"service manual"
Contents
1. INTRODUCTION General Description 1 1 Theory of Operation 1 1 Switches and Indicators 1 2 Connection Ports 1 3 Monitoring Sensors 1 4 Operational System 1 5 ACCESSORIES INSTALLATION Cutter Attachment 2 1 Dispenser Attachment 2 3 Font Module 2 5 Firmware Upgrade 2 5 OPERATIONAL SETUP Media Loading 3 1 Ribbon Loading 3 2 Input Output Connections 3 3 Media Sensor Calibration 3 3 Media Index Sensor Calibration 3 4 Dispenser Sensor Calibration 3 4 TROUBLESHOOTING Problem Isolation 4 1 Self Diagnosis Label 4 2 MAINTENANCE Cleaning 5 1 Print Head Replacement 5 1 Main Circuit Board replacement 5 3 Platen Roller Replacement 5 6 TECHNICAL DATA Physical Properties 6 1 Enviromental Specifications 6 1 Power requirements 6 1 Printer Performance 6 1 Printer Specifications 6 1 SATO CX 400 Service Manual TECHNICAL DATA Media Specifications 6 2 Ribbon Specifications 6 2 Serial Interface Specifications 6 2 Regulatory Approvals 6 3 BLOCK DIAGRAMS System Block Diagram 7 1 Control Board Block Diagram 7 2 Panel Board Schematic 7 2 Sensor Board Schematic 7 3 Main Board Wiring Diagram 7 3 SATO CX400 Service Manual INTRODUCTION This manual is laid out in a manner consistant with the product discussed and provides all of the information required for general printer setup operation troubleshooting and maintenance For special2. NAVAS DCS amp Labeling Worldwide CX400 DESKTOP PRINTER SERVICE MANUAL SATO GROUP OF COMPANIES BARCODE SATO INTERNATIONAL PTE LTD 438A Alexandra Road 05 01 02 Alexandra Technopark Singapore 119967 Tel 65 6271 2122 Fax 65 6271 2151 Website www barcodesato com Email sales sato int com SATO AMERICA INC 10350 Nations Ford Road Suite A Charlotte NC 28273 Tel 1 704 644 1650 Fax 1 704 644 1662 Website www satoamerica com Email satosales satoamerica com SATO UK LTD Valley Road Harwich Essex England Co12 4RR United Kingdom Tel 44 1255 240000 Fax 44 1255 240111 Website www satouk com Email enquiries satouk com SATO EUROPE NV Leuvensesteenweg 369 1932 Sint Stevens Woluwe Brussels Belgium Tel 32 0 2 788 80 00 Fax 32 0 2 788 80 80 Website www sato europe com Email info sato europe com SATO DEUTSCHLAND GMBH Schaberweg 28 61348 Bad Homburg Germany Tel 49 0 6 1726 8180 Fax 49 0 6 1726 818 199 Website www sato europe com Email info sato europe com SATO POLSKA SP Z 0 0 UI Okolna 2 50 422 Wroclaw Tel 48 7 1 335 23 20 Fax 48 71 335 23 25 Website www sato europe com Email info sato europe com SATO SHANGHAI CO LTD 11 Floor D Pudong South Road 1111 Pudong New Area Shanghai China 200120 Tel 86 0 21 58307080 Fax 86 0 21 58307978 Website www barcodesato com Email sales satochina com BAR CODE SATO ELECTRONICS S PTE LTD 43
3. REGULATORY APPROVALS FCC Class B CE TUV CCC and UL Page 6 2 PN 9001110A SATO CX400 Service Manual BLOCK DIAGRAMS Panel Board IEEE 1284 Ribbon Sensor SPP fm O 7 f o N fm O 2 a 2 Q Thermal Print Head RS232 Main Board 9 pin Media Sensor Stepping Motor Print Head Open Sensor External AC Adaptor System Block Diagram Figure 7 1 SATO CX400 Service Manual PN 9001110A Page 7 1 Section 7 Block Diagrams Schematics CS7 Input Port Data Flash ROM 74374 IEEE1284 SPP P1 U8 U9 U13 Cutter Baby Board JP29 PE Fault CS4 High Output Port DRAM U10 SVO SYY D15 8 a 74374 o gt 2 3 2 5 U11 o lt 2 3 wW E n Driver Pi Motor U16 U17 gt JP17 Expansion Slot JP11 Configuration Low LED Output Port gt JP16 74374 U15 Paper Sensor Control JP2 JP15 24 Volt Relay RY2 veOLHS Nd RS232 Transceiver gt RS23 EEPROM SP232ACT P2 U7 U2 Feed Key JP16 Paper Sensor JP15 Ribbon Sensor JP14 Booter Normal Dispenser Sensor Cutter Sensor JP13 Motor T M JP4 Jumper JP7 JP5 Thermal Print Head JP18 Control Board Block Diagram Figure 7 2 HEADER 6 S1 Key O O aaa 5V GND RG Panel Board Schematic Figure 7 3 Page 7 2 PN 9001110A SATO CX400 Service Manual Section 7 Block Diagrams Sc
4. and performance monitors for instant status output The red error LED and the green power LED work in conjuction to provide all of the status information required The following table provides status identification Red and green blink together Media index failure or media out Ensure media is present correctly loaded and not jammed Calibrate printer Ensure the media sensor is functioning Red and green blinking alternately Ribbon error Ensure ribbon is present correctly loaded and not jammed e Calibrate printer Ensure ribbon sensor is functioning Green constant and red blinking with long on and short off Print head is open Close print head Red and green blinking at 50 of normal intensity RS232 error Ensure computer and printer baud rates are comparable Ensure computer and printer data bits are comparable Ensure computer and printer parity bits are comparable Red and green lights are not illuminated Power source is interupted Ensure power switch is in On position Ensure source power Ensure power supply adaptor fuse is not blown Test power switch Inspect wiring harnesses and power supply adaptor Substitute power supply adaptor Replace circuit board Label will not feed Ensure media is correctly loaded Ensure the power is on the error indicator is
