Page 3 - TABLE OF CONTENTS; INTRODUCTION
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 Modul...
Page 5 - MAINTENANCE
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 Tensio...
Page 7 - About This Manual
SATO XL400-410e Operator Manual PN 9001135A Page 1-1 INTRODUCTION • About This Manual • General Description • Control Features
Page 8 - ABOUT THIS MANUAL; PROVIDES INFORMATION THAT, IF UNHEEDED, MAY
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 informationrequired for general printer configuration, operation, troubleshooting, and maintenance. Forspecialized program...
Page 9 - GENERAL DESCRIPTION
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 designedspecifically for printing labels and tags. All printer parameters are programmable using the frontpanel controls and...
Page 10 - CONTROL FEATURES
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 lab...
Page 11 - CONNECTION PORTS; AC Power Input; Memory Card Slot
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 pr...
Page 13 - TECHNICAL DATA
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
Page 15 - CHARACTER FONT CAPABILITIES
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 Widt...
Page 17 - INSTALLATION; Unpacking
SATO XL400-410e Operator Manual PN 9001135A Page 3-1 INSTALLATION • Unpacking • Parts Identification • Printer Installation • Interface Selection • Accessories Installation
Page 18 - UNPACKING & PARTS IDENTIFICATION; Figure 3-1, Unpacking and Parts Identification
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 thecarboard cover and top foam inserts. Carefully lift the printer from the shipping container,f...
Page 19 - PRINTER INSTALLATION; SITE LOCATION; Stationed on a solid flat surface; MEDIA SELECTION
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 chapterprovides instructions on how to select an interface for the host to communicate with the printer. SITE LOCATIO...
Page 20 - MEDIA LOADING; Feed the media up the media ramp to its respective position (
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 thephysical installation of media and is applicable regardless of the media type. Refer to theConfiguration unit for setup in...
Page 23 - RIBBON LOADING; Tape the free end of the ribbon to the ribbon core (
Unit 3: Installation SATO XL400-410e Operator Manual PN 9001135A Page 3-7 Figure 3-3f, Media Loading RIBBON LOADING Perform the following steps to load the printer with ribbon. This procedure covers only thephysical installation of ribbon. Refer to the Configuration unit for setup instructions. 1 Sw...
Page 28 - INTERFACE SELECTION; RS232C Asynchronous Serial; RS232 SERIAL INTERFACE; RS232C SPECIFICATIONS
Unit 3: Installation SATO XL400-410e Operator Manual PN 9001135A Page 3-12 INTERFACE SELECTION This chapter presents the printer interface types and their specifications. These specificationsinclude detailed information to assist in the selection of the most appropriate method for theprinter to inte...
Page 30 - IEEE1284 PARALLEL INTERFACE
Unit 3: Installation SATO XL400-410e Operator Manual PN 9001135A Page 3-14 IEEE1284 PARALLEL INTERFACE The parallel interface is a Plug-In, bi-directional, Interface Module that can be installed by theuser. It conforms to the IEEE1284 specification. It will automatically detect the IEEE1284 signalsa...
Page 32 - RECEIVE BUFFER
Unit 3: Installation SATO XL400-410e Operator Manual PN 9001135A Page 3-16 RECEIVE BUFFER The data stream is received from the host to the printer one job at a time. This allows thesoftware program to maintain control of the job print queue so that it can move a high priority jobin front of ones of ...
Page 33 - ACCESSORIES INSTALLATION; PCMCIA MEMORY UPGRADE
Unit 3: Installation SATO XL400-410e Operator Manual PN 9001135A Page 3-17 ACCESSORIES INSTALLATION In most instances, the printer is ordered with the desired accessories pre-installed. However,changes in printing conditions or requirements does warrant upgrades from time to time. This chapter of th...
Page 34 - STACKER UNIT
Unit 3: Installation SATO XL400-410e Operator Manual PN 9001135A Page 3-18 STACKER UNIT The XL Stacker Unit collects and stacks tags as they are printed and cut. Installation of theincluded alignment plate ensures proper spacing and alignment of the stacker with the printer.Connecting the stacker’s ...
