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S84 Service Manual A

1. Displayed if password feature is enabled PASSWORD ONLINE QTY 000000 LAN CONFIGURATION BOARD LCD lit OFFLINE QTY 000000 ENTER Cancels print job f CANCEL IP ADDRESS PROTOCOL STATUS3 0 0 0 0 STATUS4 STATUS5 SEMBL Mode ENTER SUBNET MASK CF Card Mode a User 0 0 0 0 Mode STATUS RELAY TIMING INTERFACE MODE e Bea ENQ CYCLE EDIT ENTER INTERFACE BOARD PORT NUMBER 1 ITEM NO CHECK SETTING ENABLE DISABLE XXXXX ENTER DATA PORT INTERFACE BOARD BCC CHECK SETTING ENABLE DISABLE I F 1 INES Se I F 1 ig ir ENTER ENTER IGNORE CR LF YES ENTER IGNORE CAN DLE ENTER Figure 5 5 LAN Interface Mode S8400 Series Service Manual 5 7 PN 9001161A Unit 5 Printer Configuration UNIVERSAL SERIAL BUS USB MODE This chapter provides the programming sequences required for USB interface setup Use the keys of the printer s operator panel to select and enter the required option Refer to the Menu Definition Tables in the following chapter to provide an explanation of each menu screen PASSWORD Displayed if password feature is enabled ONLINE QTY 000000 Sg OFFLINE QTY 000000 ENTER Cancels print job CANCEL ONLINE MODE me Ye ENTER INTERFACE BOARD SETTING YES NO No Yes ENTER gt ENTER DATA PORT INTERFACE BOARD SETTING F 1 I F 2 I F 1 I F 2
2. S8400 Series Service Manual 6 9 PN 9001161A Unit 6 Troubleshooting LAN ETHERNET INTERFACE Ensure the interface has been correctly configured Wait two minutes and run self test to verify If a test label does not print there may be a hardware problem wu Ensure the cable and its ports are not defective Ensure that a faulty print server or other protocol related scenarios are not creating a queue setup issue Systematically perform checks and tests to isolate the cause If using TCP IP ensure a valid IP address is specified and that all parameters are correct subnet mask gateway etc Attempt to PING the IP address assigned to the network interface If using a repeater or hub ensure the SQE is turned off Also ensure the repeater port is not defective by trying the print server on another port Install the IPX SPX protocol on a workstation to determine if the network device can be discovered via the MAC address If able configure the appropriate protocols and retest connectivity Use a crossover cable to isolate the printer from the network by connecting from the interface and workstation Verify that the parameters match on each Test connectivity WIRELESS LAN INTERFACE TROUBLESHOOTING STEP __ Ensure the interface module is correctly installed Run self test to verify 222222222222 Check the signal strength by the three LED s on the interface The more LED s are illuminated green the stronger the signal Ensu
3. Base Print Position NOILOH HIO LNldd 139V u Base Dispense Position Base Print amp Dispense Position Figure 9 4 Label Reference Position Diagram S8400 Series Service Manual 9 5 PN 9001161A Unit 9 Appendix LABEL ADJUSTMENT DIAGRAM Label feed direction Base reference point for Gap sensor printing Head _ 7 4 a ER 68 4mm a mi n ne B Pera Fei Ha 7 5mm 7 omm I Figure 9 5a Standard Position Gap Sensor Dispensing position Base reference point for printing Label feed direction 7 7 I i 14 0mm i rn E Adjustment toward a Q Ee_ _UUL ll ii a I Adjustment toward 3 50mm gt 3 50mm I I Figure 9 5b Dispense Position Gap Sensor S8400 Series Service Manual 9 6 PN 9001161A Unit 9 Appendix PRINTER CONNECTION DIAGRAM Interface Cable EXT Interface Host Computer Applicator Power Cord Figure 9 6 Printer Connection Diagram S8400 Series Service Manual 9 7 PN 9001161A Unit 9 Appendix PRINTER LOADING DIAGRAM Power Switch Ribbon Stock wound face in Ribbon Core Ribbon Boss Print Assembly Ribbon Stock wound face out Label Sensor Media Guide Figure 9 7a Ribbon amp Media Loading Diagram Figure 9 7b Ribbon Loading Diagram Cassette Load S8400 Series Service M
4. Frinter side RD SD Printer status Figure 3 5f Frinter side Editin g 1 Unit 3 Interface Specifications STATUS5 TIMING CHARTS PRINT PROCESS NOTE 1 DLE form STA SOH DLE ETA 2 DC1 form STAX SOH DEI ETA Receiving Analysis Editing 1 S8400 Series Service Manual Print 1 Print 1 Receiving Analysis Editing 2 Print 2 Obtaining printer operation Printer operatior status Receiving Analysis Editing 2 find ___ item No error Item cancellation NOTE Avoid executing the command to obtain the status e g printer operation status while printing 3 13 PN 9001161A Unit 3 Interface Specifications EXTERNAL SIGNAL The external signal interface is designed to connect the printer to an applicator Proceed to the printer s Advanced Mode for various setup activities related to the external signal There are two connector types available for the external signal interface one with a 14 pin connector and the other with a 25 pin connector SPECIFICATIONS Signal Level High 2 4 to 5 0V Low 0 0 to 0 4V Issuing Reissuing EXT signal Enable Disable in the Advanced Mode Switching EXT signal Switching jumper connector to enable 24V output by 24V and 27V power supplies When using 24V power supply Short IN 24V side by jumper connector When using 27V power supply Short IN 27V side by jumper connector Signal Types Type Print end signal PREND is low bef
5. Power off the printer to release the error Reinstall the calendar chip Replace the main circuit board as necessary Write another RFID tag 2 Ensure proper RFID setup installation Press the LINE key to clear Write another RFID tag Ensure proper RFID setup installation Write another RFID tag 2 Ensure proper RFID setup installation Ensure the cover is completely closed Ensure the cover open switch is properly positioned Replace the switch as necessary Reset the head stop position PN 9001161A Unit 6 Troubleshooting ERROR ICONS DESCRIPTION OF ERROR POSITION ON LCD Displayed when having access error to CF Compact Flash Card error S8400 Series Service Manual 6 5 PN 9001161A Unit 6 Troubleshooting WARNING SIGNAL TROUBLESHOOTING WARNING DISPLAYS 01 Ribbon POWER 7 u Near End ONLINE ZE l Limited ribbon quantity remaining Warning LABEL 2 Monitor and reload before all is used RIBBON 02 Receive Buffer Near Full Warning POWER ONLINE Little receive buffer capacity remaining LABEL ONLINE 2 Cease data transmission until existing data is analyzed RIBBON QTY 000000 03 POWER 7 Ga Command SRO a a Review print data for command error LABEL ONLINE Warning RIBBON QTY 000000 POWER ONLINE SF Ensure print head is connected LABEL ONLINE 2 Replace print head RIBBON QTY 000000 04 Head Error Warning POWER Ensure wo
6. INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST Remove two screws 2 securing defective main board 1 to the printer Withdraw defective main board 1 Disconnect all wiring harnesses from defective main board 1 and detach flash card not shown if present Remove four screws 3 from defective main board 1 to upper bracket 4 and lower bracket 5 Remove one screw 6 from board 7 to free defective main board 1 Secure board 7 and brackets 5 4 to replacement main board 1 using screws 6 and 3 respectively Insert flash card not shown as required and connect all wiring harnesses to replacement main board 1 NOTE Each of the printer s wiring harness connectors are different from all others to ensure proper mating Mate each matching half for connection Figure 7 11 Main Circuit Board Replacement S8400 Series Service Manual 7 15 PN 9001161A Unit 7 Replacement Procedures 9 Insert replacement main board 1 into the printer and secure using two screws 2 CAUTION ENSURE THAT WIRING HARNESSES ARE NOT PINCHED DURING INSTALLATION AND THAT ALL REMAIN AWAY FROM MOVINGS COMPONENTS WITHIN THE PRINTER 10 Closerear housing covers restore power factory reset and test print to ensure proper function S8400 Series Service Manual 7 16 PN 9001161A Unit 7 Replacement Procedures SECONDARY BOARD REPLACEMENT The secondary circuit board primarily c
7. S8400 Series Service Manual 9 24 PN 9001161A Unit 9 Appendix PRINTER DIMENSIONS OPPOSITE DIRECT LOAD 230 Figure 9 17b Printer Top View S8400 Series Service Manual 9 25 PN 9001161A Unit 9 Appendix 266 281 Figure 9 17c Printer Left Side View 245 265 nt View S8400 Series Service Manual 9 26 PN 9001161A Unit 9 Appendix g u EP Gi e O up y r EEE Figure 9 17f Printer Rear View S8400 Series Service Manual 9 27 PN 9001161A GLOSSARY GLOSSARY Unit 9 Appendix gt O Accessory Active Tags Addressability Advance Allen Screw Aluminum Anti Static gt O ASCII Assembly Asynchronous Audible Batch Baud Bi Directional Binary Bits Block Diagram Bolt Bore u 00 N O O op D D N op D lt O D lt ie 5 E D Alternating Current Electrical current that reverses its direction regularly and continually An optional assembly that may be used to provide an additional function RFID tags which use batteries as partial or complete source of power which are further differentiated by separating them into those with replaceable batteries and those which have the batteries inside a sealed unit Also referred to as Utilized Active Tags The band of sparks between to closely placed electrodes when current leaps the gap from one to the other American Standard Code for Information Interchang