5. below provides instructions on print head replacement CAUTION Printer electronics are susceptable to static discharge Ensure appropriate grounding measures are taken before beginning any activity inside the printer 1 Turn off power and disconnect power supply cord 2 Lift cover Figure 5 1 1 to expose print assembly 2 3 Simultaneously press the two purple buttons located on the top side of print assembly 2 and pivot upward 5 Remove the ribbon from the rewind spool to expose the print head assembly 3 6 Press downward on the upper right side of the print head assembly 3 and manipulate the unit free SATO CX400 Service Manual PN 9001110A Page 5 1 Section 5 Maintenance Remove the two screws 4 securing print head bracket 5 to print head cover 6 and separate Remove the two screws 7 securing print head 8 to print head cover 6 Disconnect the wiring harnesses from print head 8 Lift away print head 8 10 11 12 13 14 15 16 17 Prepare to install replacement print head 8 Connect replacement print head 8 to wiring harnesses Orient replacement print head 8 within cover 6 and secure using screws 5 Apply bracket 5 onto print head cover 6 and secure using two screws 4 Manipulate print head assembly 4 into print assembly 2 with the left side first Reapply printer ribbon as required and latch print assembly 2 for operation Close c
6. face of housing 5 oriented with the I position up Lower and latch print assembly 2 into operational position Close cover 1 connect power supply cord switch power on and test cycle Expansion Slot JP12 EEE mmm External Connector E aa aa JP14 Ribbon Sensor _ a JP15 Eye Mark Sensor Gap Sensor Jp24 JP2 1 r JP11 Print Head Open Sensor al Panel Board Motor _ JP17 JP18 Fr i He g Print Head nn m aa S Circuit Board Replacement Figure 5 4 SATO CX400 Service Manual PN 9001110A Page 5 5 Section 5 Maintenance PLATEN ROLLER REPLACEMENT The platen roller is high a wear part It is advised that a spare be kept on standby to ensure that print production continues unimpeded The procedure below provides instructions on platen roller replacement CAUTION Printer electronics are susceptable to static discharge Ensure appropriate grounding measures are taken before beginning any activity inside the printer 1 Turn off power and disconnect power supply cord 2 Lift cover Figure 5 5 1 to expose print assembly 2 3 Simultaneously press the two purple buttons 3 located on the top side of print assembly 2 and pivot upward 4 Remove applicable front cover attachment not shown NOTE Ifthe unit has the optional cutter module installed it may be removed via a single screw located on the top right
7. off then press the feed button Disconnect the communication cable and press the feed button If the printer feeds with the cable disconnected there is either a defect in the host computer or its cable SATO CX400 Service Manual PN 9001110A Page 4 1 Section 4 Troubleshooting Labels feed continuously Ensure media is correctly loaded and that the gap mark goes through the media sensor Ensure the sensor setup matches the media used Reprogram as necessary Poor print quality Clean the print head Ensure the media is correctly loaded and without lateral movement while being fed Ensure print darkness and print speed settings are sufficient for optimum results Test cycle using a different print media to determine if the media is of inferior quality Ensure the labels are of the correct type for the setup Host stops responding or displays printer not ready message Ensure the communication cable is connected and not defective e If through serial port ensure that a null modem cable or adaptor is used and that the host and printer share the same protocol settings Determine by the self test label If a communication switch is being used remove the switch and connect directly to the host Ensure a correct software setup Refer to software instructions for guidance Restart both the printer and the host run the original
8. side of the cover If the peeler cover is installed two screws located at the hinge must be removed N N N N A 2 N NU NN N WS Platen Roller Replacement Figure 5 5 Page 5 6 PN 9001110A SATO CX400 Service Manual 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Section 5 Maintenance Pry power switch 4 free from housing 5 and disconnect leads Remove the two screws 6 securing housing 5 to printer base 7 Manipulate housing 5 free from base 7 and lift away NOTE Pull the lower front edge of the middle cover away from the base assembly then begin manipulating the housing upward CAUTION Take note of the location and orientation of components as they are removed to assist in reassembly Remove e clip Figure 5 6 8 from the face of gear 9 Withdraw gear 9 Remove screws 10 from printer chassis 11 retaining each end of platen roller 12 CAUTION This platen incorporates the use of two different bushing sizes three of one size and a single bushing of the other Their size difference is not distinguishable to the eye If they are mixed a caliper will be required to identify which is the odd size Manipulate platen roller 12 fully to the right and withdraw outermost bushing 13 from its right shaft and then fully to the left to remove outermost bushing 14 from its l