Page 35 - OPERATION; Printer Configuration
SATO XL400-410e Operator Manual PN 9001135A Page 4-1 OPERATION • Printer Configuration • Configuration Modes • Operational Adjustments • Printing
Page 36 - PRINTER CONFIGURATION; DIP SWITCH PANELS
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-2 PRINTER CONFIGURATION The printer may be configured for specific jobs via the operator panel located on the right side ofthe printer and the interface panel comprised of three dip switch complexes and fourpotentiometers located w...
Page 40 - CONFIGURATION MODES; NORMAL MODE
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-6 CONFIGURATION MODES With exception of the Power switch located on the back side of the printer, all of the followingconfiguration activities are performed via the use of the operator panel located on the printer’s rightside and t...
Page 41 - TEST PRINT MODE
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-7 TEST PRINT MODE This mode allows the operator to print test labels for troubleshooting and for verification ofconfiguration settings. Figure 4-2, Test Print Mode TEST PRINT MODE CONFIGURATION FEED + POWER Printer beeps FEED To se...
Page 42 - ADVANCED MODE
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-8 ADVANCED MODE The Advanced Mode is provided to make basic printer operational adjustments. Typically, oncethese adjustments or settings have been made, they will not require additional address unless anew job is downloaded. The f...
Page 43 - DEFAULT SETTINGS MODE
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-9 DEFAULT SETTINGS MODE When the sequences have been completed, the printer automatically returns to its default gap oreye-mark settings. The default settings are those programmed settings of the factory prior todelivery. Figure 4-...
Page 44 - FLASH MEMORY DOWNLOAD MODE
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-10 FLASH MEMORY DOWNLOAD MODE A Flash ROM internally stores and deletes font data and custom designed character data. Thestorage capacity for custom characters is 95 for each type of 16 x 16, 22 x 22, and 24 x 24 dots.There are fou...
Page 46 - USER DOWNLOAD MODE
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-12 USER DOWNLOAD MODE This download feature allows the operator to download print jobs to the printer. Whendownloading is complete, the LCD screen will return to the original display after three seconds. Ifan error occurs, a DOWNLO...
Page 47 - HEX DUMP MODE
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-13 HEX DUMP MODE The contents of the print buffer and the data received before it is placed into the print buffer maybe examined through the use of the Hex Dump Mode. Each line of the printed data is inumeratedin the first column, ...
Page 48 - CARD MODE
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-14 CARD MODE This configuration mode is used for configuring the Flash ROM and/or PCMCIA interface cards.The following table identifies the menus of the Card Mode and their purpose. The flow chart after,sequences the operator, prin...
Page 49 - NON-STANDARD CLEAR MODE
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-15 NON-STANDARD CLEAR MODE Returns non standard protocol code to the default value. The default values are STX (7B), ETX(7D), ESC (5E), ENQ (40), NUL (7E), CAN (21), OFFLINE (5D). Follow the sequences in th flowchart below to perfo...
Page 50 - SERVICE MODE
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-16 SERVICE MODE Allows the programming of various dimensional settings and the language used. Refer to thetable below for an explaination of each menu encountered. The following flow chart providesconfiguration sequence. Figure 4-1...
Page 60 - OPERATIONAL ADJUSTMENTS; POTENTIOMETER
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-26 OPERATIONAL ADJUSTMENTS These operational adjustments are for fine tuning the printer as necessary following theconfiguration process and are confined to the three potentiometers located on the adjustmentpanel in addition to the...
Page 62 - CUTTER SENSOR POSITIONING
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-28 CUTTER SENSOR POSITIONING The cutter assembly has dual adjustable sensors and is designed to permit lateral movement ofthe sensor assembly to accomdate multiple media types. To position the sensor, loosen its setscrew and move t...
Page 63 - OPERATOR PANEL
Unit 4: Operation SATO XL400-410e Operator Manual PN 9001135A Page 4-29 OPERATOR PANEL The operator panel may be used at two different angles. The normal angle is flush with thesurface of the printer. Pressing against the upper portion of the panel causes it to tilt backwardsto allow better viewing ...
Page 65 - TROUBLESHOOTING
SATO XL400-410e Operator Manual PN 9001135A Page 5-1 TROUBLESHOOTING • Error Signals • Printer Troubleshooting • InterfaceTroubleshooting • Performance Testing • Test Print Troubleshooting • Sensor Locations
Page 66 - ERROR SIGNALS; ERROR SIGNAL TABLE; LED
Unit 5: Troubleshooting SATO XL400-410e Operator Manual PN 9001135A Page 5-2 ERROR SIGNALS This unit coorelates the three types of error signals with probable causes and problem resolution.Three types error signals are: LED, LCD Message, and an audible beep. ERROR SIGNAL TABLE LED LCD MESSAGE BEEP R...