8. When the ribbon spindles gears are engaged with their respective pulley gear combo a separate gear pulley and belt configuration tranfers torque from the ribbon rewind spindles to ribbon rollers via a single timing belt located on the printer s print side The ripbon rewind spindle rotates on axis while maintaining its projectory to takeup and rewind used ribbon To facilitate removal of the used ribbon material it is wound onto a cardboard sleeve referred to as a core The core is inserted onto the spindle s boss and rotates in unison When rewinding is complete the core is removed along with the used ribbon material and a replacement core is inserted in its place For ribbon loading there are two methods available as purchase options direct loaded or cassette loaded Direct loaded ribbon spindles are hard mounted to the printer and may not be removed except for service The cassette loaded feature permits ribbon stock to be loaded onto spindles that are detachable from the cassette The cassette is inserted into the printer s print side so that its spindles may engage with respective gears mentioned in paragraph 2 The cassette loaded feature permits multiple other cassettes to be loaded and maintained on standby for printer insertion and use when the exisiting supply is exhausted thusly reducing down time As a purchase option a ribbon saver feature may be installed for applications requiring a small amount of thermal transfer print on
9. 09 Inches 104mm 203 Dots Per Inch ddpmm 4 to 16 Inches Per Second 102 406mm s Maximum Speed 305 Dots Per Inch 12dpmm 4 to 14 Inches Per Second 102 356mm s 609 Dots Per Inch 24dpmm 2 to 6 Inches Per Second 51 152mm s 203 Dots Per Inch 8dpmm Resolution 305 Dots Per Inch 12dpmm 609 Dots Per Inch 24dpmm 203 Dots Per Inch 8dpmm 4 09 x 98 4 Inches Wide 104mm W x 2500mm L Maximum Printable Area 305 Dots Pre Inch 12dpmm 4 09 x 59 0 Inches Wide 104mm W x 1500mm L 609 Dots Per Inch 24dpmm 4 09 x 15 7 Inches Wide 104mm W x 400mm L MEDIA Media Width 0 394 to 5 039 Inches 10 128 mm Media Width with Backing Paper 0 5 to 5 1 Inches 13 131 mm Length Pitch Media Length 0 6 Inches 15 mm to printable area Type Die Cut Labels Waste removed Roll 0 125 inch Gap or Eye Mark Thickness 0 002 to 0 012 Inches 0 05 0 31mm Media Width mm Label Supply Load grams Liner Rewind Load grams Width Minimum 0 98 Inches 25mm Maximum 5 04 Inches 128mm Ribbon Length m Label Pitch mm Ribbon Handling e saa 1 01 0 008 Inches 25 6mm 0 2mm Black standard Other Tints non standard S8400 Series Service Manual 2 3 PN 9001161A Unit 2 Technical Data CHARACTER FONT CAPABILITIES MATRIX FONTS XU 5 dots W x 9 dots H Helvetica XS 17 dots W x 17 dots H Univers Condensed Bold XM 24 dots W x 24 dots H Univers Condensed Bold 203dpi 8dots mm 15 dots W x 22 dots H OA Fon
10. 31 PN 9001161A Unit 5 Printer Configuration WIRELESS LAN INTERFACE MODE TABLE 5 8 INTERFACE BOARD SETTING r 1 F 2 E IGNORE CAN DLE YES NO 4 h LAN CONFIGURATION BOARD LCD IP ADDRESS 0 0 0 0 E SUBNET MASK 0 0 0 0 er GATEWAY ADDRESS 0 0 0 0 TR PROTOCOL STATUS3 STATUS4 STATUS5 STATUS RELAY TIMING ENQ CYCLE ITEM NO CHECK ENABLE DISABLE BCC CHECK ENABLE DISABLE 48 S8400 Series Service Manual Allows the selection of which interface board will be set up in subsequent menus Interface Port 1 I F 1 is the smaller card slot of the printer and Interface Port 2 I F 2 is the printer s middle card slot The default setting is I F 2 and accommodates a standard interface card I F 1 is to be used for optional PCI interface cards Allows the determination of whether the Cancel CAN and Data Link Escape DLE codes will be processed or ignored Select the YES option to ignore the codes and NO to process them This screen will only appear when the communication protocol is STATUS4 Allows the deternination of whether the interface will be configured on the interface board or the LCD This screen will only appear if the LAN Wireless LAN or Mini LAN interface board has been installed Power off the printer then on again to enable the changes Sets a unique static IP Address using the TCP IP Protocol The format of an IP Address is a 32 bit numeric address wri
11. 7 Replacement Procedures RIBBON SPINDLE DRIVE MOTORS BELTS PULLEYS REPLACEMENT This printer incorporates the utilization of two drive motors one for the ribbon supply spindle and the other for the ribbon rewind spindle Each motor driven spindle has its own belt and pulley configuration For the purpose of this instruction complete dismantling of the entire assemblies is covered However in most cases only partial removal may be necessary to access the damaged or worn component In such cases remove only the components necessary and advance in the instructions to re assemble what has been removed 1 Switch off the printer and observe applicable lockout tagout procedures 2 Remove all interface cards and open the rear housing covers NOTE Figure 9 1 in the Appendix unit displays cover open or removal CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST Remove two screws 1 Figure 7 5a securing motor assembly 2 to printer frame 3 Lift away motor bracket 4 tension spring 5 and disconnect motor wiring harness not shown Perform steps a through c if the motor requires replacement a Remove two screws 6 securing defective motor 7 to plate 8 b Secure plate 8 to replacement motor 7 using two screws 6 c Advance to step 11 to install and connect motor assembly 2 NOTE A properly installed plate will be oriented so that its chamfered
12. ADVANCED MODE TABLE 5 2 The calendar is a feature that allows the date and time to be manually set using the operator SA panel or through command codes This screen prompts to indicate whether calendar setting is desired or not If YES is selected the calendar setup screen will appear If NO is selected the menu will advance and bypass the calendar setup option This menu screen allows the calendar settings to be altered The calendar is divided into five sets of two digits The first two allows for the year to be set followed by the month the day the hour then the minute CALENDAR XX XXIXX XX XX LISI This menu screen allows the setting of the automated calendar check diagnostic function CALENDAR CHECK ENABLE DISABLE Determines whether each printer character occupies a designated space fixed regardless of the characters width or if the character s space is representative of its width proportional This will apply to all printer resident font types CHARACTER PITCH PROPORTIONAL FIXED The ESC sequence in SBPL SATO Basic Programming Language commands may be defined SSSTESSRERNE as standard using non printable code 1BH or non standard some other user code STANDARD NON STANDARD Allows the determination of whether the printer will automatically enter the SEMBL Mode upon SEMBL MODE powering on the printer AUTO START YES NO 4 8 Allows the ribbon saver feature to be enabled Disabled is the
13. Ea Rca BER EA Ea co BER i S8400 Series Service Manual 3 6 PN 9001161A Unit 3 Interface Specifications UNIVERSAL SERIAL BUS USB The Universal Serial Bus USB interface is a Plug In Interface Module that can be installed by the user It requires a driver shipped with each printer that has the interface installed that must be loaded onto the PC and configured to support USB peripherals using Windows 2000 or above Details for loading the USB driver are contained in the USB Interface Manual that is shipped with each printer with a USB Optional interface installed Up to 127 devices may be connected to a USB port using powered hubs ATTENTION This Interface Type Is Not Compatible With Windows 98 Or Windows Me SPECIFICATIONS Printer Connector USB Type B Plug Cable 10 feet 3 m maximum Host Windows 2000 or above with USB Port Power Supply BUS Power through cable Power Consumption 5 V at 80 ma S8400 Series Service Manual 3 7 PN 9001161A Unit 3 Interface Specifications 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 It requires a driver shipped with each printer that has the interface installed The driver that must be loaded onto the host computer and configured to run one of the supported network protocols using a 10Base T or 100Base TX LAN connection Details for loading the LAN driver are contained in the LAN
14. LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON S8400 Series Service Manual Om SENSOR ERROR Ensure ribbon stock is properly loaded Ensure ribbon has not been damaged Ensure proper printer configuration Ensure media is properly loaded Clean sensor transmit receive surfaces Ensure correct sensor configuration Replace sensor as necessary Clean the print head s contact surface 2 Replace the print head Ensure CF Card is properly installed 2 Format CF Card Delete unnecessary data from flash card 2 Ensure proper download data size Ensure proper download data size Ensure correct send data and communication settings Ensure correct send data and communication settings Ensure correct print head installation 2 Ensure correct printer configuration for print head Ensure correct Kanji ROM installation 2 Replace the board as necessary PN 9001161A ERROR DISPLAYS Unit 6 Troubleshooting ERROR LED DISPLAY LCD DISPLAY DESCRIPTION 20 Calendar Error 22 Cover Open Error POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON S8400 Series Service Manual