9. when a malfunction has occured Power Indicator Error Indicator Feed Button Power Switch DETAIL Switches and Indicators Figure 1 2 CONNECTION PORTS Parallel Port Located on the left rear side of the printer Permits PC connection for advanced programming control and operation Serial Port Located on the right rear side of the printer Converts the serial port signal to from the micro controller to RS232 voltage level Also permits PC connection for advanced programming control and operation VAC Power Supply Port Located centrally on the rear of the printer Permits the connection of the voltage supply transformer SATO CX400 Service Manual PN 9001110A Page 1 3 Section 1 Introduction CONNECTION PORTS Extension Connection Port Accessible from the front of the printer and is located behind the face cover Permits the connnection of optional extension modules Front View ote A ER Serial Port VAC Power Supply Port Parallel Port Extension Port Rear View Connection Ports Figure 1 3 MONITORING SYSTEMS Media Index Sensor Determines the print location upon the label by detecting a label gap or eye mark and then stepping the media to the print position Ribbon Sensor Allows the printer to continuously monitor the presence of ribbon when operating in the thermal transfer mode Dispenser Sen
10. 8A Alexandra Road 05 01 02 Alexandra Technopark Singapore 119967 Tel 65 6271 5300 Fax 65 6273 6011 Website www barcodesato com www satosingapore com Email sales satosingapore com SATO BAR CODE amp LABELLING SDN BHD Suite B 08 11 amp 12 Block B Plaza Mont Kiara No 2 Jalan Kiara Mont Kiara 50480 Kuala Lumpur Malaysia Tel 60 3 6203 5950 Fax 60 3 6203 1209 Website www barcodesato com Email sales satosbl po my BARCODE SATO THAILAND CO LTD 370 8 Supattra Building 5th Floor Rama9 Road Bangkapi Huay Kwang Bangkok 10320 Thailand Tel 662 719 7780 3 Fax 662 719 7784 Website www barcodesato com Email sales satothailand co th 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 television reception requiring the operator to take whatever steps nec essary to correct the interference All rights reserved This document nor any part of it may be reproduced or issued to third parties in any form without the express permission of SATO America Inc The material in this document is provided for general information only and is subject to change without notice SATO America Inc does not assume responsibility for any errors or omissions 06 Nov 03 TABLE OF CONTENTS
11. N 9001110A Page 4 3 Section 4 Troubleshooting Page 4 4 PN 9001110A SATO CX400 Service Manual MAINTENANCE CLEANING During general use atmospheric debris will work its way into the unit Ribbon and paper debris will also accumulate on its moving parts Periodic cleaning is manditory to ensure proper function and long life Typically fading of the printed image is the first sign that the unit requires cleaning As the debris continues to build up the image will become increasing lighter It is highly recommended that this be prevented by the initiation of a cleaning schedule if regular or intensive use is forecast Turn off power switch and disconnect power supply cord Lift top cover to expose print assembly Simultaneously press the two purple buttons located on the top side of print assembly Pivot printer assembly upward to expose printer chassis Remove the printer ribbon and print media from the unit Wipe or vacuum away larger loose debris Moisten a cotton swab with isoprophl alcohol and wipe the print head and rollers clean CON OOF WN gt Dry with a soft dry material CAUTION Harsh cleaners must not be used Mediums containing Hexane also must not be used as it will negatively react to plastic PRINT HEAD REPLACEMENT The print head is a high wear part It is advised that a spare be kept on standby to ensure that print production continues unimpeded The procedure
12. discharge Ensure appropriate grounding measures are taken before beginning any activity inside the printer 1 Turn off power and disconnect power supply cord Lift cover Figure 2 1 1 to expose print assembly 2 Simultaneously press the two purple buttons located on the top side of print assembly 2 and pivot upward WO N Remove the two screws 3 securing front cover 4 to cover hinge 5 If peeler 6 is present remove screw 7 and manipulate rightward Lift away peeler 6 Pry power switch Figure 2 2 8 from housing 9 and disconnect leads Remove the two screws 10 securing housing 9 to base assembly 11 Manipulate housing 9 from base assembly 11 and lift away CON DOO fF NOTE Pull the lower front edge of the housing away from the base assembly then begin manipulating the housing upward 9 Plug daughter board not shown into port JP29 of mother board 12 10 Direct the two leads of daughter board through the power switch slot of housing 9 11 Tuck the prior two power switch leads safely away within the housing unconnected 12 Manipulate housing 9 onto base assembly 11 oriented as was removed 13 Secure housing 9 to base assembly 11 using two screws 10 14 Plug power switch 8 into the two leads of daughter board SATO CX400 Service Manual PN 9001110A Page 2 1 Section 2 Accessories Installation 15 Insert power switch 8 i
