SATO S8424 - Manual

S8400 Series Operator Manual PN: 9001160B MAINTENANCE Cleaning Procedures 6-2 Replacement Procedures 6-3 Print Head 6-3 Platen Rollers 6-4 Interface Board 6-5 Fan Filter 6-6 Adjustment Procedures 6-7 Label Sensor Positioning 6-7 Print Head Pressure 6-8 Print Head Alignmnent 6-9 Ribbon Guide Alignmen...

Unit 1: Introduction S8400 Series Operator Manual 1-2 PN: 9001160B ABOUT THIS MANUAL This manual is laid out consistent with the product discussed and provides all of the information required forgeneral printer configuration, operation, troubleshooting, and maintenance. For specialized programming, ...

Unit 1: Introduction S8400 Series Operator Manual 1-3 PN: 9001160B GENERAL DESCRIPTION The S8400 series print engines are specifically designed for use in high-volume, automated print/apply labelingapplications demanding unparalleled reliability and around the clock operation. These print engines of...

Unit 1: Introduction S8400 Series Operator Manual 1-5 PN: 9001160B CONTROL FEATURES This chapter identifies the interactive control features of the printer. These functions are defined generally here.More specific explanations will be found throughout this manual on how to use them. Figure 1-2, Oper...

S8400 Series Operator Manual 2-1 PN: 9001160B TECHNICAL DATA • Physical Characteristics• Power• Environmental• Processing• Command• Interface Modules• Regulatory Approvals• Print• Media• Ribbon• Sensing• Character Font Capabilities• Barcode Capabilities

Unit 2: Technical Data S8400 Series Operator Manual 2-3 PN: 9001160B PRINT Method Direct Thermal / Thermal Transfer Head Width 4.09 Inches (104mm) Maximum Speed 203 Dots Per Inch (8dpmm): 4 to 16 Inches Per Second (102-406mm/s) 305 Dots Per Inch (12dpmm): 4 to 14 Inches Per Second (102-356mm/s) 609 ...

Unit 2: Technical Data S8400 Series Operator Manual 2-4 PN: 9001160B SENSING Gap Adjustable Reflective Eye-Mark Adjustable Ribbon Near End Enable/Disable Media Out Constant Cover-Open Constant Head-Open Constant CHARACTER FONT CAPABILITIES MATRIX FONTS XU 5 dots W x 9 dots H (Helvetica) XS 17 dots W...

Unit 2: Technical Data S8400 Series Operator Manual 2-5 PN: 9001160B BAR CODE CAPABILTIES Linear Bar Codes UPC A/E EAN 8/13 Code 39Code 93 Code 128 Interleaved 2 of 5 Industrial 2 of 5 Matrix 2 of 5 Bookland RSS-14 MSI POSTNET UCC/EAN 128 NW-7 (Codabar) Two Dimemsional QR Code Data Matrix (ECC200) M...

S8400 Series Operator Manual 3-1 PN: 9001160B INSTALLATION • Unpacking & Parts Identification • Printer Installation • Printer Loading • Operational Mode Selection • Interface Selection • Accessories Installation

Unit 3: Installation S8400 Series Operator Manual 3-2 PN: 9001160B UNPACKING & PARTS IDENTIFICATION Unpack the printer as directed in the folowing procedure. 1. Place the shipping container (box) upright on a stable, flat surface. 2. Open the box, remove any loose items and the first layer of pa...

Unit 3: Installation S8400 Series Operator Manual 3-3 PN: 9001160B PRINTER INSTALLATION This chapter provides guidance on how to station, connect, and load the printer once unpacked. Following printersetup, proceded to the next chapter for information on interface selection. SITE LOCATION • Statione...

Unit 3: Installation S8400 Series Operator Manual 3-5 PN: 9001160B PRINTER LOADING MEDIA SELECTION The size and type of labels 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...

Unit 3: Installation S8400 Series Operator Manual 3-8 PN: 9001160B OPERATIONAL MODE SELECTION There are two modes of printer operation: Dispense or Continuous. The difference between the two is the way thatthe label and paper backing is ejected. Before printer configuration, one must determine which...

Unit 3: Installation S8400 Series Operator Manual 3-9 PN: 9001160B INTERFACE SELECTION This unit presents the printer interface types and their specifications. These specifications include detailedinformation to assist in the selection of the most appropriate method for the printer to interface with...