15. Module to the available test connector on the main circuit board Figure 6 1 Connect the multimeter ground probe to the pin identified as GRD on the Test Module Connect the multimeter positive probe to the pin identified as SIG on the Test Module Switch on the printer and rotate the test module dial to the required position Table 6 1 Record the multimeter values and confirm they are within specified tolerances Table 6 1 Troubleshoot and replace components as directed in their relative procedures N o OS Sf O0O000 o Test Module Dial Connect ground probe here Connect positive probe here 000000 Test Connector S8400 Series Service Manual 6 11 PN 9001161A Unit 6 Troubleshooting TEST REFERENCE CHART MODULE DIAL CONNECTOR PIN FUNCTION Not applicable to this printer A Used to determine voltage of components that require between 4 7 and 5 3 VDC to properly function A Used to determine voltage of components that require between 1 7 and 12 9 VDC to properly function A Used to determine voltage of components that require between 3 1 and 3 5 VDC to properly function A Used to determine voltage of components that require 24 0 VDC to properly function Used in conjunction with potentiometer VR1 to set eye mark sensor sensitivity Used in conjunction with potentiometer VR2 to set gap sensor sensitivity Used to test Ribbon End sensor on the feed side RE2 Measurement must be made while the pr
16. NOTE A properly installed ribbon saver sensor will be oriented so that it engages the toothed disc plate to its right 6 Close rear housing covers install interface cards restore power and test print to ensure proper function Figure 7 22 Ribbon Saver Sensor Replacement S8400 Series Service Manual 7 32 PN 9001161A Unit 7 Replacement Procedures COVER OPEN SWITCH REPLACEMENT DIRECT LOAD The cover open switch disables the printer if the printer s front cover is not fully closed The switch is spring loaded and is depressed when the front housing cover is closed prompting a signal to be transmitted to the processor The processor in turn relays a signal to the panel board Switch off the printer and observe applicable lockout tagout procedures Open the printer s front housing cover and remove ribbon stock from printer Remove two screws 1 Figure 7 23 securing cover 2 to the printer Manipulate cover 2 from printer Remove two screws 3 securing defective switch 4 to the printer Disconnect wiring harness not shown from defective switch 4 and connect to replacement switch 4 Secure replacement switch 4 to the printer using two screws 3 Manipulate cover 2 into the printer so as to cover switch 4 and its wiring harness not shown a oS di oS YS Secure cover 2 using two screws 1 Figure 7 23 Cover Open Switch Replacement Direct Load S8400 Series
17. NOTE For the multi buffer mode it is possible to continue data communications while printing 2 Error process Paper end occurred Head open Head close Press the LINE key Press the LINE key Printer side I I I I ER RD tee a o eS e a a a a al a an l a an a a RS 225 m mju os 2 2 Bee Se Se 2 Se we Se SS 2S 2 a oe eee eee eee ee Se GE S Printer status b Piss eh p a a a a a a a a a ee ott a PRL __ Prini _ Figure 9 10b Multiple Item Buffer Timing Charts S8400 Series Service Manual 9 12 PN 9001161A Unit 9 Appendix X ON X OFF TIMING CHARTS 1 Normal process Power ON Press the LINE key Press the LINE key Printer side I I I I I I sD A Initial_ XON Eh XONI ________ oe ca XON u OFA _____ XONI_ _____ XOFfA _____ e 500m gt I RD ee eee eee STX ETX 1 STX ETX 2 f________ I Online Printer status Receiving Analysis Editing Print 2 NOTE In this protocol executing the polling of XON at intervals of 500ms from the power supply to the first data reception 2 Error process Press the LINE key Press the LINE key Paper end occurred Press the LINE key Printer side SD RD Printer status Figure 9 11a Single Item Buffer Timing Chart 1 Normal process Receive buffer Receive buffer Power ON near full occurred near full released Press the LINE key Press the LINE key Printer side I I SD poca im I I I I I STX ETX 1 STX ETX 2 STX ETX
18. PREND 3 4 de end enti Changing ribbon Ribbon end Machine error MACHINE ERROR Figure 3 10d S8400 Series Service Manual Head open Head close Print operation End of 4 print PREND 2 3 4 Paper end Ribbon end Machine error 3 17 PN 9001161A Unit 3 Interface Specifications Printing Pitch sensor Pulse continuous fat No pulse input Motion 2 Pitch sensor Pulse oa a No pulse Input Figure 3 11 Operation Mode Flow Chart S8400 Series Service Manual 3 18 PN 9001161A ACCESSORIES INSTALLATION e Interface Installation e Compact Flash Card e Remote Operator Panel S8400 Series Service Manua 4 1 PN 9001161A Unit 4 Accessories Installation ACCESSORIES INSTALLATION This unit provides installation instructions of the purchase options available for this printer These instructions only cover physical hardware installation Refer to the Printer Configuration unit of this manual to configure the printer for their use INTERFACE INSTALLATION The diagram below displays the physical installation of interface hardware Refer to the Configuration unit of this manual for instructions on printer setup for the interface type chosen 1 Switch off the printer 1 Figure 4 1 and and follow applicable lockout tagout procedures Remove interface slot covering not shown from printer 1 as applicable Insert chosen interface board 2 into its assigned slot and secure using t
19. Ready To Printer DB9 4 DSR Data Set Ready 6 6 DSR Data Set Ready ToHost 6 DTR Data Terminal Ready SG Signal Ground Bi Directional SG Signal Ground This connection at the host side of the interface would depend upon the pin that is being used as the Ready Busy signal by the driving software Typically on a PC it would be either CTS pin5 or DSR pin 6 on a DB 25 connector Ta a e e e e e e e e e e e o dan Figure 3 2 Serial Connector Pin Assignments S8400 Series Service Manual 3 4 PN 9001161A Unit 3 Interface Specifications X ON X OFF CABLE REQUIREMENTS Communicates with the host to determine if the printer is ready to receive data by sending XON HEX 11H or XOFF HEX 13H code to the TD line The single and multiple item buffers are switchable in the Interface Mode of the printer TD D i G SG Signal Ground Bi Directional SG Signal Ground NOTE Depending on the host used it may be required to loop CS and RS maintaining at high level on the host side For more information refer to the host computer documentation NOTE Refer to the Charts amp Diagrams unit of this manual to view timing charts for Ready Busy and X ON X OFF S8400 Series Service Manual 3 5 PN 9001161A Unit 3 Interface Specifications IEEE1284 PARALLEL INTERFACE The parallel interface is a plug in module that can be installed by the user and
20. Sensors Head Open Sensor Ribbon Sensors Ribbon End Sensor Direct Load Ribbon End Sensor Cassette Load Ribbon Saver Sensor Cover Open Switch Direct Load Fuse Fan Fan Filter 7 1 PN 9001161A Unit 7 Replacement Procedures REPLACEMENT PROCEDURES This unit provides in depth instruction on all primary component and assembly replacement in addition to most secondary components Use the text in conjunction with their accompanied graphics to ensure complete comprehension throughout the process Especially observe all cautionary or warning notations CAUTION STATIC ELECTRICITY CAN RESULT IN COMPONENT DAMAGE OBSERVE APPROPRIATE GROUNDING PROCEDURES WHEN REPLACING ANY COMPONENTS PRINT HEAD REPLACEMENT If the print head becomes damaged or worn it can be easily removed and replaced without having to make critical adjustments Before replacing the print head check the head counter values by printing a test pattern Instructions relating to the Head Counter may be found in the Configuration unit of this manual Switch off the printer and observe applicable lockout tagout procedures Disengage print head latch 1 Figure 7 1 and remove ribbon stock as necessary Pull outward on print head release lever 2 to release defective print head 3 from the print assembly Disconnect the two wiring harnesses not shown from defective print head 3 do a Se Da Reconnect two wiring harnesses not shown to replacement prin
21. as Transponder The printing method that creates an image by transferring ink from a heat activated ribbon onto the media using the heat from a thermal printhead Switch D A printhead is composed of a set of pins referred to as elements which may be selectively heated through electrical induction Regular paper media is used in this application in conjunction with the heat sensitive ribbon The ribbon deposits a coating of dark material onto the paper when exposed to intense heat Thermal Transfer Thermal transfer printing is more durable than direct thermal printing and is often used when a label needs to endure longer than a year The science that deals with the relationship of heat and mechanical energy also the Thermodynamics l I conversion of one into the other Threads The spiral grooves on the shaft of a screw The three projectories of an object X axis is the distance left and right the Y axis is the distance up and down and the Z axis is the distance inward and outward Three Dimensional A piece of wire bent into a spiral and connected on each end by different objects to allow them Keralen Spring to be pulled apart and then automatically return to their original position once released A device used to increase or decrease electricity s voltage and current The device consists of one or more windings typically copper which the ratio of the number of turns inversely determines the voltage chan