13. e has been selected for use The correct one must be selected by printer commands or through the application software Print Mode 8 Identifies the print mode setting TT Thermal Transfer and DT Direct Thermal Last Label Tear Off 9 Indicates whether the back feed function is utilized for tearing off printed labels Control Code Denifition 10 Displays the control code setting Control codes affect the commands and special controls Pitch Offset 11 The offset value affects the start print position in relation to the label s leading edge Cut Count 12 On board counter of the total cut sequences Permits monitoring of component life cycles Memory Slot 1 13 Provides on board non volatile flash memory for storing graphics font characters etc 512K bytes Memory Slot 2 14 Optional on board non volatile flash memory for storing graphics font characters etc 2M or 4M bytes SATO CX400 Service Manual ATR TRU tt ASE i RA Boat ET OG Det NR ro at KG 03 91 21 V 98 0089 COMM 680 N 8 1 DARKNESS COARSE 2888 FINE 206 INCHES PRINTED 90005207 PRINT SPEED 2 IPS INDEX NONE PRINT MODE TT LAST LABEL TEAR OFF OFF STX 82 ETX 83 ESC 1B NULL 88 OFFLINE 49 PITCH OFFSET 19 mm CUT COUNT 49999 MEM SLOT 1 524288 BYTES INSTALLED MEM SLOT 2 8 BYTES INSTALLED HEX DUMP MODE CYCLE POWER FOR NORMAL MODE Self Diagnosis Label Figure 3 1 P
14. e to ensure that despenser sensor 10 wire is oriented so that it is not being pinched CAUTION Ensure that the left clip does not pinch the sensor wire as it passes through the cover mounting brackets 11 Plug dispenser sensor 10 into external connection port 12 12 Apply wire clamp 13 to sensor 10 wire 13 If not already present insert dispenser 14 into the mounting slots of printer chassis 15 oriented so that their mounting orifices are aligned NOTE The dispenser must be inserted into the right side slot first then manipulated into the left slot The peeler mounting orifice is located on the front right side of the printer chassis above the external connection port 14 Secure dispenser 14 and clamp 13 using screw 15 15 Ensure that print media and ribbon are properly loaded in the printer 16 Lower and latch print assembly 2 into operational position 17 Close cover 1 connect power supply cord and apply power 18 Set the EZPROM through commands lt ESC gt A lt ESC gt CKO lt ESC gt Z FONT MODULE The font module stores special font types and characters The maximum capacity options of the font module is 2 M or 4 M bytes FIRMWARE UPGRADE The printer s operating systems software may be upgraded or reloaded through the parallel port located on its back side Connect the parallel interface cable supplied with the printer to the computer LPT1 port and the p
15. eed it through the discharge slot of cover 5 Lower and press print head assembly into operational position O O NOg When the error LED stops blinking press the feed button to begin printing SATO CX400 Service Manual PN 9001110A Page 3 1 Section 3 Operation Media Loading Figure 3 1 RIBBON LOADING Perform the following procedure only if thermal transfer printing is desired If thermal transfer printing is desired program the printer accordingly Refer to the Programming Manual for guidance 1 Lift cover Figure 3 2 1 to expose print assembly 2 2 Simultaneously press the two purple buttons 3 located on the top side of print assembly 2 and pivot upward 3 Place ribbon roll 4 between ribbon supply spindles 5 so that the coated side is oriented outward NOTE The coated side has the duller sheen If still unsure scratch each side to determine which is coated NOTE The ribbon supply spindle is located on the lower side of the print assembly Page 3 2 PN 9001110A SATO CX400 Service Manual Section 3 Operation NOTE The ribbon cores and spindles for supply and take up are notched When a core is properly installed it will nest with its respective spindle 4 Feed enough of ribbon 4 out so as to insert take up core 6 onto rewind spindles 7 5 Advance purple thumbwheel 8 of rewind spindles 7 to take up ribbon slack Ribb
16. eft shaft Lift out the right end of platen roller 12 and then withdraw the left end from chassis 11 Remove remaining bushings 15 from each end of platen roller 12 Prepare to reassemble the unit Apply a single bushing 15 to each end of platen roller 12 Insert the longer end of roller 12 fully into the left orifice of chassis 11 and then manipulate the shorter end into the right orifice of the chassis Apply from the exterior of chassis 11 remaining bushings 14 and 13 to the left and right ends of platen roller 12 respectively Secure the assembly in place with one screw 10 on each end Insert gear 9 onto the left shaft of platen roller 12 and secure using e clip 8 Manipulate housing Figure 5 5 5 over printer chassis 9 down to rest on printer base 7 Secure housing 5 to printer base 7 using two screws 6 applied from the underside Reattach the applicable cover and or attachment Connect power switch 4 to its respective leads and insert into face of housing 5 oriented with the on position up Lower and latch print assembly 2 into operational position Close cover 1 connect power supply cord switch power on and test cycle SATO CX400 Service Manual PN 9001110A Page 5 7 Section 5 Maintenance Platen Roller Replacement Figure 5 6 Page 5 8 PN 9001110A SATO CX400 Service Manual TECHNICAL DATA All technical data deemed pertinent has been tabulated below for q