Unit 3: Installation S8400 Series Operator Manual 3-10 PN: 9001160B RS232C HIGH-SPEED SERIAL INTERFACE This High Speed Serial Interface is a Plug-In Interface Module that can be installed in the printer by the user. INTERFACE SPECIFICATIONS Asynchronous ASCII Half-duplex communicationBi-Directional ...

Unit 3: Installation S8400 Series Operator Manual 3-12 PN: 9001160B IEEE1284 PARALLEL INTERFACE The parallel interface is a plug-in module that can be installed by the user and conforms to IEEE1284specifications. It automatically detects the IEEE1284 signals and operates in the high speed mode. If t...

Unit 3: Installation S8400 Series Operator Manual 3-14 PN: 9001160B LOCAL AREA NETWORK (LAN) ETHERNET A Local Area Network (LAN) interface is an optional Plug-In Interface Module that can be installed by the user. Itrequires a driver shipped with each printer that has the interface installed. The dr...

Unit 3: Installation S8400 Series Operator Manual 3-16 PN: 9001160B Figure 3-10, Socket Connection Diagram LED INDICATOR STATUS Link LED (green) Network Port Off --- Front Panel Blinking Waiting for link On Linked Status LED (orange) Network Port Off --- Front Panel Blinking Receiving packet Wireles...

Unit 3: Installation S8400 Series Operator Manual 3-17 PN: 9001160B ALL INTERFACES RECEIVE BUFFER The data stream is received from the host to the printer one job at a time. This allows the software program tomaintain control of the job print queue so that it can move a high priority job in front of...

Unit 3: Installation S8400 Series Operator Manual 3-18 PN: 9001160B RECEIVE BUFFER CONTROL Causes For Receive Buffer Near Full Receive buffer near full occurs when the remaing free space of the buffer drops to0.95MB of 2.95MB capacity or when the remaining free space is available for storing50 of 50...

Unit 3: Installation S8400 Series Operator Manual 3-19 PN: 9001160B PRINT PROCESS (Figure 3-11d) COMMAND PROCESS (Figure 3-11e) BCC ERROR PROCESS (Figure 3-11f) STATUS5 TIMING CHARTS

Unit 3: Installation S8400 Series Operator Manual 3-20 PN: 9001160B EXTERNAL SIGNAL The external signal interface is designed to connect the printer to an applicator. Proceed to the printer’s AdvancedMode for various setup activities related to the external signal. There are two connector types avai...

Unit 3: Installation S8400 Series Operator Manual 3-22 PN: 9001160B Figure 3-13, 14-Pin Connector Assignments Figure 3-14, 25-Pin Connector Assignments INPUT SIGNAL WAVE FORM START PRINTING (Figure 3-15a) REPRINTING (Figure 3-15b)

Unit 3: Installation S8400 Series Operator Manual 3-23 PN: 9001160B OUTPUT SIGNAL WAVE FORM BASIC OPERATION (Figure 3-16a) PAPER END (Figure 3-16b) RIBBON END (Figure 3-16c) MACHINE ERROR (Figure 3-16d)

Unit 3: Installation S8400 Series Operator Manual 3-25 PN: 9001160B ACCESSORIES INSTALLATION This unit provides installation instructions of the purchase options available for this printer. These instructions onlycover physical hardware installation. Refer to the Printer Configuration unit of this m...

Unit 3: Installation S8400 Series Operator Manual 3-26 PN: 9001160B REMOTE OPERATOR PANEL This purchase option allows the operator panel to be detached from the printer and secured in a remote locationconvenient for user access. Refer to the instructions provided with the kit for installation guidan...