22. by the disappearance or reduction of prevailing negative print characteristics Retighten set screw 1 when the best dial position is chosen NOTE For reference purposes the embossed number on the dial s end that is positioned closest to the print head is the dial setting NOTE If the dial is too difficult to manually adjust using fingertips A slotted screwdriver may be inserted into its end for easier dial rotation ATTENTION If some print problems persist the print head alignment may require adjustment Following print head alignment the print head balance may require a different setting and the procedure repeated Print Assembly ni I N Be 0 IN f ee DO eae num e eri gt O SAT x POSITION Label Thickness 0 20mm to 031mm S8400 Series Service Manual 8 3 PN 9001161A Unit 8 Adjustment Procedures PRINT HEAD ALIGNMENT Print head position has a direct impact on print quality The print head must be parallel with the platen roller for the printed image to be consistent across the label 1 Ensure the print head is latched 2 Look downward to print head 1 Figure 8 3 to locate head alignment plate 2 3 Ensure the values of alignment scales A and B are the same NOTE If the scale values are not the same this may be the cause of print quality issues However matching scale values does not ensure proper alignment If the scales do not match follow this procedur
23. default condition RIBBON SAVER ENABLE DISABLE PARALLEL INTERFACE MODE TABLE 5 3 Is the premiere screen of the Interface Mode The Interface Mode allows the parameters to be set for the printer to communicate with a host and vice versa Select the YES option to configure an interface board for bi directional communication the menu will advance to multiple configuration screens depending on the type of interface borad installed Selecting the NO option will bypass those screens Allows the selection of which interface port will be assigned to receive print data Interface Port 1 I F 1 is the smaller card slot of the printer and Interface Port 2 I F 2 is the printer s middle card slot The default setting is F 2 and accommodates a standard interface card I F 1 is to be used re for the optional PCI interface cards DATA PORT S8400 Series Service Manual 5 25 PN 9001161A Unit 5 Printer Configuration PARALLEL INTERFACE MODE TABLE 5 3 Determines whether the print data code requires deletion Hexadecimal graphic data will not be AGE CARNE deleted Select YES to delete all Carriage Returns CR and Line Feed LF commands in the data stream including graphics and 2D bar codes Select the NO option to process them This feature is primarily used to maintain compatibility with earlier models of SATO printers Allows the selection of which interface board will be set up in subsequent menus Interface Port 1 E I
24. device An object that is designed to be moved from one position to another for the purpose of preventing or allowing the opening of another object Movement to the left or to the right horizontal movement Liquid Crystal Display A display technology involving optical glass panels whose opacity can be controlled by electrical signals A liquid crystal surface is sandwiched between two polarizing panels and when voltage is applied to certain areas the crystal darkens A light source behind the panel transmits through the transparent crystals and is mostly blocked by the darkened ones Light Emitting Diode A semiconductor light source that emits visible light or invisible infrared radiation The color of the emitted light depends on the chemical composition of the semiconducting material used An object that turns on a fixed point usually to engage or disengage a latch A film or sheet placed onto and adhered flatly over another material Relative to RFID the functional period within which maintenance adjustment and repair is not reasonably expected The measurement of length without consideration of other dimensions Print media that does not have a space between each label as does the eye mark and gap type media This media is continuous and is divided based on printer programming An active connection to another document graphic or address By selecting the designated button text graphic or screen location
25. guidance Fan Filter Figure 7 26 Fan Filter Replacement S8400 Series Service Manual 7 36 PN 9001161A ADJUSTMENT PROCEDURES e Label Sensor Positioning e Print Head Pressure Print Head Alignment e Ribbon Guide Alignment Media Pressure Roller Balance Printer Belt Tensioning e Ribbon Cassette Belt Tensioning e Eye Mark Sensor Penetration e Gap Sensor Penetration e Operational Adjustments S8400 Series Service Manual 8 1 PN 9001161A Unit 8 Adjustment Procedures LABEL SENSOR POSITIONING The label sensor assembly provides a mounting apparatus for the eye mark gap and paper end sensors The position adjustment for standard label media is Omm the inner most position Zero Omm is the default setting When non standard media is used the label sensor must be adjusted to align with media s reference mark The adjustment range for eye mark sensor usage is 45 0 to 65 5mm and the gap sensor adjustment range is 5 0 to 66mm The sensor adjustment scale is in 5mm increments Open the front housing cover or remove the ribbon cassette to access print assembly 1 Figure 8 1 Lift upward on print head latch 2 to disengage the print head as required Lift upward on label sensor latch 3 to hinge open the upper half of label sensor assembly 4 Place label media 5 face up and laterally onto printer chassis 6 Relatch label sensor assemb
26. in flow charts throughout this manual as applicable DEFINITION Allows volume control of the printer s audible alarm POTENTIOMETERS PITCH OFFSET DARKNESS Adjusts the print density resulting in a lighter or darker print image For adjusting the print position Adjusts the peel or dispense stop position FUNCTION ot UOC CANCEL Figure 1 2 Operator Panel S8400 Series Service Manual 1 7 PN 9001161A TECHNICAL DATA S8400 Series Service Manual e Physical Characteristics Power Environmental Processing Command Interface Modules Regulatory Approvals Print Media Ribbon Sensing Character Font Capabilities Barcode Capabilities 2 1 PN 9001161A Unit 2 Technical Data Input Voltage 100 240 Volts AC 10 50 60 Hertz 5 Power Consumption 220 Watts 2 7 to 1 1 Amperes operating Accelleration Perfomance 3 5G Frequency 10Hz or below Vibration Time within 5 minutes FRAM 32 Kilobytes SRAM integrated calendar 8 Kilobytes COMMAND Standard SATO Barcode Printer Language SBPL INTERFACE MODULES RS232C 9600 to 57 600 bps 25 Pin Serial Port RS422 485 9600 to 57600 bps RS232C 9 Pin PCI Universal Serial Bus USB USB Adapter 12 Mbps PCI Local Area Network LAN 10BASE T 100BASE TX Automatic Switching Wireless LAN 802 119 Wireless S8400 Series Service Manual 2 2 PN 9001161A Unit 2 Technical Data PRINT Method Direct Thermal Thermal Transfer Head Width 4
27. informational screen only indicating that reset activity is complete DEFAULT SETTING COMPLETED PLEASE POWER OFF TEST PRINT MODE TABLE 5 17 Is the initial screen of the Test Print Mode TEST PRINT MODE CONFIGURATION The printer s configuration settings CONFIGURATION BARCODE The printer s installed barcodes BARCODE HEAD CHECK HEAD CHECK A pattern to check print head elements MEMORY e MEMORY The printer s internal memory FONT The contents of the installed fonts FACTORY A factory test label will be printed This menu screen only appears if CONFIGURATION BARCODE or HEAD CHECK was chosen si in the previous menu The increments of measure is 1cm 10 cm For factory test prints this screen appears instead of the previous screen for setting print size Large 10cm and small 4cm are the only two options Is a directional screen prompting action on how to terminate print activity Press FEED to stop printing and press again to resume printing If the external signal is enabled the test print must be initiated with a print start signal via the EXT port HEX DUMP MODE TABLE 5 18 Is the premiere screen to the Hex Dump Mode The contents of the print buffer and the data received before it is placed into the print buffer may be examined through the use of the Hex Dump Mode Each line of the printed data is enumerated in the first column the second column contains the data in hexadecimal format and
