"service manual"

CX400

DESKTOP PRINTER

SERVICE MANUAL

SATO CX400 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: [email protected]

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: [email protected]

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: [email protected]

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: [email protected]

SATO BAR CODE & LABELLING

SDN BHD

Suite B-08-11&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: [email protected]

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: [email protected]

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: [email protected]

SATO POLSKA SP Z O.O.

Ul Okolna 2, 50-422 Wroclaw

Tel: 48-71-335-23-20

Fax: 48-71-335-23-25

Website: www.sato-europe.com

Email: [email protected]

BAR CODE SATO ELECTRONICS (S) PTE LTD

438A 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: [email protected]

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: [email protected]

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 necessary 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

INTRODUCTION

General Description

Theory of Operation

Switches and Indicators

Connection Ports

Monitoring Sensors

Operational System

ACCESSORIES INSTALLATION

Cutter Attachment

Dispenser Attachment

Font Module

Firmware Upgrade

OPERATIONAL SETUP

Media Loading

Ribbon Loading

Input/Output Connections

Media Sensor Calibration

Media Index Sensor Calibration

Dispenser Sensor Calibration

TROUBLESHOOTING

Problem Isolation

Self-Diagnosis Label

MAINTENANCE

Cleaning

Print Head Replacement

Main Circuit Board replacement

Platen Roller Replacement

TECHNICAL DATA

Physical Properties

Enviromental Specifications

Power requirements

Printer Performance

Printer Specifications

SATO CX-400 Service Manual

4-1

4-2

5-1

5-1

5-3

5-6

6-1

6-1

6-1

6-1

6-1

1-1

1-1

1-2

1-3

1-4

1-5

2-1

2-3

2-5

2-5

3-1

3-2

3-3

3-3

3-4

3-4

TECHNICAL DATA

Media Specifications

Ribbon Specifications

Serial Interface Specifications

Regulatory Approvals

BLOCK DIAGRAMS

System Block Diagram

Control Board Block Diagram

Panel Board Schematic

Sensor Board Schematic

Main Board Wiring Diagram

7-1

7-2

7-2

7-3

7-3

6-2

6-2

6-2

6-3

SATO CX400 Service Manual

INTRODUCTION

1

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 specialized 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 exhausted 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

Printer Assembly

Print Head Assembly

Chassis Assembly

Paper Holder

Housing

Base

Paper Guides

Front Cover

Platen Roller

Primary Components, Figure 1-1

SWITCHES & INDICATORS

Power Switch

Feed Key

Power Indicator

Page 1-2

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.

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.

Continuously illuminated when functional.

Blinks when a malfunction has occured.

PN 9001110A SATO CX400 Service Manual

Section 1: Introduction

SWITCHES & INDICATORS

Error Indicator Not illuminated when the printer is operational.

Blinks when a malfunction has occured.

DETAIL

Power Indicator

Error Indicator

Feed Button

Power Switch

Switches and Indicators, Figure 1-2

CONNECTION PORTS

Parallel Port

Serial Port

VAC Power Supply Port

SATO CX400 Service Manual

Located on the left rear side of the printer. Permits PC connection for advanced programming, control, and operation.

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.

Located centrally on the rear of the printer. Permits the connection of the voltage supply transformer.

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.

MONITORING SYSTEMS

Media Index Sensor

Ribbon Sensor

Dispenser Sensor

Print Head Open Sensor

Front View

Extension Port

Rear View

Serial Port

VAC Power Supply Port

Parallel Port

Connection Ports, Figure 1-3

Determines the print location upon the label by detecting a label gap or eye mark and then stepping the media to the print position.

Allows the printer to continuously monitor the presence of ribbon when operating in the thermal transfer mode.

Monitors the presence of a label in the dispenser. When the label is removed from the dispenser, the next label will be prompted

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

Flash Memory

DRAM

EEPROM

Centronics Interface

Ouput Ports

Relay

Extension Connection Port

Configuration Jumper

Boot/Normal

The SH7034 microcontroller utilizes a 16 bit external and

32 bit internal data bus based on the Hitachi SH1.

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.

The 2 MB of DRAM is located on the main board. Volatile data such as working buffers and parameters are allocated here.

On board memory is 128 Bytes.

Converts the serial port signal to and from the microcontroller to the RSR232C voltage levels.