17. eration The CX 400 printer is delivered factory calibrated and should not require calibration upon initial setup However the use of off brand media or ribbon often has an adverse operational effect Thusly load the consumables and attempt operation to determine if calibration is necessary MEDIA LOADING Media must be loaded and in the same manner regardless of whether direct thermal or thermal transfer printing is to be performed However following media installation ensure that the correct printer program is also loaded NOTE To assist in the instruction of media loading the print assembly has been removed from the illustration below to provide a better view of more important features The actual printer will have the print assembly attached The print assembly is not removable 1 Lift cover Figure 3 1 1 to expose the print assembly 2 Simultaneously press the two purple buttons located on the top side of the print assembly and pivot upward 3 Unwrap the new media 2 and unwind a few labels from the roll 4 Separate paper roll holder 3 and insert media roll 2 so that it unwinds from the bottom 5 Lock paper roll holder 3 into position by the downward movement of the purple switch attached Separate purple paper guides 4 and feed media 2 across chassis between them Slide paper guides 4 together to make light contact with each side of media 2 Pull media 2 forward and f
18. from base 7 and disconnect wiring harness NOTE Pull the lower front edge of the housing away from the base assembly then begin manipulating the housing upward 8 Remove the four screws Figure 5 3 8 securing printer chassis 9 to printer base 7 9 Disconnect all wiring harnesses from mother board 11 10 Remove the four screws 10 securing main circuit board 11 to printer base 7 11 Prepare to replace main circuit board 11 12 Place replacement circuit board 11 into base 7 oriented so that mounting holes are aligned and secure using four screws 10 13 Connect all wiring harnesses to replacement circuit board 11 as was removed 14 Place printer chassis 9 onto base 7 oriented so that mounting holes are aligned and secure using four screws 8 T Circuit Board Replacement Figure 5 3 Page 5 4 PN 9001110A SATO CX400 Service Manual 15 16 17 18 19 20 Section 5 Maintenance CAUTION Before securing the printer chassis to the base ensure that the power switch and light leads are routed to the right of the unit and such that they are not being pinched Manipulate housing 5 over printer chassis 9 down to rest on printer base 7 Secure housing 5 to printer base 7 using two screws 6 applied from the underside Reinstall applicable front cover attachment Connect power switch 4 to its respective two leads and insert into
19. he systems configuation Boot Normal Is a two position switch that when in the normal position allows the program on the expansion board to be executed only after the power has been reset When in the boot position the boot program will be executed first This permits the CPU to reload a program into the on board Flash ROM after complete corruption The default setting is in the normal position SATO CX400 Service Manual PN 9001110A Page 1 5 ACCESSORIES INSTALLATION Optional accessories are those hardware and software items that may be purchased and used in conjunction with the basic printer package Namely these are the cutter attachment dispenser attachment and font module Since the hardware options affect the method of operational setup they must be installed prior to any setup activities If applicable refer the relative procedure below for specific instructions on accessory installation before proceeding to the Operational Setup unit CUTTER ATTACHMENT The cutter assembly is an attachment for the automated cutting of labels tags or tickets A back feed function is included for retracting the label back to the first print position after cutting The following procedure provides detailed instructions on cutter assembly installation and assumes that the unit is without additional attachments that may pose an impediment to cutter installation CAUTION Printer electronics are susceptable to static
20. hematics OC1 1 3 a _ 2 4 R359F Sensor Board Schematic Figure 7 4 Panel Board Motor Thermal Sensor A y MAIN BOARD Print Head Open JP24 Sensor Thermal Print Head JP12 JP13 y AC Media IR Ribbon Adaptor Sensor LED Sensor Connect Sensor Board 19 VAC Board Board Board JP1 Print Head Open Cutter Module Sensor Main Board Wiring Diagram Figure 7 5 SATO CX400 Service Manual PN 9001110A Page 7 3 Section 7 Block Diagrams Schematics Page 7 4 PN 9001110A SATO CX400 Service Manual
21. ized programming refer to the Programming Manual also provided with the product GENERAL DESCRIPTION SATO CX400 printers are compact desktop printers designed especially for bar code labeling and tagging The CX uses SATO Command Language making it simple to integrate with other SATO models Designed for convenience the CX has many advanced features such as larger media capacity user replaceable print head and platen a high lift print head carriage that makes it easy to clean and load supplies The printer is also designed to use eye mark or gap label sensing The CX400 uses a single sensor element for both direct thermal and thermal transfer printing The printing method may be selected by using configuration settings in the software program or by sending the commands directly to the printer The current setup may be determined by printing a self test label which identifies all setup parameters A slot in the rear of the unit permits external feeding of media for larger rolls with greater linear feet THEORY OF OPERATION When activated the media and ribbon where applicable are fed conjunctively past the print head by an integrated drive train The drive train is electric motor driven coupled to a gear configuration located on the left side of the printer chassis Paper guides within the chassis assembly ensure that the media remains properly positioned during the printing process and is fed unimpeded through the front cover The exhau