28. measure distance or a short tool for measurement To increase or decrease the proportionate size of an object example text or graphics on a printed label An electronic display To nest or couple one object to another The same as to nest The next to follow the primary in sequence or importance In RFID an antennas transmitter and receiver electronics integrated in a single package A SATO specific mode of printer operation that can execute the program of BASIC format in the printer This allows the printer to be configured and operated without interfacing with an external computer or software The degree of ease or difficult to gain a response example a sensor transmitter signal may require increase to penetrate the thickness of print media in order to be receipted by its receiver A device that responds to a physical stimulus and produces and electronic signal The operational distance between two RFID tags One to follow another in a specified order examples 1 2 3 A B C A general purpose interface that can be used for almost any type of device in which only 1 bit of communication is transmitted at a time Attachment hardware specifically used to secure an object may be moved in a specific position or location Any rod bar or tube 9 35 PN 9001161A Unit 9 Appendix GLOSSARY Simultaneous To take place at the same time Sleeve A thin hollow material that is inserted onto another to provide proporti
29. one is taken to the predetermined linked location Meter A unit of measure in the metric system equal to 39 37 inches Megabytes Used to describe data transfer rates or storage capacity of approximately 1 million bytes depending on the manner of compression Millimeter A unit of measure in the metric system equal to 0 03937 1 25 inches In printing a batch of unprinted labels or tags depending on the manner of compression A unit of measure in the metric system equal to 0 03937 1 25 inches In RFID a vehicle equipped with a system for locating tagged vehicles containers and other objects for the purpose of inventory control 9 32 PN 9001161A Unit 9 Appendix A milky white synthetic material used in manufacturing that is purchased in blocks and machined to the desired shape resembles plastic Nylon Material In label printing it is the repositioning distance that the printer must make after advancing the printed label for cutting or dispensing The offset is the distance that the media must be retracted following one of those activities so that printing may again take place Omni Directional The ability of an RFID tag to operate in any orientation Orientation Sensitivity In RFID the range or measurement of decreased readability by non optimal orientation Offset Orientation Having to do with the manner or angle of placement O Ring A typically circular object made of round elastic material to provide
30. one side and high resistance on the other Diode A group of tiny switches directly attached to a circuit board to enable configuration for a SIPARIO Compie particular type of application These switches are two position On Off The printing method that uses a chemically coated heat sensitive media Once the heat from the thermal printhead is applied to the media the media darkens with the image Direct Thermal l Ba Direct thermal printing does not require ribbon and is typically used in applications where the label needs to endure for a year or less Disable To deactivate or make unable to function Divergent To deviate from the norm or to possess opposing positions Dots Per Inch The quantity of printed dots within a square inch area the print density Dynamic Random Access Memory DRAM is the most common kind of RAM and is a network of electrically charged points in which a computer stores quickly accessible data in the form of Os and 1s Each storage or memory cell can be directly accessed if the intersecting row or column is known Each cell consists of a capacitor and a transistor l The components and sub assemblies that comprise the mechanical apparatus of motion or Drive Train e kinetic energy Multiple items that do not share the same center example a circle whose center axis is not the same as that of another to whom it is connected The opposite of concentric E Clip Type E snap ring Electrically Erasa
31. opening housing covers CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST Withdraw defective flash memory card 1 from flash memory board 2 Insert replacement flash memory card 1 into flash memory board 2 Close rear housing covers install interface cards restore power and download to ensure proper function Figure 4 2 Compact Flash Memory Card Installation S8400 Series Service Manual 4 3 PN 9001161A Unit 4 Accessories Installation REMOTE OPERATOR PANEL This purchase option allows the operator panel to be detached from the printer and secured in a remote location convenient for user access Refer to the instructions provided with the kit for installation guidance S8400 Series Service Manual 4 4 PN 9001161A PRINTER CONFIGURATION e Printer Configuration e Configuration Modes e Menu Definition Tables S8400 Series Service Manua 5 1 PN 9001161A Unit 5 Printer Configuration PRINTER CONFIGURATION This unit provides in depth instruction on printer configuration for operation and for some troubleshooting The printer may be configured via the buttons and or potentiometers located on the printer s operator panel All of the printer s buttons switches and potentiometers are used singularly or in conjunction to perform configuration activities Refer to the Control F
32. screws 10 securing print head latch handle 11 Withdraw latch handle 11 6 Remove three screws 12 and two screws 13 from front plate 14 Leave front plate 14 in place a N Figure 7 3a Ribbon Roller Replacement S8400 Series Service Manual 7 4 PN 9001161A 10 11 12 13 14 15 16 17 18 19 20 Unit 7 Replacement Procedures Remove one screw 15 Figure 7 3b and two screws 16 from rear plate 17 Withdraw ribbon roller assembly 18 from printer NOTE Manually hold the print head in the closed position to manipulate the roller assembly from the printer Loosen set screw not shown and detach snap ring not shown to remove gear 19 from front roller 20 Withdraw front roller 20 rear roller 21 and belt 22 from ribbon roller assembly 18 Apply replacement belt 22 to replacement rear roller 21 Insert replacement rear roller 21 and replacement front roller 20 into ribbon roller assembly 18 Route replacement belt 22 as displayed in Figure 7 3b Apply gear 19 to front roller 20 and secure using snap ring not shown and set screw not shown Hold ribbon roller assembly 18 together while inserting into the printer and secure two screws 16 one screw 15 Figure 7 3b Ribbon Roller Replacement Secure front plate 14 Figure 7 3a to the print assembly using two screws 13 and three screws 12 NOTE Ensure all loose components a
33. slot in frame 3 and connect to harness A pr oe Se Dea Secure replacement ribbon sensor 5 to printer frame 3 using screw 4 NOTE A properly installed sensor will be oriented so it s facing downward Repeat steps 4 through 7 for the second sensor 5 as necessary Reconnect wiring harness not shown to panel board assembly 2 and secure to frame 3 using screws 1 10 Reload printer restore power and test print to ensure proper function OA ta i Z dr 3 3 DA x SI TZ a N si E i N N U DI EA O La N XJ AT T_ N w A NI Lo i N a 1 J i B r lt A gt Y N A ii TEL 64 i a L B A QL e B LS i 9 NG 5 A 4 x 4 4 G gt Ea A 9 TC A gr L f J AX i VA apr 19 o Pai p Ao S VEY I IN ANY vu A gt i j 5 A as E se gt lt nn 3 J lt 7 A TR an pr N A la gt Figure 7 19 Ribbon Sensor Replacement S8400 Series Service Manual 7 28 PN 9001161A Unit 7 Replacement Procedures RIBBON END SENSOR REPLACEMENT DIRECT LOAD The ribbon end sensor informs the operator when ribbon stock has been exhausted and reloading is required 1 2 3 4 9 6 ATTENTION Before assuming the sensor is defective and replacing the assembly ensure that the condition is not the result of debris buildup Thoroughly clean the sensor
34. storing 50 of 500 items in the history buffer Release Of Receive Buffer Near Full Receive buffer near full can be released when the remaining free space rises to 1 95MB or when the remaining free space is available for storing 200 items in the history buffer STATUSS5 TIMING CHARTS NORMAL PROCESS Figure 3 5a Power ON Printer side L_ Ben le Initial ENG paz STA ETA 2 NO ne 3 i 4 l sj Buffer near full occurred Buffer near full release Press the LINE key Press the LINE key I SD r I I Frinter status Editing Eingi NOTE 1 ENG form is as follows STA SOH ENG ETA an optional item number is in 2 Avoid ENG transmission while sending the print data STA ESCHA ESC HZ ETA This may cause the return status error or the printer error Figure 3 5b Printer side RD SD Printer status Editing 2 NOTE 1 CAN form is as follows STA SOH CAN ETA an optional item number is in 2 To send the next data wait approximately 100ms after sending CAN Figure 3 5c Paper end Head open Head close Press the LINE key Printer side I ENG Editing 1 NOTE 1 When the paper end has occurred Open the head Set the label Close the head for feed operation 2 When the head is closed the paper end will be released S8400 Series Service Manual 3 12 PN 9001161A Figure 3 5d Printer side RD SD Frinter status Figure 3 5e