The data recieved from the host is transmitted to the micro-controller.

The ports control the motor, LED, media sensor, 24 volt relay, and interface fault conditions.

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.

Permits the connnection of all optional extension modules.

Selects the systems configuation.

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

2

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 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 2-1, 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.

4. Remove the two screws (3) securing front cover (4) to cover hinge (5).

5. If peeler (6) is present, remove screw (7) and manipulate rightward. Lift away peeler (6).

6. Pry power switch (Figure 2-2, 8) from housing (9) and disconnect leads.

7. Remove the two screws (10) securing housing (9) to base assembly (11).

8. Manipulate housing (9) from base assembly (11) and lift away.

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) into 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.

1

2

6

3

4

1

7

5

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: <ESC>A <ESC>CK1 <ESC>Z.

Page 2-2 PN 9001110A SATO CX400 Service Manual

Section 2: Accessories Installation

12

12

10

11

9

9

8

8

16

16

17

14

15

DETAIL

15

13

14

13

DETAIL

17

10

11

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: Printer 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.

Page 2-4

4

7

1

8

6

11

10

REARVIEW

9

2

15

14

13

3

12

4

16

10

5

Dispenser Installation, Figure 2-3

PN 9001110A SATO CX400 Service Manual

Section 2: Accessories Installation

6. Manipulate roller shaft (8) with roller (9) from front cover (4).

7. Apply sensor (10) to cover (4) as design dictates and secure using screw (11).

8. Insert the connector end of sensor (10) through the left bracket of cover (4).

9. Insert roller shaft (8) into roller (9) and manipulate into brackets of cover (4).

10. 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. Observe 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 E2PROM through commands: <ESC>A <ESC>CK0 <ESC>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 printer 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

1. Load the printer with ribbon and media as required.

2. Turn the printer on and allow 3 seconds to power up.

3. Enter the MS-DOS mode on the computer.

4. Type “X:SATO” (were X is the location fo the Firmware Upgrade file) at the DOS prompt.

5. Allow 5 minutes for the power and error LED’s to begin blinking in synchronicity.

6. Toggle the power switch off and then on again to complete the process.

7. Press and hold the printer feed button until it begins printing a self-testing label.

8. Switch the printer off and then on again to return to operation mode.

9. Examine the self-test label contents to ensure a correct upgrade or reload.

10. Repeat as necessary until the printed check sum is 0000.

11. Disconnect computer from the parallel port.

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

3

This section provides all guidance and instructions necessary for simple printer setup and

OPERATIONAL SETUP

operation. 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.

6. Separate purple paper guides (4) and feed media (2) across chassis between them.

7. Slide paper guides (4) together to make light contact with each side of media (2)

8. Pull media (2) forward and feed it through the discharge slot of cover (5).

9. Lower and press print head assembly into operational position.

10. 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

1

2

MED

IA

3

4

5

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.

1

1

4

2

5

2 3

RIBB

ON

8

4

RIBB

ON

7

6

RIBB

ON

Ribbon 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: <ESC>A <ESC>&11 <ESC>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 <ESC>A <ESC>CP1 <ESC>Z.

3. Send the following commands to the printer: <ESC>A <ESC>&10 <ESC>Z.

4. Allow 5 seconds for the printer to complete the process.

0.75" (19mm)

0.06" (1.5mm) =NON-PRINT

0.25" (5.0mm)

LABEL

PRINT HEAD

EYE-MARK ON

BOTTOM OF LINER

BACKING PAPER INSIDE EDGE

MIN. LENGTH

= 0.59" (15mm)

LABEL

LABEL INSIDE EDGE

0.06" (1.5mm) = NON-PRINT

MIN LABEL PITCH

0.39" (10mm)

GAP, NOTCH, OR BAR WIDTH

MIN: 0.04" (2mm)

MAX. 1.0" (25mm)

Page 3-4

Figure 3-3, Label Stock Diagram

PN 9001110A 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 Windows

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: <ESC>A <ESC>CI1 <ESC>CA <ESC>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: <ESC>A <ESC>CI2 <ESC>CA <ESC>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: <ESC>A <ESC>&P1 <ESC>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: <ESC>A <ESC>&P0 <ESC>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

4

The CX400 label printer has integrated systems 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.

• 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 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.