S8400 Series Operator Manual 4-1 PN: 9001160B PRINTER CONFIGURATION • Printer Configuration• Configuration Modes• Menu Definition Tables

Unit 4: Printer Configuration S8400 Series Operator Manual 4-3 PN: 9001160B CONFIGURATION MODES This chapter provides an overview of the various configuration modes of the operation menu. All of theconfiguration activities are performed via the use of the operator panel located on the printer’s face...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-4 PN: 9001160B ADVANCED MODE The Advanced Mode is provided to make advanced printer operational adjustments. Typically, once theseadjustments or settings have been made, they will not require additional address unless the application chang...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-5 PN: 9001160B PARALLEL INTERFACE MODE This chapter provides the programming sequences required for IEEE1284 interface setup. Use the keys of the printer’s operator panel and enter the required options. Refer to the Menu Definition Tables ...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-6 PN: 9001160B SERIAL INTERFACE MODE This chapter provides the programming sequences required for RS232, RS422, or RS485 interface setup. Use the keys of the operator panel to select and enter the required options. Refer to the Menu Defini...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-9 PN: 9001160B CENTRONICS INTERFACE MODE This chapter provides the programming sequences required for Centronics interface setup. Use the keys of the printer’s operator panel to select and enter the required options. Refer to the Menu Defi...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-10 PN: 9001160B WIRELESS LAN (LOCAL AREA NETWORK) INTERFACE MODE Use the keys of the printer’s operator panel to select and enter the required options. Refer to the Menu DefinitionTables in the following chapter to provide an explanation o...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-11 PN: 9001160B SERVICE MODE Allows the programming of various dimensional settings, sensor thresholds, and language options. Use the keys of the printer’s operator panel to select and enter the required options. Refer to the Menu Definiti...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-12 PN: 9001160B FACTORY MODE The Factory Mode permits counter reset of various components. Use the keys of the printer’s operator panel to select and enter the required options. Refer to the Menu DefinitionTables in the following chapter t...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-13 PN: 9001160B WORK SHIFT MODE The Work Shift Mode allows for specific production shift information to be printed on a label when used with theprinter SBPL command. Use the keys of the printer’s operator panel to select and enter the requ...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-14 PN: 9001160B HIDDEN MODE The Hidden Mode allows operator access to set Label-Out Sensor status and Work Shift mode status. Figure 4-12 provides the specific sequence of events required by the operator, the printer, and the printer’ssoft...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-15 PN: 9001160B DOWNLOAD MODE This download feature allows the operator to upgrade or downgrade firmware to the printer. When downloading iscomplete, the LCD screen will return to the original display. If an error occurs, a DOWNLOAD ERROR ...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-16 PN: 9001160B BOOT DOWNLOAD MODE This download mode is used when the firmware becomes corrupted and the normal download mode is notsuccessful. Use the printer’s keys to select and enter the required options. Refer to the Menu Definition ...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-17 PN: 9001160B PRINT CANCEL MODE Figure 4-15 provides the specific sequence of events required by the operator, the printer, and the printer’ssoftware to cancel a print job once initiated. Use the printer’s operator panel to select and en...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-18 PN: 9001160B DEFAULT SETTINGS MODE Figure 4-16 provides the specific sequence of events required by the operator, the printer, and the printer’ssoftware to return the printer to the configuration as received from the factory. Use the pr...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-19 PN: 9001160B TEST PRINT MODE Figure 4-17 provides the specific sequence of events required by the operator. the printer, and the printer’ssoftware for a test label to be printed. Test labels are designed to identify failures in configur...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-20 PN: 9001160B HEX DUMP MODE The contents of the print buffer and the data received before it is placed into the print buffer may be examinedthrough the use of the Hex Dump Mode. Each line of the printed data is enumerated in the first co...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-22 PN: 9001160B STAND ALONE MODE The Stand Alone Mode allows the printer to function independently from a host computer once a fixed format hasbeen sent, and saved, to the flash-memory card. The data may be saved to the flash-memory card w...

Unit 4: Printer Configuration S8400 Series Operator Manual 4-23 PN: 9001160B MENU DEFINITION TABLES USER MODE (TABLE 4-1) MENU DESCRIPTION Is the entrance screen to the User Mode. The User Mode allows various print parameters to beset. This screen shows the adjusted value for the potentiometers on t...

S8400 Series Operator Manual 5-1 PN: 9001160B TROUBLESHOOTING • Error Signal Troubleshooting• Warning Signal Troubleshooting• Troubleshooting Table• Interface Troubleshooting• Test Print Modes

Unit 5: Troubleshooting S8400 Series Operator Manual 5-2 PN: 9001160B ERROR SIGNAL TROUBLESHOOTING ERROR DISPLAYS ERROR LED DISPLAY LCD DISPLAY DESCRIPTION 01 Machine Error POWER:ONLINE:LABEL:RIBBON: OnOffOffOff 1. Ensure all wiring harnesses are properly connected.2. Replace main circuit board as n...