Page 67 - PRINTER TROUBLESHOOTING; TROUBLESHOOTING TABLE; IMAGE VOIDS
Unit 5: Troubleshooting SATO XL400-410e Operator Manual PN 9001135A Page 5-3 PRINTER TROUBLESHOOTING TROUBLESHOOTING TABLE IMAGE VOIDS Damaged print head. Replace print head. Damaged electronics. Replace circuit board. Damaged or worn platen roller. Replace platen roller. Vertical line in printed im...
Page 69 - INTERFACE TROUBLESHOOTING; PARALLEL INTERFACE; CHK
Unit 5: Troubleshooting SATO XL400-410e Operator Manual PN 9001135A Page 5-5 INTERFACE TROUBLESHOOTING This unit provides a checklist for the various interface types. Locate the checklist relative to theinterface used and perform each of the troubleshooting tasks until the problem has been isolated....
Page 70 - LAN EHTERNET INTERFACE
Unit 5: Troubleshooting SATO XL400-410e Operator Manual PN 9001135A Page 5-6 LAN EHTERNET INTERFACE CHK TROUBLESHOOTING STEP Ensure the interface has been correctly configured. Wait two minutes and run self-test to verify. If atest label does not print, there ma y be a hardware problem. Ensure the s...
Page 71 - PERFORMANCE TESTING; MULTIMETER WITH TEST MODULE
Unit 5: Troubleshooting SATO XL400-410e Operator Manual PN 9001135A Page 5-7 PERFORMANCE TESTING This unit explains how to troubleshoot circuitry and adjust sensors using a multimeter. Theseactivities may be performed with or without test module assistance in conjunction with themultimeter. MULTIMET...
Page 72 - MULTIMETER ALONE; TEST CHART
Unit 5: Troubleshooting SATO XL400-410e Operator Manual PN 9001135A Page 5-8 MULTIMETER ALONE Testing of circuitry and sensor adjustment may be performed by using a multimeter without theassistance of the test module. To perform this task the multimeter probes must be attached to thecorrect connecto...
Page 73 - TEST PRINT TROUBLESHOOTING; HEX DUMP
Unit 5: Troubleshooting SATO XL400-410e Operator Manual PN 9001135A Page 5-9 TEST PRINT TROUBLESHOOTING Chapter provides instruction on special printing to identify and resolve specific print problems. HEX DUMP Allows the operator to determine if there wereproblems in the downloading of data. TEST L...
Page 74 - TEST LABEL PRINTING
Unit 5: Troubleshooting SATO XL400-410e Operator Manual PN 9001135A Page 5-10 TEST LABEL PRINTING The test label is designed to assist in the identification of print problems. Follow the flow chartprovided below to perform this activity. Figure 5-4, Test Print Mode NOTE: The only print problem that ...
Page 75 - SAMPLE TEST LABEL
Unit 5: Troubleshooting SATO XL400-410e Operator Manual PN 9001135A Page 5-11 Figure 5-5, Sample Test Label D S W 3 D S W 2 D S W 1 N O N E SAMPLE TEST LABEL Label Contents Will Vary Depending on Test Label Type. Compare this scale on each side to ensure the print is evenly spaced horizontally. Comp...
Page 76 - SENSOR LOCATIONS
Unit 5: Troubleshooting SATO XL400-410e Operator Manual PN 9001135A Page 5-12 SENSOR LOCATIONS This chapter provides a diagram identifying the locations of the printer’s various sensors. Refer tothe diagram provided below. Figure 5-6, Sensor Locations
Page 78 - CLEANING PROCEDURES
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-2 CLEANING PROCEDURES Cleaning of the printer is a necessary maintenance activity to ensure print quality and long printerlife. There are two basic types of cleaning involved; the removal of loose debris and the removalof residue...
Page 79 - REPLACEMENT PROCEDURES; FUSE REPLACEMENT
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-3 REPLACEMENT PROCEDURES The printer contains replaceable components and sub-assemblies. This chapter contains step-by-step instructions for the removal and replacement of those primary components and sub-assemblies that are subj...