22. nter electronics are susceptable to static discharge Ensure appropriate grounding measures are taken before beginning any activity inside the printer SATO CX400 Service Manual PN 9001110A Page 2 3 Section 2 Accessories Installation 1 Turn off power and disconnect power supply cord 2 Lift cover 1 to expose print assembly 2 3 Simulataneously press the two purple buttons located on the top side of print assembly 2 and pivot upward 4 Remove the two screws 3 securing cover 4 to cover hinge 5 and lift away 5 Remove clips 6 and 7 from the left and right ends of roller shaft 8 respectively NOTE Before removing the retaining clips from each end of the roller shaft it is advised that their orientation be observed and noted REARVIEW Dispenser Installation Figure 2 3 Page 2 4 PN 900 1110A SATO CX400 Service Manual Section 2 Accessories Installation Manipulate roller shaft 8 with roller 9 from front cover 4 Apply sensor 10 to cover 4 as design dictates and secure using screw 11 Insert the connector end of sensor 10 through the left bracket of cover 4 Insert roller shaft 8 into roller 9 and manipulate into brackets of cover 4 O O ON O Secure the roller assembly with clips 7 and 6 to the right and left ends of shaft 8 respectively 11 Reapply cover 4 to cover hinge 5 and secure using screws 3 10 Observ
23. nto its respective slot of housing 9 oriented with the on position upward 16 Plug cutter assembly lead 13 into external connector 14 17 Manipulate cutter assembly 15 into the face of printer chassis 16 18 Secure cutter assembly 15 to printer chassis 16 by applying screw 17 to their upper right corner NOTE When properly installed the tab of the cutter assembly bracket shall insert into the slot of the printer chassis and the cutter will nest there as the peeler cover prior to removal Cutter Installation Figure 2 1 19 Ensure print media and ribbon are properly loaded in the printer 20 Lower the print assembly and latch in position 21 Close cover connect power supply cord and apply power 22 Send the following command stream to enable lt ESC gt A lt ESC gt CK1 lt ESC gt Z Page 2 2 PN 9001110A SATO CX400 Service Manual Section 2 Accessories Installation DETAIL Cutter Installation Figure 2 2 DISPENSER ATTACHMENT The dispenser assembly incorporates an integrated label sensor as part of the monitoring feature The sensor identifies the presence of a label and prevents the printing of the next label until it is removed The following procedure provides detailed instructions on dispenser and dispenser sensor installation The procedure assumes that the unit is without additional attachments that may pose an impediment to sensor installation CAUTION Pri
24. on Loading Figure 3 2 INPUT OUTPUT CONNECTIONS For typical operation the voltage power transformer is the only required connection Its connection port is centrally located on the rear of the printer Refer to the Introduction unit of this manual for specific identification if necessary The parallel and serial ports are required for sending commands and data from the host to the printer Instructions for their use may be found in the Programming manual Their locations are also in the rear of the printer MEDIA SENSOR CALIBRATION The media dispenser sensor monitors media presence When the print media is exhausted the sensor signals an error condition If the sensor incorrectly detects the presence of print media available for use the dispenser sensor may require calibration Perform the applicable steps below relative to the media type used SATO CX400 Service Manual PN 9001110A Page 3 3 Section 3 Operation For Eye Mark Detection 1 Install both printer ribbon and print media while in the TT mode 2 Send the following commands to the printer lt ESC gt A lt ESC gt amp 11 lt ESC gt Z 3 Allow 5 seconds for the printer to complete the process For Label Gap Detection 1 Install print media into the printer while 2 Place the printer in the TT mode by sending lt ESC gt A lt ESC gt CP1 lt ESC gt Z 3 Send the following commands to the printer lt ESC gt A lt ESC gt amp 10 lt ESC gt Z 4 Allow 5 seconds for the printe
25. over 1 connect power supply cord and switch power on Test cycle for proper function Print Head Replacement Figure 5 1 Page 5 2 PN 9001110A SATO CX400 Service Manual Section 5 Maintenance MAIN CIRCUIT BOARD REPLACEMENT The circuit board should never require replacement except in the event of an electrical failure Therefore ensure that the component failure is not sourced elsewhere prior to circuit board removal CAUTION Printer electronics are susceptable to static discharge Ensure appropriate grounding measures are taken before beginning any activity inside the printer 1 Turn off power and disconnect power supply cord 2 Lift cover Figure 5 2 1 to expose print assembly 2 3 Simultaneously press the two purple buttons 3 located on the top side of print assembly 2 and pivot upward 4 Remove applicable front cover attachment NOTE If the unit has the optional cutter module installed it may be removed via a single screw located on the top right side of the cover If the peeler cover is installed two screws located at the hinge must be removed Pull Outward and Lift Here Circuit Board Replacement Figure 5 2 SATO CX400 Service Manual PN 9001110A Page 5 3 Section 5 Maintenance 5 Pry power switch 4 free from housing 5 and disconnect leads 6 Remove the two screws 6 securing housing 5 to printer base 7 7 Manipulate housing 5