35. the operator the printer and the printer s software Use the printer s operator panel to select and enter the required options Refer to the Menu Definition Tables in the following chapter to provide an explanation of each menu screen Printer beeps LABEL OUT SENSOR YES NO d E Figure 5 12 Hidden Mode S8400 Series Service Manual 5 14 PN 9001161A DOWNLOAD MODE Unit 5 Printer Configuration This download feature allows the operator to upgrade or downgrade firmware to the printer When downloading is complete the LCD screen will return to the original display If an error occurs a DOWNLOAD ERROR will display Use the printer s operator panel to select and enter the required options Refer to the Menu Definition Tables in the following chapter to provide an explanation of each menu screen S8400 Series Service Manual Printer beeps DOWNLOAD WAITING DOWNLOADING l BDE Sa ee DOWNLOAD COMPLETE ENTER Printer is on standby waiting for download to begin Receiving downloaded data Briefly displays when download is complete Figure 5 13 Download Mode PN 9001161A BOOT DOWNLOAD MODE Unit 5 Printer Configuration This download mode is used when the firmware becomes corrupted and the normal download mode is not successful Use the printer s keys to select and enter the required options Refer to the Menu Definition Tables in the following chapter to prov
36. the right column contains the same data in ASCII format Only one type of data will be printed at a time This screen allows the selection of the data to be Ten printed Repeat the Hex Dump process to print the other data types if required RECEIVE DATA The INTERNAL DATA option allows the printing of setting for the internal buffer RECEIVE BUFFER INTERNAL DATA S8400 Series Service Manual 5 40 PN 9001161A Unit 5 Printer Configuration CF COMPACT FLASH CARD MODE TABLE 5 19 Is the premiere screen of the CF Card Mode The Card Mode allows management of the optional Compact Flash Card Allows the determination of formatting the flash card Select the YES option to advance to the formatting screens Select the NO option to return to the first screen of the CF Card Mode YES NO This menu screen initiates the formatting process when selecting the YES option Select the NO option to return to the first screen of the CF Card Mode YES NO Screen confirms that formatting is in process and displays its progress status A tinted field will 5 move laterally from the left toward the right as formatting progresses When the tinted bar reaches 100 on the scale formatting is complete a 18S Da ie Confirms that formatting has completed and prompts for action to exit the CF Card Mode CF CARD FORMAT COMPLETE PRESS ENTER STAND ALONE MODE TABLE 5 20 Allows a previously sent data item to be saved If the YES option is cho
37. them lt gt O 2 U O m di ai OR PANEI ED DEFINITION POWER Illuminates green when the printer is powered on Terminates when powered off ONLINE Illuminates green when the printer is in an online state Terminates when the printer goes offline LABEL Off Normal state Red Constant When a Label Error has occurred rm RIBBON Off Normal state Red Flashing Ribbon supply is low Red Constant When a Ribbon Error has occurred DEFINITION Removes power supply at its entry to the printer KEYS POWER LINE Moves the printer from an online to offline state and vise versa Has other special functions as identified in flow charts throughout this manual as applicable FEED Advances the label media when pressed Has other special functions as identified in flow charts throughout this manual as applicable FUNCTION Pressing steps the LCD back to a previous menu Has other special functions as identified in flow charts throughout this manual as applicable ENTER Used to select a menu option and to advance the menu screen accordingly Has other special functions as identified in flow charts throughout this manual as applicable CANCEL Pressing steps the LCD back to a previous menu Has other special functions as identified in flow charts throughout this manual as applicable Allows the operator to scroll through various menus and menu options Has other special functions as identified
38. 3 STK ETX 4 I RD Sau sede dea 1 Offline Printer status Sem ee u a a i I RecelvingiAnalsele _ Ripper REN I I Editing 1 i Print 2 i eo I i NOTE In this protocol executing the polling of XON at intervals of 500ms from the power supply to the first data reception 2 Error process Head open Head close Printer side Press the LINE key Paper end occurred Press the LINE key SD n to STX ETX i WERE RE EZIO I Online Offline Online Printer status F uan e a a en en I I I I l I I Print 1 Print 1 Figure 9 11b Multiple Item Buffer Timing Chart S8400 Series Service Manual 9 13 PN 9001161A Unit 9 Appendix SESSION CONNECT DISCONNECT DIAGRAM 1 Port1024 for print data Host Printer connected cz to LAN LISTEN CONNECT ACCEPT CONNECTED PRINT DATA PRINTING PRINT DATA PRINTING CLOSE CLOSE DISCONNECTED LISTEN 2 Port1025 for status return Printer connected to LAN LISTEN CONNECT ACCEPT CONNECTED PRINTER STATUS STATUS REQUEST PRINTER STATUS CLOSE CLOSE DISCONNECTED 4 z LISTEN Figure 9 12 Session connect Disconnect Diagram S8400 Series Service Manual 9 14 PN 9001161A Unit 9 Appendix PRINTER MOUNTING DIAGRAM Figure 9 13 Printer Mounting Diagram S8400 Series Service Manual 9 15 PN 9001161A Unit 9 Appendix PRINTER DIMENSIONS STANDARD WICASSETTE Figure
39. 61A Unit 7 Replacement Procedures PANEL LCD BOARD REPLACEMENT Circuit boards generally have long lives due to the lack of moving parts Generally if a circuit board becomes defective it is contributable to a negative external condition If It is determined that the circuit board has become defective search the printer over for possible visual factors that may have led to the damage le ir 5 Switch off the printer and observe applicable lockout tagout procedures Locate panel board assembly 1 Figure 7 15a located on the upper front of printer frame 2 Remove two knurled thumbscrews 3 securing panel board assembly 1 to printer frame 2 Lift away panel board assembly 1 and disconnect wiring harness not referenced 3 P p J am je _ 1 x QJ SE A J J N gt S a A Ba N A LO Figure 7 15a Panel LCD Board Replacement Remove four screws 4 Figure 7 15b securing mounting plate 5 to panel cover 6 Lift away plate 5 6 er A x d E TT x eo DL gt WI y le SS l i p IL j X p W N in he IL Ir a we a j pi 5 SENT Figure 7 15b Panel LCD Board Replacement S8400 Series Service Manual 7 20 PN 9001161A O m a Unit 7 Replacement Procedures Detach LCD board 9 from panel board 8 and replace as necessary Attach LCD board 9 to panel boar
40. 7 and disconnect wiring harness not shown Connect wiring harness not shown to replacement upper sensor 8 attach to upper cover 7 oO N DN Secure upper cover 7 to lower cover 6 using two screws 5 S8400 Series Service Manual 7 23 PN 9001161A Unit 7 Replacement Procedures Figure 7 17c Label Sensor Replacement S8400 Series Service Manual 7 24 PN 9001161A Unit 7 Replacement Procedures Remove two screws 9 Figure 7 1 c securing lower label assembly 10 to center frame 4 Withdraw 10 10 Remove two screws 11 securing defective lower sensor 12 to lower label assembly 10 and disconnect wiring harness not shown 11 Connectwiring harness not shown to replacement lower sensor 12 12 Secure replacement lower sensor 12 to lower label assembly 10 using two screws 11 13 Secure lower label assembly 10 to center frame 4 using two screws 9 14 Secure upper label assembly 3 Figure 7 17a to center frame 4 using two screws 2 15 Load printer restore power and test print to ensure proper function S8400 Series Service Manual 7 25 PN 9001161A Unit 7 Replacement Procedures HEAD OPEN SENSOR REPLACEMENT The head open sensor disables the printer if the print head is not properly latched The sensor is of a transmit receive variety When the print head is latched a metal plate is rotated between the two sensor halves prompting a signal to be transmitted to the pro
41. 7 6 PN 9001161A Unit 7 Replacement Procedures 6 Remove two screws 6 Figure 7 4b securing defective platen motor 7 to motor bracket 8 7 Secure replacement platen motor 7 to motor bracket 8 NOTE A properly installed motor will be oriented so that its spindle protrudes through its orifice in the bracket wall and its wiring harness toward its longest side 8 Inspect and replace belts A B C and pulleys not referenced as required NOTE Detach snap ring 9 retaining any pulley to withdraw and replace NOTE The belt configuration for the S8408 printer is different from that of the S8412 and S8424 Ensure the belts are applicably configured to their respective pulleys CAUTION A PROPERLY TENSIONED BELT WILL BE JUST ENOUGH TO PREVENT SLIPPAGE AN OVERLY TENSIONED BELT WILL EXCESSIVELY INCREASE DRAG ON THEIR PULLEYS AND INCREASE COMPONENT WEAR 58408 Printer 58412 58424 Printer Figure 7 4b Platen Drive Motor Belt Pulley Replacement 9 Insert motor assembly 3 Figure 7 4a into printer frame 4 10 Secure the assembly 3 and five ground cables not shown using one screw 2 and two screws 1 11 Connect the motors wiring harness not shown to secondary board 5 12 Closerear housing covers install interface cards restore power and test print to ensure proper function NOTE Figure 9 1 of the Appendix unit displays cover installation S8400 Series Service Manual 7 7 PN 9001161A Unit