Unit 5: Troubleshooting S8400 Series Operator Manual 5-5 PN: 9001160B ERROR ICONS LCD ICONS DESCRIPTION OF ERROR POSITION ON LCD Displayed when detecting Label End. Icon 1 Displayed when detecting Ribbon End. Icon 1 Displayed when detecting Sensor Error. Icon 1 Displayed when detecting Head Open. Ic...

Unit 5: Troubleshooting S8400 Series Operator Manual 5-6 PN: 9001160B WARNING SIGNAL TROUBLESHOOTING WARNING DISPLAYS WARNING LED DISPLAY LCD DISPLAY DESCRIPTION 01 Ribbon Near-End Warning POWER:ONLINE:LABEL:RIBBON: OnOnOffBlink 1. Limited ribbon quantity remaining.2. Monitor and reload before all i...

Unit 5: Troubleshooting S8400 Series Operator Manual 5-7 PN: 9001160B TROUBLESHOOTING TABLE TROUBLESHOOTING TABLE IMAGE VOIDS Dirty print head. Clean print head. Damaged print head. Replace print head. Damaged electronics. Replace circuit board. Damaged or worn roller. Replace rollers. Poor label qu...

Unit 5: Troubleshooting S8400 Series Operator Manual 5-8 PN: 9001160B NO PRINTED IMAGE Print head is disconnected. Ensure print head wiring harness is connected on each end. No voltage output. Replace fuse. Test power supply and replace as required. Defective print head. Replace print head and reset...

Unit 5: Troubleshooting S8400 Series Operator Manual 5-9 PN: 9001160B INTERFACE TROUBLESHOOTING This chapter provides a checklist for the various interface types. Locate the checklist relative to the interface usedand perform each of the troubleshooting tasks until the problem has been isolated. PAR...

Unit 5: Troubleshooting S8400 Series Operator Manual 5-10 PN: 9001160B LAN ETHERNET INTERFACE CHK TROUBLESHOOTING STEP Ensure the interface has been correctly configured. Wait two minutes and run self-test to verify. If a test label does notprint, there may be a hardware problem.Ensure the cable and...

Unit 5: Troubleshooting S8400 Series Operator Manual 5-11 PN: 9001160B TEST PRINT MODES Chapter provides instruction on special printing to identify and resolve specific print problems. HEX DUMP Allows the operator to determine if there were problems in the downloading of data. TEST LABEL Allows the...

Unit 5: Troubleshooting S8400 Series Operator Manual 5-12 PN: 9001160B TEST LABEL PRINTING The test label is designed to assist in the identification of print problems. Follow the flow chart provided below toperform this activity. Figure 5-2, Test Print Mode TEST PRINTPRESS ENTER KEY ENTER FEED + PO...

Unit 5: Troubleshooting S8400 Series Operator Manual 5-13 PN: 9001160B Figure 5-3, Sample Test Label NOTE: The only print problem that the following sample test label does not display isfading of print image from one side of the label to the other. This is the result ofimproper print head balance. D...

S8400 Series Operator Manual 6-1 PN: 9001160B MAINTENANCE • Cleaning Procedures • Replacement Procedures • Adjustment Procedures

Unit 6: Maintenance S8400 Series Operator Manual 6-2 PN: 9001160B CLEANING PROCEDURES Cleaning of the printer is a necessary maintenace activity to ensure print quality and longer printer life. There aretwo basic types of cleaning involved; the removal of loose debris and the removal of residue. Use...

Unit 6: Maintenance S8400 Series Operator Manual 6-3 PN: 9001160B REPLACEMENT PROCEDURES This unit provides in-depth instruction on all primary component and assembly replacement, in addition to mostsecondary components. Use the text in conjunction with their accompanied graphics to ensure completec...

Unit 6: Maintenance S8400 Series Operator Manual 6-4 PN: 9001160B PLATEN ROLLER REPLACEMENT The printer’s platen roller is considered to be a high-wear component due to constant treading of the print mediaand ribbon stock against its contact surface. This constant contact will eventually wear groove...

Unit 6: Maintenance S8400 Series Operator Manual 6-5 PN: 9001160B INTERFACE BOARD REPLACEMENT Circuit boards generally have long lives due to the lack of moving parts. Generally, if a circuit board becomesdefective, it is contributable to a negative external condition. If it is determined that the c...