• 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 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):

Version Information (2):

RS232 Protocols (3):

Darkness (4):

Print Length (5):

Print Speed (6):

Used to check the print head, motor, roller, and other mechanical assemblies.

Includes the date code, firmware version, and the check sum value.

Contains the baud rate, parity, data bit number, and the number of stop bits.

Provides the darkness setting. May be altered through printer commands.

On board memory of the total linear length of print activity. This non-resettable feature permits monitoring of component life cycles and warranty validation.

Identifies the print speed setting. The default speed is 3 ips.

Page: 4-2 PN 9001110A SATO CX400 Service Manual

Media Sensor Used (7):

Print Mode (8):

Last Label Tear-Off (9):

Control Code Denifition (10):

Pitch Offset (11):

Cut Count (12):

Memory Slot 1 (13):

Memory Slot 2 (14):

Section 4: Troubleshooting

Identifies which media sensor type has been selected for use.

The correct one must be selected by printer commands or through the application software.

Identifies the print mode setting. TT = Thermal Transfer and DT

= Direct Thermal.

Indicates whether the back-feed function is utilized for tearing off printed labels.

Displays the control code setting. Control codes affect the commands and special controls.

The offset value affects the start print position in relation to the label’s leading edge.

On board counter of the total cut sequences. Permits monitoring of component life cycles.

Provides on board non-volatile flash memory for storing graphics, font characters, etc. 512K bytes.

Optional on board non-volatile flash memory for storing graphics, font characters, etc. 2M or 4M bytes.

Self-Diagnosis Label, Figure 3-1

SATO CX400 Service Manual PN 9001110A Page: 4-3

Section 4: Troubleshooting

Page: 4-4 PN 9001110A SATO CX400 Service Manual

MAINTENANCE

5

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.

1. Turn off power switch and disconnect power supply cord.

2. Lift top cover to expose print assembly.

3. Simultaneously, press the two purple buttons located on the top side of print assembly.

4. Pivot printer assembly upward to expose printer chassis.

5. Remove the printer ribbon and print media from the unit.

6. Wipe or vacuum away larger, loose debris.

7. Moisten a cotton swab with isoprophl alcohol and wipe the print head and rollers clean.

8. 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 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

7. Remove the two screws (4) securing print head bracket (5) to print head cover (6) and separate.

8. Remove the two screws (7) securing print head (8) to print head cover (6).

9. Disconnect the wiring harnesses from print head (8). Lift away print head (8).

10. Prepare to install replacement print head (8).

11. Connect replacement print head (8) to wiring harnesses.

12. Orient replacement print head (8) within cover (6) and secure using screws (5).

13. Apply bracket (5) onto print head cover (6) and secure using two screws (4).

14. Manipulate print head assembly (4) into print assembly (2) with the left side first.

15. Reapply printer ribbon as required and latch print assembly (2) for operation.

16. Close cover (1), connect power supply cord, and switch power on.

17. Test cycle for proper function.

7

4

3

6

8

5

1

2

Page: 5-2

Print Head Replacement, Figure 5-1

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.

1

5

3

2

7

6

SATO CX400 Service Manual

Circuit Board Replacement, Figure 5-2

PN 9001110A

4

Pull Outward and Lift Here

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) 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).

8

9

8

11

10

Page: 5-4

7

Circuit Board Replacement, Figure 5-3

PN 9001110A SATO CX400 Service Manual

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.

15. Manipulate housing (5) over printer chassis (9) down to rest on printer base (7).

16. Secure housing (5) to printer base (7) using two screws (6) applied from the underside.

17. Reinstall applicable front cover/attachment.

18. Connect power switch (4) to its respective two leads and insert into face of housing (5) oriented with the “I” position up.

19. Lower and latch print assembly (2) into operational position.

20. Close cover (1), connect power supply cord, switch power on, and test cycle.

Expansion Slot

External Connector

JP12

JP14

Ribbon Sensor

JP15

Eye-Mark Sensor

Gap Sensor

Print Head Open Sensor

JP2-1

JP24

Motor

Ground

Print Head

Daughter Board

JP17

JP18

JP29

SATO CX400 Service Manual

Circuit Board Replacement, Figure 5-4

PN 9001110A

JP16

Panel Board

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: 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.