26. r to complete the process 0 06 1 5mm NON PRINT 0 75 19mm 0 25 5 0mm i N GAP NOTCH OR BAR WIDTH MIN 0 04 2mm MAX 1 0 25mm PRINT HEAD MIN LABEL PITCH EYE MARK ON gerne en 0 39 10mm BOTTOM OF LINER 0 59 15mm BACKING PAPER INSIDE EDGE LABEL INSIDE EDGE 0 06 1 5mm NON PRINT NOILOJYIG 0333 1391 Figure 3 3 Label Stock Diagram Page 3 4 PN 900 1110A SATO CX400 Service Manual Section 3 Operation MEDIA INDEX SENSOR CALIBRATION CX 400 Printers can use an eye mark black bar label gap or label notch sensing The gap and notch sensor is a transmissive or see thru type with an infrared light source directed through the label from above and detected by a separate receiving sensor underneath the label liner tag A reflective sensor is used to detect eye marks printed on the bottom of the label liner or tag The eye mark must not reflect more than 12 of the light Since the same receving sensor is used for all three types of sensing it must be calibrated with the media that will be used For thermal transfer printing the ribbon must be installed while the calibration is performed Media sensor calibration may also be required if the printer frequently fails to print has excessive print position variance or the print image is mis located Calibration may be performed by either clicking on the calibration buttons of the Label Gallery Free software through the Windo
27. rinter parallel port Place the Firmware upgrade disk in the computer and follow the instructions in the Readme TXT file SATO CX400 Service Manual PN 9001110A Page 2 5 Section 2 Accessories Installation Load the printer with ribbon and media as required Turn the printer on and allow 3 seconds to power up Enter the MS DOS mode on the computer Type X SATO were X is the location fo the Firmware Upgrade file at the DOS prompt Allow 5 minutes for the power and error LED s to begin blinking in synchronicity Toggle the power switch off and then on again to complete the process Press and hold the printer feed button until it begins printing a self testing label Switch the printer off and then on again to return to operation mode Examine the self test label contents to ensure a correct upgrade or reload Repeat as necessary until the printed check sum is 0000 Disconnect computer from the parallel port O O ON DOA O N gt a NOTE The check sum value should always be 0000 Otherwise there are error bits in the onboard flash memory The sum value is the last four characters printed in the upper left row of the self test label Refer to Self Diagnosis in the Troubleshooting section of his manual if still unsure Page 2 6 PN 9001110A SATO CX400 Service Manual OPERATIONAL SETUP is section provides all guidance and instructions necessary for simple printer setup an op
28. software and try again Self test label will not print Ensure that the correct media has been loaded Disconnect the communication cable restart printer attempt to print again PRINTER SELF DIAGNOSIS A simple self diagnosis may be initiated by either a series of printer commands or activated via the feed button located on the printer face Upon activation of the self diagnosis process the printer will print a label identifying various parameters and conditions as they exist within the system The table below defines the parameters and conditions identified on the self diagnosis label SELF DIAGNOSIS LABEL Image Pattern 1 Used to check the print head motor roller and other mechanical assemblies Version Information 2 Includes the date code firmware version and the check sum value RS232 Protocols 3 Contains the baud rate parity data bit number and the number of stop bits Darkness 4 Provides the darkness setting May be altered through printer commands Print Length 5 On board memory of the total linear length of print activity This non resettable feature permits monitoring of component life cycles and warranty validation Print Speed 6 Identifies the print speed setting The default speed is 3 ips Page 4 2 PN 9001110A SATO CX400 Service Manual Section 4 Troubleshooting Media Sensor Used 7 Identifies which media sensor typ
29. sor Monitors the presence of a label in the dispenser When the label is removed from the dispenser the next label will be prompted Print Head Open Sensor Detects when the print assembly is not latched into the print position Page 1 4 PN 9001110A SATO CX400 Service Manual Section 1 Introduction OPERATIONAL SYSTEMS MicroController The SH7034 microcontroller utilizes a 16 bit external and 32 bit internal data bus based on the Hitachi SH1 Flash Memory Has 2M bytes of Flash ROM located on the main board for Firmware character and bar code font storage The flash ROM has a total size of 1M x 16 bit DRAM The 2 MB of DRAM is located on the main board Volatile data such as working buffers and parameters are allocated here EEPROM On board memory is 128 Bytes RS232 Transceiver Converts the serial port signal to and from the microcontroller to the RSR232C voltage levels Centronics Interface The data recieved from the host is transmitted to the micro controller Ouput Ports The ports control the motor LED media sensor 24 volt relay and interface fault conditions Relay Removes the 24 volt supply to the thermal print head during the transient period while the power is being switched on Otherwise the thermal print head may be damaged Extension Connection Port Permits the connnection of all optional extension modules Configuration Jumper Selects t
