that require only occasional changes. Since they affect the basic operation of the printer, the procedure for entering this mode is designed to prevent someone from accidently changing the settings. To enter the Service Mode, the printer is powered on while pressing the START/STOP simultaneously with the MEDIA TYPE key while powering the printer on.The printer will “beep”...
Section 3: Configuration 3.5 SERVICE MODE (CONT’D) Sensor Setup service mode sensor setup The XL Series printers determine the location of the leading edge of the label or tag by measuring the difference between light levels when it sees either a media edge or a black I-Mark. This adjustment allows you to manually set the threshold voltage level, between the maximum and minimum light levels.
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Section 3: Configuration 3.5 SERVICE MODE (CONT’D) Calculate the starting point voltage using the formula. Use the START/STOP key to step the counter to the desired setting. The display will increment one step for each time the START/STOP key is pressed. If the START/STOP key is held pressed for more than two seconds, it will automatically go into the fast scroll mode.
This position can be adjusted relative to the “000” reference line (see page 3-26) +/- 99 dots in increments of 1 dot using the following procedure (1 dot = .005" for the XL400e and .0033" for the XL410e). Once the position is set, it can be adjusted +/- 3.75 mm using the PRINT POSITION potentiometer on the Control panel (see page 3-19).
+/- 99 dots in increments of 1 dot using the following procedure (1 dot = .005" for the XL400e and .0033" for the XL410e). Once the position is set, it can be adjusted +/- 3.75mm using the CUT POSITION potentiometer on the Control panel (see page 3-20).
Section 3: Configuration 3.5 SERVICE MODE (CONT’D) Press the FEED key to enter the desired Service Mode. Use the START/STOP key to select the type of media to be used. Once the correct media type is shown in the display message, pressing the FEED key will advance to the Backfeed Offset direction adjustment.
Section 3: Configuration 3.6 USER TEST PRINT This option allows you to print a Test Label. It is recommended that you print a Test Label after you have changed any of the settings in the User Mode. The test label allows you to verify that you indeed did make the desired changes.
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Section 3: Configuration 3.7 SERVICE TEST PRINT (CONT’D) Pressing the FEED key will start the Small Service Print Test label print mode. The printer can be paused by pressing the FEED key again. To exit the Service Print Test Mode, pause the printer using the FEED key and then remove power.
Section 3: Configuration 3.8 POTENTIOMETER ADJUSTMENTS Four potentiometer adjustments are located on the Control panel underneath a protective cover at the rear of the printer. To access the potentiometers, remove the cover by loosening the screw. Offset) Print Position (Pitch Offset) After the pitch has been set with the LCD panel, it is sometimes desirable to make minor adjustments.
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Press the FEED key to feed out a blank label. Adjust the position using the Cut Position potentiometer on the Control panel and feed another label by depressing the FEED key. When the adjustment is correct, turn the printer off. DEFAULT OFFSET SETTINGS, XL400E Page 3-20 XL400/410e Operator’s Manual...
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Section 3: Configuration Display This potentiometer is used to adjust the contrast of the LCD display for optimum viewing under various lighting conditions. Print Darkness There are three Print Darkness settings that can be set either via the LCD panel or with software commands.
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Section 3: Configuration This page has been left blank intentionally. Page 3-22 XL400/410e Operator’s Manual...
Section 4: Cleaning and Maintenance CLEANING AND MAINTENANCE 4.1 INTRODUCTION This section provides information on user maintenance for the XL Series printers. The following information is covered here: • Adjusting the Print Quality • Cleaning the Print Head, Platen and Rollers 4.2 PROCEDURES Adjusting the Print Quality Print quality on the XL printers can be adjusted in two different ways: print darkness and speed.
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If it does not have sufficient time to cool, the bar will be “smeared” on the trailing edge. The Print Speed can be set to 5, 6, 7 or 8 inches per second for the XL400e, or 4, 5 or 6 for the XL410e using the LCD panel (see page 3-9) or with the Print Speed command code.
2. Release the print head by rotating the green Head release lever counterclockwise. Print Head 3. Moisten a cotton swab with SATO Thermal Print Head and Platen Cleaner. Platen Roller 4. Carefully rub the cotton swab over the length of the print head and along and around the Platen and Ribbon Rollers.
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Section 4: Cleaning and Maintenance 4.3 CLEANING THE PRINT HEAD, PLATEN, ROLLERS AND SENSORS (CONT’D) 10. Moisten a cotton swab with SATO Thermal Print Head and Platen Cleaner. 11. Carefully clean the entire surface of the Cut Roller. Rotate the roller to expose the complete surface while cleaning.
In order to provide flexibility in communicating with a variety of host computer systems all XL printers can be configured for operation with either parallel or serial data transfers. Both the XL400e and the XL410e come standard with two interface types. The Centronics Parallel interface will probably be the most useful in communicating with IBM PCs and compatibles.
Section 5: Interface Specifications 5.3 THE RECEIVE BUFFER The XL printers have the ability to receive a data stream from the host in one of two ways. The receive buffer may be configured to accept one print job at a time or multiple print jobs. The single job print buffer is generally used by software programs that wish to maintain control of the job print queue so that it can move a high priority job in front of ones of lesser importance.
Section 5: Interface Specifications 5.3 THE RECEIVE BUFFER (CONT’D) The receiving buffer will not be able to receive more data again until a “Buffer Available” condition occurs. This takes place when the receiving buffer has emptied so that only 56K bytes of data are being held (8K bytes from being full).