42. 9 14a Printer Three Quarter View Figure 9 14b Printer Top View S8400 Series Service Manual 9 16 PN 9001161A Unit 9 Appendix Figure 9 14d Printer Front View S8400 Series Service Manual 9 17 PN 9001161A Unit 9 Appendix 121 266 s aaa T a Te 11_ 1k k H fg N Ti I iim p I a I 104 nt Lod LI Figure 9 14f Printer Rear View S8400 Series Service Manual 9 18 PN 9001161A Unit 9 Appendix PRINTER DIMENSIONS OPPOSITE W CASSETTE Figure 9 15b Printer Top View S8400 Series Service Manual 9 19 PN 9001161A Unit 9 Appendix rt MRS MA er 1 fool Lo ed EE a Mia ul Al IAT E N il O T IK u Figure 9 15c Printer Left Side View 245 Figure 9 15d Printer Front View S8400 Series Service Manual 9 20 PN 9001161A Unit 9 Appendix Figure 9 15f Printer Rear View S8400 Series Service Manual 9 21 PN 9001161A Unit 9 Appendix PRINTER DIMENSIONS STANDARD DIRECT LOAD 219 230 Figure 9 16b Printer Top View S8400 Series Service Manual 9 22 PN 9001161A Unit 9 Appendix Figure 9 16c Printer Left Side View E WO Figure 9 16d Printer Front View S8400 Series Service Manual 9 23 PN 9001161A Unit 9 Appendix 266 3 OJ H Hf eee af a he 3 aes DAL SECR SE E i e EE OS I eee Figure 9 16f Printer Rear View
43. ABLE DISABLE NON STANDARD SEMBL MODE AUTO START Yes ENTER YES gt pe Figure 5 2 Advanced Mode S8400 Series Service Manual 5 4 PN 9001161A Unit 5 Printer Configuration 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 in the following chapter to provide an explanation of each menu screen PASSWORD Displayed if password feature is enabled ONLINE QTY 000000 Sg OFFLINE QTY 000000 ENTER RECEIVE BUFFER ITEM NO CHECK Cancels print job SEMBL Mode CF Card Mode CANCEL MULTI 1 ITEM ENABLE DISABLE ENTER ENTER BCC CHECK ENABLE DISABLE User 1P ENTER a za RIO GTO T ENTER INTERFACE BOARD SETTING YES NO DATA PORT INTERFACE BOARD SETTING I F 1 I F 2 I F 1 I F 2 ik ik ENTER Not available with Status 5 Protocol or Status 4 with 1 item buffer IGNORE CR LF PROTOCOL IGNORE CAN DLE STATUS4 STATUSS5 4 n ENTER YES NO Figure 5 3 Parallel Interface Mode S8400 Series Service Manual 5 5 PN 9001161A Unit 5 Printer Configuration 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 ent
44. Boss Torque Limiter Direct Load 7 13 Ribbon Boss Torque Limiter Cassette Load 7 14 Main Board 7 15 Secondary Board 7 17 Flash Memory Board 7 18 Power Board 7 19 Panel amp LCD Board 7 20 Interface Board 7 22 Label Sensor 7 23 Head Open Sensor 7 26 Ribbon Sensor 7 28 Ribbon End Sensor Direct Load 7 29 Ribbon End Sensor Cassette Load 7 31 Ribbon Saver Sensor 7 32 Cover Open Switch Direct Load 7 33 Fuse 7 34 Fan 7 35 Fan Filter 7 36 ADJUSTMENT PROCEDURES Adjustment Procedures Label Sensor Positioning 8 2 Print Head Pressure 8 3 Print Head Alignmnent 8 4 Ribbon Guide Alignment 8 5 Media Pressure Roller Balance 8 6 Printer Belt Tensioning 8 7 Ribbon Cassette Belt Tensioning 8 8 Print Head Balance 8 9 Print Head DPI Change 8 10 Eye Mark Paper End Sensor Sensitivity 8 12 Gap Sensor Sensitivity 8 13 Operational Adjustments 8 14 Pitch 8 14 Offset 8 14 Darkness 8 14 S8400 Series Service Manual PN 9001161A APPENDIX Cover Removal Diagram 9 2 Block Diagram 9 3 Print Setup Dimensions 9 4 Label Reference Position 9 5 Label Adjustment Diagram 9 6 Printer Connection Diagram 9 7 Printer Loading Diagram 9 8 Typical Applicator Process 9 10 Printer Packing amp Unpacking Diagram 9 11 Ready Busy Timing Charts 9 12 X On X Off Timing Charts 9 13 Session Connect Disconnect Diagram 9 14 Printer Mounting Diagram 9 15 Printer Dimensions Standard w Cassette 9 16 Printer Dimensions Opposite w Cassette 9 19 Printer Dimensio
45. Error Correcting Protocol Relative to RFID the rules by which the error correcting mode operates In RFID the techniques used to ensure that only correct information is presented to the Error Management i systems user Error Rate In RFID the number of errors per number of transactions In RFID the electronics which drive an antenna When coupled with antenna they are Exciter l collectively referred to as a scanner Also referred to as a transmitter Expansion Port A plug accessing additional 1 0 capability on a computer or peripheral device Print media with a mark on the paper backing between each label for the label sensor to read Eye Mark Media This mark is used by the printer to identify the end of the printed label so that the next up can be properly positioned for printing S8400 Series Service Manual 9 30 PN 9001161A Unit 9 Appendix GLOSSARY Relative to RFID the programming of information into a tag occurring as part of the Factory Programming manufacturing process resulting in a read only tag In RFID programming that usually occurs before the tag is installed on the object to be Field Programming identified enabling the introduction of data relevant to the specifics of the application However the tag would typically have to be removed from its object l In RFID the ability to limit the operations that can be performed on portions of data fields Field Protection stored in a tag Fillet T
46. F 1 is the smaller card slot of the printer and Interface Port 2 I F 2 is the printer s middle card SETTING slot The default setting is I F 2 and accommodates a standard interface card I F 1 is to be used radi IR for the optional PCI interface cards Allows setting of bi directional communication protocol PROTOCOL STATUS4 STATUSS Allows the selection of the receive buffer type Select MULTI for multiple item buffer and 1ITEM n for a single item buffer MULTI 1 ITEM Allows setting for ACK width of the IEEE1284 interface The display will appear when the TEE interface is present and one item 1ITEM is selected as a receive buffer ACK SIGNAL XX X US Allows item number check to be enabled or disabled Will only appear when STATUSS is set for ITEM NO CHECK the protocol ENABLE DISABLE Allows BCC Check for ACK width of the IEEE1284 interface The display will only appear when STATUSS is set for the protocol BCC CHECK ENABLE DISABLE Allows the determination of whether the Cancel CAN and Data Link Escape DLE codes will be FRESE processed or ignored Select the YES option to ignore the codes and NO to process them This screen will only appear when the communication protocol is STATUS4 SERIAL INTERFACE MODE TABLE 5 4 Is the premiere screen of the Interface Mode The Interface Mode allows the parameters to be set for the printer to communicate with a host and vice versa Select the YES
47. ION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN DAMAGED COMPONENTS ALWAYS REMOVE ALL INTERFACE CARDS PRIOR TO OPENING THE REAR HOUSING COVERS Screw x1 ee Interface Cards Screw x2 Figure 9 1 Cover Open Diagram S8400 Series Service Manual 9 2 PN 9001161A Unit 9 Appendix BLOCK DIAGRAM lt GND SIOSUIS UOIIIN si JOSU8S uado 19109 M Josuas uado pesH E i Josues EIPSIN Label Sensors a vog AYUVONODIS 33MOd LOW MAIN CIRCUIT BOARD ry ENO IND ayvog 13NVd ayvog do JOJO SAUG ayvog YIMOd YOUMS JOEMOd Figure 9 2 Block Diagram PN 9001161A 9 3 S8400 Series Service Manual Unit 9 Appendix PRINT SETUP DIMENSIONS Gap 0 197 2 61 Eye Mark 0 177 2 3 lt a Gap Eye Mark Paper End CN CAN Sensors Print Width 4 09 Invalid Area for Print i W 0 118 Print Head Eye Mark 5 08 Gap 4 84 NOILDIAIA LNIdd 199V gt lt 0 59 Dispenser Figure 9 3 Print Setup Dimensions S8400 Series Service Manual 9 4 PN 9001161A Unit 9 Appendix LABEL REFERENCE POSITION CONTINUOUS MODE TRANSMISSION SENSOR REFLECTIVE SENSOR Base Print Position __ DISPENSE MODE TRANSMISSION SENSOR REFLECTIVE SENSOR
48. Interface Manual that is shipped with each printer with a LAN Optional interface installed SPECIFICATIONS Protocol Status3 return Protocol for Driver cyclic response mode Protocol for Driver ENQ response mode Status5 return IP Address 0 0 0 0 to 255 255 255 255 Subnet Mask 0 0 0 0 to 255 255 255 255 Gateway Address 0 0 0 0 to 255 255 255 255 DIPSWITCH SETTINGS SWITCH SETTING Reserved setup prohibited LAN board EEPROM initialization configuration Print configuration details on a label Print a self diagmosis of the board onto a label SOFTWARE SPECIFICATIONS NOTE Print data can be sent by LPR and FTP of TCP IP and dedicated socket protocol Printer status is obtainable by dedicated socket protocol NOTE In the TCP IP protocol enviroment LPD and FTP are provided for printing TELNET for variable setup ARP RARP and BOOTP DHCP for address setup LPD protocol complies with RFC1179 and handles the list of logical printer name as queue name such as Ip sjis euc In addition a banner page can be printed by a proper setup When sending the job by LPR the transmission order of data file control file within the job will not affect print operation In addition if the banner page is specified it will be added to each data file Job deletion by LPR is not available FTP protocol complies with RFC959 and handles the list of logical printer name as a transfer directory File transfer to this directory executes print o