30. sted ribbon material is rewound onto a take up core installed within drive train driven spindles A series of strategically located sensors sends signals to the processing unit The processing unit in turn sends response signals to the various features based on programmed and recieved data Correct signals initiates print head activity SATO CX400 Service Manual PN 9001110A Page 1 1 Section 1 Introduction Cover T Printer Assembly I Print Head Assembly Chassis Assembly Paper Holder me y ON i DE lt A Housing d DEER ann Y AE Paper Guides Base gt n Front Cover Platen Roller Primary Components Figure 1 1 SWITCHES amp INDICATORS Power Switch A two position switch that controls power to the printer When the 0 position is pressed power is removed from the printer When the 1 position is pressed power is supplied to the printer Feed Key Press and hold during startup for test label Press during printing to pause Press during pause to feed a blank label or print the duplicate of the prior label Press to reset the printer to the factory settings Power Indicator Continuously illuminated when functional Blinks when a malfunction has occured Page 1 2 PN 900 1110A SATO CX400 Service Manual Section 1 Introduction SWITCHES amp INDICATORS Error Indicator Not illuminated when the printer is operational Blinks
31. uick reference Find the relative section header and then locate the specific type of technical data in the left column PHYSICAL PROPERTIES Dimensions 7 76 197mm x 10 2 257mm x 6 5 164mm Weight 3 67kg Including power module ENVIROMENTAL SPECIFICATIONS Operating Temperature 5 to 40 C Storage Temperature 20 to 60 C Operating Humidity 25 to 85 RH Non Condensing Storage Humidity 25 to 85 RH Non Condensing POWER REQUIREMENTS Source Voltage to Power Module 120 VAC 60 Hz 90 W Supply from Power Module 19 VAC Operational Power Consumption 70 W Standby Power Consumption Less than 2W PRINTER PERFORMANCE Print Speed 1 2 3 4 ips Resolution 203 Dots per Inch 3 domm Maximum Print Width 4 1 104mm Maximum Print Length 50 1270mm PRINTER SPECIFICATIONS Print Method Thermal Transfer or Direct Thermal Onboard CPU Hitachi SH7034 16 Bit External 32 Bit Internal Integrated CLock 20M Hz 26 MIPS Panel Features Green Power LED Red Error LED Feed Button DRAM 2MB Flash ROM 2MB Additional Memory 2 or 4 MB Flash ROM SATO CX400 Service Manual PN 9001110A Page 6 1 Section 6 Technical Data PRINTER SPECIFICATIONS Onboard Sensors Media Index Reflecti
32. ve or Gap Eye Mark Ribbon Out Sensor Print Head Open Text Fonts U S M WB WL XU XS XM XB XL OCR A B Text Rotation 0 90 180 270 Degrees Four direction rotational Graphics Formats SATO Hex Binary PCX Graphics Rotation 0 90 180 270 Degrees Bar Code Capabilities UPC A E EAN8 13 EAN128 Code 39 Code 93 Code 128 MSI 125 M25 Codabar PDF417 UCC128 Postnet Bookland MaxiCode Interface Connections RS 232C Serial Interface Port w DB9 S Connector IEEE 1284 Compatible Parallel Interface Port AC Power Module 120 VAC Input 19 VAC Output Class 2 Wall Mounting Brackets Located on bottom for anchor mounting to wall MEDIA SPECIFICATIONS Media Type Direct Thermal Paper or synthetic label or tag Thermal Transfer Paper or synthetic label or tag Maximum Label Roll Diameter 5 127mm Label Roll Core Diameter 0 75 19 05mm Minimum Inter label Gap 0 08 2mm Maximum Inter label Gap 1 25 4mm RIBBON SPECIFICATIONS Ribbon Material Wax resin or combination Maximum Ribbon Roll Diameter 1 50 38mm Maximum Ribbon Length 100m Ribbon Roll Core Diameter 0 72 18 4mm SERIAL INTERFACE SPECIFICATIONS Interface Type RS 232C Port w DB9 S Connector Speed 9600 19200 or 38400 Baud Parity Odd Even or None Data Bits 7or8 Stop Bits 1or2 Default Parameters 9600 Bauds No Parity 8 Data Bits 1 Stop Bit
33. ws Printer Driver or more directly by sending printer commands to the printer To signify a successful calibration the printer will feed 6 linear inches of label upon completion Perform the applicable steps below relative to the media type used For Eye Mark Detection 1 Install both printer ribbon and print media while in the prper mode DT or TT 2 Send these commands to the printer lt ESC gt A lt ESC gt Cl1 lt ESC gt CA lt ESC gt Z 3 Allow the printer to feed 6 linear inches of labels to complete the calibration For Label Gap Detection 1 Install the print media while in the TT mode 2 Send these commands to the printer lt ESC gt A lt ESC gt CI2 lt ESC gt CA lt ESC gt Z 3 Allow the printer to feed 6 linear inches of labels to complete the calibration DISPENSER SENSOR CALIBRATION For Thermal Transfer 1 Place a label in the discharge slot over the sensor 2 Send the following commands to the printer lt ESC gt A lt ESC gt amp P1 lt ESC gt Z 3 Allow 5 seconds for the printer to complete the process For Direct Thermal 1 Place a label in the discharge slot over the sensor 2 Send the following commands to the printer lt ESC gt A lt ESC gt amp PO lt ESC gt Z 3 Allow 5 seconds for the printer to complete the process SATO CX400 Service Manual PN 9001110A Page 3 5 Section 3 Operation Page 3 6 PN 9001110A SATO CX400 Service Manual TROUBLESHOOTING The CX400 label printer has integrated systems
Download Pdf Manuals
Related Search