Page 80 - PRINT HEAD REPLACEMENT
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-4 PRINT HEAD REPLACEMENT If the print head becomes damaged or wears out, it can be easily replaecd using a screwdriver.Critical adjustments are not required because the print head is a subassembly mounted to apermanent, factory a...
Page 81 - RIBBON ROLLER REPLACEMENT
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-5 RIBBON ROLLER REPLACEMENT The ribbon roller is a high wear component due to the ribbon medium treading on its surface. Theribbon roller is the only roller approved for replacement by the operator. For all other rollerreplacemen...
Page 82 - ADJUSTMENT PROCEDURES; PRINT DEFECTS
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-6 ADJUSTMENT PROCEDURES To maintain optimum performance and print quality, periodically mechanical adjustments willhave to be made. These adjustments are typically required following the replacment of acomponent. Other adjustment...
Page 83 - PRINT HEAD BALANCE ADJUSTMENT; characteristics are corrected.; Figure 6-5, Print Head Balance Adjustment
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-7 PRINT HEAD BALANCE ADJUSTMENT If the print head balance is out of adjustment, the printed image will be darker on side of the labelthan the other and the media stock will be proned to want to travel in the direction of leastres...
Page 84 - PRINT HEAD ALIGNMENT
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-8 PRINT HEAD ALIGNMENT Print head position has a direct impact on print quality. An improperly aligned print head willcause the print to be inconsistent across the label. The following procedure will provide guidanceon print head...
Page 85 - PRESSURE ROLLER ALIGNMENT
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-9 PRESSURE ROLLER ALIGNMENT The pressure roller works in conjunction with the feed roller, sandwiching the loaded mediabetween the two. It is the drive-coupled feed roller that advances the media forward to the platenroller. The ...
Page 86 - PRESSURE ROLLER BALANCE
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-10 PRESSURE ROLLER BALANCE The pressure roller works in conjunction with the feed roller, sandwiching the loaded mediabetween the two. It is the drive-coupled feed roller that advances the media forward to the platenroller. The p...
Page 87 - RIBBON GUIDE ADJUSTMENT
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-11 RIBBON GUIDE ADJUSTMENT If the print ribbon is not spread smoothly over the print head when it makes contact with themedia, print voids will occur at the point of the ribbon fold. Typically, this is the result of the axis ofon...
Page 88 - RIBBON SPINDLE TENSIONING
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-12 RIBBON SPINDLE TENSIONING The printer has two ribbon spindles; one to supply ribbon medium from the rear of the printer pastthe print head to the spindle closest to the front for the purpose of rewinding the used medium.The re...
Page 89 - Detach the access panel located on the left side of the printer.
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-13 PITCH SENSOR ADJUSTMENT (LABEL GAP & CENTER HOLE MEDIA) This sensor adjustment regulates penetrating ability for media referencing. Penetrationmodification is performed via two potentiometers that is part of the potentiome...
Page 93 - PITCH SENSOR ADJUSTMENT (SIDE HOLE MEDIA)
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-17 PITCH SENSOR ADJUSTMENT (SIDE HOLE MEDIA) This sensor adjustment regulates penetrating ability for media referencing. Penetrationmodification is performed via two potentiometers that is part of the potentiometer complexlocated...
Page 94 - JUMP HOLE SENSOR ADJUSTMENT
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-18 JUMP HOLE SENSOR ADJUSTMENT This sensor adjustment regulates penetrating ability for media referencing. Penetrationmodification is performed via two potentiometers that is part of the potentiometer complexlocated behind the ac...
Page 95 - RIBBON SENSOR ADJUSTMENT
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-19 RIBBON SENSOR ADJUSTMENT This sensor adjustment regulates penetrating ability for ribbon feed. Penetration modification isperformed via a potentiometer that is part of the potentiometer complex located behind theaccess panel o...
Page 96 - CUTTER SENSOR ADJUSTMENT; Load the printer with media and ribbon as applicable and power on.; CUTTER REFERENCE CHART
Unit 6: Maintenance SATO XL400-410e Operator Manual PN 9001135A Page 6-20 CUTTER SENSOR ADJUSTMENT This sensor adjustment regulates penetrating ability for the cutter sensor. Penetrationmodification is performed via a potentiometer that is part of the cutter assembly. To establish thepenetration lev...