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Section 5: Interface Specifications 5.4 RS232C SERIAL INTERFACE (CONT’D) Pin Assignments RS232C Interface Signals Direction Signal Definition Reference FG (Frame Ground) To Host TD (Transmit Data) - Data from the printer to the host computer. Sends X-On/X-Off characters or status data (Bi-Directional protocol).
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Section 5: Interface Specifications 5.4 RS232C SERIAL INTERFACE (CONT’D) Cable Requirements Host Interconnection Printer FG (Frame Ground) RD (Receive Data) RTS (Request To Send) CTS (Clear To Send) DSR (Data Set Ready) 20 DTR (Data Terminal Ready) SG (Signal Ground) Data Streams Once the flow control method has been chosen for the RS232C interface, the data stream must be sent in a specific manner.
Section 5: Interface Specifications 5.4 RS232C SERIAL INTERFACE (CONT’D) Cable Requirements Host Interconnection Printer FG (Frame Ground) TD (Transmit Data) RD (Receive Data) RTS (Request To Send) CTS (Clear To Send) DSR (Data Set Ready) 20 DTR (Data Terminal Ready) SG (Signal Ground) Data Streams The data streams for X-On/X-Off are constructed in the same way as they are for...
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Section 5: Interface Specifications 5.5 BIDIRECTIONAL COMMUNICATIONS (CONT’D) If a CAN (18 hexadecimal) command is received by the printer, the printer will cancel the current print job and clear all data from the receive buffer. Status Response The Bi-Com protocol is an advanced version of bi-directional communications where the printer can also report the number of labels remaining to be printed for the current print job.
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Section 5: Interface Specifications Status Byte Definition, Bi-Com Protocol ASCII Definition OFF-LINE No Errors Ribbon Near End Buffer Near Full Ribbon Near End and Buffer Near Full ON-LINE, WAITING FOR DATA No Errors Ribbon Near End Buffer Near Full Ribbon Near End and Buffer Near Full ON-LINE, PRINTING No Errors Ribbon Near End...
Section 5: Interface Specifications 5.6 CENTRONICS PARALLEL INTERFACE Electrical Specifications Printer Connector AMP 57-40360 (DDK) or equivalent Cable Connector AMP 57-30360 (DDK) or equivalent Cable Length 10 ft or less Signal Level High = +2.4V to +5.0V Low = 0V to -0.4V Data Streams Single Job Buffer: This buffer mode is not available when the Centronics interface is used.
Section 5: Interface Specifications 5.7 ACCESSORY (EXT) CONNECTOR Pin Assignments Direction Signal Description No Connection Reference Signal Ground To Rewinder Enables the Rewinder No Connection To Printer Full Switch - Stops the printer when the stacker or rewinder is full To Stacker Enables the stacker No Connection.
Section 6: Troubleshooting TROUBLESHOOTING This section has been devised to help you if you are unable to produce output on the XL “e” Series printers. Use this section to make sure the basics have been checked, before deciding you are unable to proceed any further. The section is divided into three parts: •...
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Section 6: Troubleshooting When you send the print job to the printer and it does not respond, and there is no error mes- sage on the PC: A. Check your data stream for some of the basics. Is your job framed as follows? <ESC>A—DATA—<ESC>Z B.
Baud Rate, Parity, Data Bits, or Stop Bits in relation to your host computer. If you are confused as to what the printer’s current RS232 settings are, you may choose the SATO defaults (all DIP switches in the OFF position) to achieve 9600 baud, no parity, 8 data bits, and 1 stop bit.
Section 6: Troubleshooting 6.4 ERROR SIGNALS Audible Error Condition To Clear Beep Message Error On Machine Error 1 Long Machine Error Cycle power on/off Error On EEPROM Error 1 Long EEPROM Read/Write Cycle power on/off Error On Head Error 3 Short Print Head is damaged Replace Print Head Cycle power on/off...
Section 7: Optional Accessories OPTIONAL ACCESSORIES 7.1 INTRODUCTION This section contains instructions for using the following XL Series optional features: • Label Rewinder • PCMCIA Memory Cards • Calendar • Stacker 7.2 LABEL REWINDER The rewinder is an external unit that allows for labels and tags to be rewound in rolls up to 8.5 inches in diameter.
Section 7: Optional Accessories 7.3 PCMCIA MEMORY CARDS Description The Memory Card Option provides the connectors and interface board for two PCMCIA memory cards slots. The two Memory Card slots, labeled A and B, are accessible on the Back Panel. Each card slot can have a standard PCMCIA memory card installed with a maximum of 2MB each, allowing the printer memory to be expanded up to 4MB.
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Section 7: Optional Accessories Memory Error Table ERROR DESCRIPTION INDICATION REMEDY Low Battery - Low battery con- ERROR LED: Blinking Replace Memory Card battery. dition is detected when Audible Beep: 1 long Note that all data will be lost printer is turned on. Display: Card Low Bat- when the battery is removed.
7.4 STACKER The Integrated Stacker option can stack up to 500 tags at the maximum print speed of the XL400e or XL410e. It obtains its power through the EXT Accessory port connector on the rear of the XL printer. SPECIFICATIONS...
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Section 7: Optional Accessories Installation The Stacker Option consists of four major components: • Stacker- The Stacker collects and stacks the tags as they are printed and cut. • Tag Stop - The Tag Stop is adjusted to the length of the label. It is magnetically held in place and should be adjusted for the length of the tags being stacked.
A qualified technician should perform the upgrade as it requires modifica- tions to the main PCB assembly. Please call SATO Technical Support if you need to add this option to an existing printer in the field.
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