1

Page: 5-6

5

4

3

2

7

6

Platen Roller Replacement, Figure 5-5

PN 9001110A SATO CX400 Service Manual

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) 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.

8. Remove e-clip (Figure 5-6, 8) from the face of gear (9). Withdraw gear (9).

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.

10. 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 left shaft.

11. Lift out the right end of platen roller (12) and then withdraw the left end from chassis (11).

12. Remove remaining bushings (15) from each end of platen roller (12).

13. Prepare to reassemble the unit.

14. Apply a single bushing (15) to each end of platen roller (12).

15. 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.

16. Apply from the exterior of chassis (11), remaining bushings (14) and (13) to the left and right ends of platen roller (12) respectively.

17. Secure the assembly in place with one screw (10) on each end.

18. Insert gear (9) onto the left shaft of platen roller (12) and secure using e-clip (8).

19. Manipulate housing (Figure 5-5, 5) over printer chassis (9) down to rest on printer base (7).

20. Secure housing (5) to printer base (7) using two screws (6) applied from the underside.

21. Reattach the applicable cover and/or attachment.

22. Connect power switch (4) to its respective leads and insert into face of housing (5) oriented with the on position up.

23. Lower and latch print assembly (2) into operational position.

24. 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

9

8

10

14

2

8

15

11

13

10

12

15

Platen Roller Replacement, Figure 5-6

Page: 5-8 PN 9001110A SATO CX400 Service Manual

TECHNICAL DATA

6

All technical data deemed pertinent has been tabulated below for quick reference. Find the relative section header and then locate the specific type of technical data in the left column.

PHYSICAL PROPERTIES

Dimensions

Weight

7.76” (197mm) x 10.2” (257mm) x 6.5” (164mm)

(3.67kg) Including power module.

ENVIROMENTAL SPECIFICATIONS

Operating Temperature

Storage Temperature

Operating Humidity

Storage Humidity

(5° to 40° C)

(-20° to 60° C)

25 to 85 % RH, Non-Condensing

25 to 85 % RH, Non-Condensing

POWER REQUIREMENTS

Source Voltage to Power Module

Supply from Power Module

Operational Power Consumption

Standby Power Consumption

120 VAC, 60 Hz, 90 W

19 VAC

70 W

Less than 2W

PRINTER PERFORMANCE

Print Speed

Resolution

Maximum Print Width

Maximum Print Length

PRINTER SPECIFICATIONS

Print Method

Onboard CPU

Integrated CLock

Panel Features

DRAM

Flash ROM

Additional Memory

1, 2, 3, 4 ips

203 Dots per Inch (8 dpmm)

4.1” (104mm)

50” (1270mm)

Thermal Transfer or Direct Thermal

Hitachi SH7034 (16 Bit External, 32 Bit Internal)

20M Hz (26 MIPS)

Green Power LED, Red Error LED, Feed Button

2MB

2MB

2 or 4 MB Flash ROM

SATO CX400 Service Manual PN 9001110A Page 6-1

Section 6: Technical Data

PRINTER SPECIFICATIONS

Onboard Sensors

Text Fonts

Text Rotation

Graphics Formats

Graphics Rotation

Bar Code Capabilities

Interface Connections

Media Index - Reflective or Gap/Eye-Mark.

Ribbon Out Sensor

Print Head Open

U, S, M, WB, WL, XU, XS, XM, XB, XL, OCR-A/B.

0, 90, 180, 270 Degrees, Four direction rotational.

SATO Hex/Binary, PCX.

0, 90, 180, 270 Degrees

UPC A/E, EAN8/13, EAN128, Code 39, Code 93, Code 128,

MSI, I25, M25, Codabar, PDF417, UCC128, Postnet, Bookland,

MaxiCode.

RS-232C Serial Interface Port w/ DB9-S Connector

IEEE-1284 Compatible Parallel Interface Port

120 VAC Input, 19 VAC Output. Class 2.

Located on bottom for anchor mounting to wall.

AC Power Module

Wall Mounting Brackets

MEDIA SPECIFICATIONS

Media Type

Maximum Label Roll Diameter

Label Roll Core Diameter

Minimum Inter-label Gap

Maximum Inter-label Gap

RIBBON SPECIFICATIONS

Ribbon Material

Maximum Ribbon Roll Diameter

Maximum Ribbon Length

Ribbon Roll Core Diameter

Direct Thermal - Paper or synthetic label or tag.