Unit 6: Maintenance S8400 Series Operator Manual 6-6 PN: 9001160B FAN FILTER REPLACEMENT The fan filter prevents atmospheric debis from being drawn into the printer adversely affecting componentperformance. The filter is adhesive on the contact side. To install, simply remove the contaminated filter...

Unit 6: Maintenance S8400 Series Operator Manual 6-7 PN: 9001160B ADJUSTMENT PROCEDURES This unit covers all of the printer and printer accessory adjustments. These adjustments include mechanicaladjustments required following the replacement of components and assemblies, in addition to, the operatio...

Unit 6: Maintenance S8400 Series Operator Manual 6-8 PN: 9001160B PRINT HEAD PRESSURE Print head pressure is the equalization of pressure against the platen roller from one end to the opposite. If the printhead balance is out of adjustment, the printed image will be darker on one side of the label t...

Unit 6: Maintenance S8400 Series Operator Manual 6-9 PN: 9001160B PRINT HEAD ALIGNMENT Print head position has a direct impact on print quality. The print head must be parallel with the platen roller for theprinted image to be consistent across the label. 1 Ensure the print head is latched. 2 Look d...

Unit 6: Maintenance S8400 Series Operator Manual 6-10 PN: 9001160B RIBBON GUIDE ALIGNMENT If the print ribbon is not spread smoothly over the print head when it makes contact with the media, print voids willoccur at the point of the ribbon fold. Typically, this is the result of the axis of one of th...

Unit 6: Maintenance S8400 Series Operator Manual 6-11 PN: 9001160B MEDIA PRESSURE ROLLER BALANCE Pressure roller balance adjustment may be required if the media is inclined to meander at the printer’s rear to oneside. When all things are properly aligned and balanced, the media will continuously fee...

Unit 6: Maintenance S8400 Series Operator Manual 6-12 PN: 9001160B RIBBON CASSETTE BELT TENSIONING The ribbon cassette timing belt has a spring loaded adjustment feature so that manual adjustment is not required.Simply loosen the applicable screw to allow spring torsion to determine the degree of te...

Unit 6: Maintenance S8400 Series Operator Manual 6-13 PN: 9001160B PRINT HEAD BALANCE Print head balance is the equalization of pressure against the platen roller from one end to the opposite. If the printhead balance is out of adjustment, the printed image will be darker on one side of the label th...

Unit 6: Maintenance S8400 Series Operator Manual 6-15 PN: 9001160B GAP SENSOR SENSITIVITY This sensor adjustment regulates penetrating ability for media referencing. To establish penetration, upper andlower voltage levels must be set and the difference between the two voltage levels should be maximi...

Unit 6: Maintenance S8400 Series Operator Manual 6-16 PN: 9001160B OPERATIONAL ADJUSTMENTS These operational adjustments are for fine tuning the printer as necessary following the configuration process andare largely confined to the four potentiometers located on the operator panel. Refer to the tab...

Unit 7: Appendix S8400 Series Operator Manual 7-2 PN: 9001160B READY/BUSY TIMING CHARTS Figure 7-1a, Single-Item Buffer Timing Charts Figure 7-1b, Multiple-Item Buffer Timing Charts

Unit 7: Appendix S8400 Series Operator Manual 7-4 PN: 9001160B SESSION CONNECT/DISCONNECT DIAGRAM Figure 7-3, Session connect/Disconnect Diagram

Unit 7: Appendix S8400 Series Operator Manual 7-11 PN: 9001160B PRINTER DIMENSIONS (STANDARD DIRECT LOAD) Figure 7-6a, Printer Three/Quarter View Figure 7-6b, Printer Top View

Unit 7: Appendix S8400 Series Operator Manual 7-14 PN: 9001160B PRINTER DIMENSIONS (OPPOSITE DIRECT LOAD) Figure 7-7a, Printer Three/Quarter View Figure 7-7b, Printer Top View

Unit 7: Appendix S8400 Series Operator Manual 7-17 PN: 9001160B GLOSSARY GLOSSARY AC (Alternating Current) Electrical current that reverses its direction regularly and continually. Accessory An optional assembly that may be used to provide an additional function. Active Tags RFID tags which use batt...