Thermal Transfer - Paper or synthetic label or tag.

5” (127mm)

0.75” (19.05mm)

0.08” (2mm)

1” (25.4mm)

Wax, resin, or combination.

1.50” (38mm)

100m

0.72” (18.4mm)

SERIAL INTERFACE SPECIFICATIONS

Interface Type RS-232C Port w/ DB9-S Connector.

Speed

Parity

Data Bits

Stop Bits

Default Parameters

9600, 19200, or 38400 Baud.

Odd, Even, or None.

7 or 8

1 or 2

9600 Bauds, No Parity, 8 Data Bits, 1 Stop Bit.

REGULATORY APPROVALS

FCC Class B, CE, TUV, CCC, and UL.

Page 6-2 PN 9001110A SATO CX400 Service Manual

BLOCK DIAGRAMS

IEEE 1284

IEEE 1284

SPP

SPP

RS232

(9 pin)

RS232

(9 pin)

Main Board

Main Board

Panel Board

Panel Board

Ribbon Sensor

Ribbon Sensor

Thermal Print Head

Thermal Print Head

Media Sensor

Media Sensor

Platen

Platen

Roller

Print Head Open Sensor

Print Head Open Sensor

Stepping

Stepping

Motor

External AC Adaptor

External AC Adaptor

System Block Diagram, Figure 7-1

7

SATO CX400 Service Manual PN 9001110A Page 7-1

Section 7: Block Diagrams/Schematics

Flash ROM

Flash ROM

(U8, U9)

DRAM

(U10)

DRAM

(U10)

Expansion

(JP11)

Slot

(JP11)

EEPROM

(U7)

EEPROM

(U7)

Configuration

Jumper

Configuration

Jumper

(JP7)

CS7

CS4

D15-8

D7-0

Input Port

CS7

74374

(U13)

Input Port

74374

(U13)

Data

Data

IEEE1284-SPP

CS4

High

Output Port

D15-8

(U11)

High

PE/Fault

74374

PE/Fault

Driver

(U11)

(U16, U17)

Driver

(U16, U17)

(P1)

Cutter

Cutter

(JP29)

Motor

(JP17)

Motor

(JP17)

D7-0

Low

74374

Low

Output Port

(U15)

74374

(U15)

Paper Sensor Control

(RY2)

LED

(JP16)

LED

(JP2, JP15)

RS232 Transceiver

RS232 Transceiver

Feed Key

SP232ACT

24 Volt Relay (RY2)

RS23

(P2)

RS23

(P2)

Paper Sensor

Ribbon Sensor

Cutter Sensor

(JP13)

(JP15)

(JP14)

Booter/Normal

(JP5)

(JP4)

(JP13)

Motor T. M.

(JP4)

Thermal Print Head

(JP18)

Control Board Block Diagram, Figure 7-2

J1

J1

1

1

4

5

2

3

6

2

3

4

5

6

Key1

Key1

+5V

+5V

GND

GND

Page 7-2

Panel Board Schematic, Figure 7-3

PN 9001110A SATO CX400 Service Manual

Section 7: Block Diagrams/Schematics

1

2

OC1

3

3

2 4

4

R359F

R359F

Sensor Board Schematic, Figure 7-4

1

JP1

1

JP1

2

2

3

3

4

4

Panel Board

Panel Board Motor

Motor Motor Thermal Sensor

Motor Thermal Sensor

(JP16)

(JP16)

(JP3)

(JP17)

(JP17)

(JP4)

(JP4)

(JP18)

(JP18) Thermal Print Head

Thermal Print Head

(JP24)

(JP24)

(JP3)

(JP15)

(JP15)

(JP2-1)

(JP2-1)

(JP14)

(JP14)

(JP12)

(JP12)

(JP13)

(JP13)

Print Head Open

Sensor

AC

Adaptor

(19 VAC)

(19 VAC)

AC

Adaptor

Media

Sensor

Board

Media

Sensor

Board

IR

LED

Board

IR

LED

Board

Ribbon

Sensor

Board

Ribbon

Sensor

Board

Connect Sensor Board

Connect Sensor Board

(JP1)

(JP1)

Print Head Open

Sensor

Cutter Module

Cutter Module

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

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