49. LABEL Allows the operator to identify specific problems regarding mechanical performance and setup HEX DUMP MODE The contents of the print buffer can be examined using the Hex Dump Mode In the left column each line of data received is numbered The center column provides the data in hexadecimal format And in the right column same data is provided in the ASC Il format Follow the flow chart provided below to perform this activity Displayed if password feature is enabled PASSWORD Za ONLINE QTY 000000 HEX DUMP MODE ze g O AT OFFLINE QTY 000000 Service Interface Ka gt gt Cancels print job SELECT DUMP DATA RECEIVE DATA RECEIVE BUFFER INTERNAL DATA Internal Data Receive Data Receive Buffer SEMBL MODE ENTER ENTER ENTER Sea TOT Hex Dump is printed ADVANCED MODE Agag E ni ir gt Figure 6 3 Hex Dump Mode S8400 Series Service Manual 6 13 PN 9001161A Unit 6 Troubleshooting TEST LABEL PRINTING The test label is designed to assist in the identification of print problems Follow the flow chart provided below to perform this activity Printer beeps TEST PRINT MODE CONFIGURATION BARCODE HEAD CHECK MEMORY FONT FACTORY Scrolls options Barcode Head Check Memory ENTER ENTER ENTER TEST PRINT SIZE Configuration Factory ENTER E 10cm TEST PRINT PRESS ENTER KEY TEST PRINT SIZE LARGE SMALL Power off to cease pri
50. N type of interface set this to DISABLE ITEM NO CHECK ENABLE DISABLE Allows BCC check to be enabled or disabled Will only appear if STATUS5 is set for protocol When the printer driver is set for GAP sensor printing transmissive mode BCC CHECK will be switched to DISABLE ENABLE DISABLE When performing a test print of any LAN type of interface set this to DISABLE PORT NUMBER 1 ene PORT NUMBER 2 eee BCC CHECK This menu screen shows the setting of Port Number 1 for raw data transfer This menu screen shows the setting of Port Number 2 for raw data transfer S8400 Series Service Manual 5 29 PN 9001161A Unit 5 Printer Configuration LAN INTERFACE MODE TABLE 5 5 This menu screen shows the setting of Port Number 3 for raw data transfer PORT NUMBER 3 XXXXX ar USB INTERFACE MODE TABLE 5 6 Is the premiere screen of the Interface Mode The Interface Mode allows the parameters to be set for the printer to communicate with a host and vice versa Select the YES option to configure an interface board for bi directional communication the menu will advance to multiple configuration screens depending on the type of interface borad installed SETTING ae Selecting the NO option will bypass those screens Allows the selection of which interface port will be assigned to receive print data Interface Port 1 I F 1 is the smaller card slot of the printer and Interface Port 2 I F 2 is the printe
51. R CLEAR S N XXXXXXXX NONE ALL CANCEL HEAD CUT ENTER DISPENSE CANCEL ENTER COUNTER CANCEL INDICATION ENTER INTERFACE BOARD CANCEL REVISION Factory Other Options ENTER ENTER PRINT SIZE REV XX CANCEL ENTER SMALL LARGE i b ENTER LIFE COUNTER TEST PRINT PRESS ENTER KEY XX M Dispense Close Print Head ENTER ENTER CUT COUNTER DISPENSE COUNTER Prints test XX M label CANCEL ENTER Figure 5 10 Factory Mode S8400 Series Service Manual 5 12 PN 9001161A Unit 5 Printer Configuration WORK SHIFT MODE The Work Shift Mode allows for specific production shift information to be printed on a label when used with the printer SBPL command Use the keys of the printer s operator panel to select and enter the required options Refer to the Menu Definition Tables in the following chapter to provide an explanation of each menu screen YES option must have been selected for the Shift Code within the Hidden Mode menu z ONLINE QTY 000000 Press and hold the following keys for 10 seconds LINE FEED ENTER SHIFT TIME XX XX E CANCEL ENTER Figure 5 11 Work Shift Mode S8400 Series Service Manual 5 13 PN 9001161A Unit 5 Printer Configuration HIDDEN MODE The Hidden Mode allows operator access to set Label Out Sensor status and Work Shift mode status Figure 5 12 provides the specific sequence of events required by
52. R LEVEL I MARK XXV SLICE LEVEL XX 2 SENSOR LEVEL GAP LEVEL OFFSET SENSOR LEVEL GAP XXV SLICE LEVEL XXV a AUTO ONLINE FEED YES NO ENTER S8400 Series Service Manual FEED ON ERROR MES NO pe gl SE FORWARD BACKFEED DISTANCE DEFAULT XXX MM Vie EXT 9PIN SELECT MODE1 MODE2 ENTER WEB ACCELERATION FAST NORMAL SELECT LANGUAGE ENGLISH FRENCH GERMAN SPANISH ITALIAN PORTUGESE PRIORITY SETTING COMMAND INTERNAL ENTER RIBBON NEAR END ENABLE DISABLE ENTER ENTER LABEL RE DETECT PASSWORD NO ENABLE DISABLE FUNCTION KEY NONE REPRINT SEMBL MODE PROGRAM COPY YES PROGRAM COPY CF CARD gt ROM ROM gt CF CARD SAVE PRINT LOG ENABLE DISABLE CF CARD gt ROM COPY START YES CLEAR PRINT LOG ROM gt CF CARD YES NO COPY START YES OUTPUT PRINT LOG FROM SUBPORT ENABLE DISABLE i PROGRAM COPY COMPLETE PRESS ENTER KEY Figure 5 9 Service Mode PN 9001161A Unit 5 Printer Configuration 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 Definition Tables in the following chapter to provide an explanation of each menu screen PASSWORD Displayed if password feature is enabled MAINTENANCE MODE SERVICE MODE FACTORY MODE SERIAL NO COUNTE
53. SABLE LABEL RE DETECT ENABLE DISABLE SET PASSWORD ON OFF d h PASSWORD NO XXXX LISI COMPATIBLE MODE ON OFF d b S8400 Series Service Manual Allows the establishment of a specific distance the media will be advanced and retracted in addition to distance set by the OFFSET potentiometer on the operator panel If using thermal transfer for printing set the feed distance less than 30mm to avoid detection of the ribbon end by accident Allows selection of output mode options MODE1 outputs signal in the status of existence non existence for the number of remaining labels to be printed MODE2 outputs signal in the status of online offline Allows the printer to use either a NORMAL or FAST web acceleration Large heavy label rolls should use the NORMAL option while smaller lighter rolls can use the FAST option Allows the hexadecimal code to be specified for the character replaced with the Euro Character The default is D5H Allows the user to assign a method of command priority Where programming instructions conflict the printer will allow this assignment to take priority This priority assignment affects the settings for print darkness print speed start position correction operation mode print method and sensor types Select the ENABLE option to set the printer to automatically notify when ribbon supply is nearly exhausted Select ENABLE to allow the printer to redetect label pitch after the printer has been turned on
54. SB Adapter e Local Area Network LAN Ethernet e 802 11g Wireless e Receive Buffer all interfaces e ACK NAK Protocol all interfaces e Status5 Return all interfaces e External Signal Interface 3 1 PN 9001161A Unit 3 Interface Specifications INTERFACE SPECIFICATIONS This unit presents the printer interface types and their specifications These specifications include detailed information to assist in the selection of the most appropriate method for the printer to interface with the host The five acceptable interface methods are e RS232C High Speed Serial e EEE1284 Parallel e Universal Serial Bus USB e Local Area network LAN Ethernet e 802 11g Wireless Following the selection of the desired interface proceed to the next unit for instructions on how to configure the printer for that interface type WARNING NEVER CONNECT OR DISCONNECT INTERFACE CABLES OR USE A SWITCH BOX WITH POWER APPLIED TO EITHER THE HOST OR THE PRINTER THIS MAY CAUSE DAMAGE TO THE INTERFACE CIRCUITRY IN THE PRINTER HOST AND IS NOT COVERED BY WARRANTY NOTE Some hosts monitor the Request To Send RTS signal pin 4 of 25 to determine if the printer is ready to receive data Since the printer does not generate this signal the RTS line must be held true high in order to allow communication This can be performed by connecting the RTS pin to the Clear To Send CTS signal pin 5 of 25 Interface Card i ET
55. Service Manual 7 33 PN 9001161A Unit 7 Replacement Procedures FUSE REPLACEMENT The fuse is wired to the power receptacle through the main circuit board and protects the printer from power surges from the electrical source If a surge of electricity reaches the fuse its filiment will melt creating a disruption of the flow In order to bridge the gap so the printer may again be functional the damaged fuse must be replaced 1 Switch off the printer and observe applicable lockout tagout procedures 2 Open the rear housing covers to access power board 1 Figure 7 24 NOTE Figure 9 1 of the Appendix unit displays cover open or removal CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST 3 Detach defective fuse 2 from power board 1 and insert replacement fuse 2 in its place NOTE The orientation of the fuse does not matter It only has to be installed into its respective cylinder and be able make contact on each end to function NOTE Fuse amperage and voltage rating may be found stamped into the fuse s metal contacts or labeled on the printer s rear CAUTION IMPROPER FUSE USAGE MAY RESULT IN DESTROYED ELECTRICAL COMPONENTS AND OR FIRE ENSURE THE DAMAGED FUSE IS REPLACED WITH ONE OF IDENTICAL PHYSICAL DIMENSIONS AND AMPERAGE TO DO THIS DUPLICATE THE INFORMATION STAMPED ON THE FUSE S METAL CASING Figure 7 24 Fus
56. TION Printer Configuration 5 2 Configuration Modes 5 3 User Mode 5 3 Advanced Mode 5 4 Parallel Interface Mode 5 5 Serial Interface Mode 5 6 Local Area Network LAN Interface Mode 5 7 Universal Serial BUS USB Interface Mode 5 8 Centronics Interface Mode 5 9 Wireless LAN Local Area Network Interface Mode 5 10 Service Mode 5 11 Factory Mode 5 12 Work Shift Mode 5 13 Hidden Mode 5 14 Download Mode 5 15 Boot Download Mode 5 16 Print Cancel Mode 5 17 Default Settings Mode 5 18 Test Print Mode 5 19 Hex Dump Mode 5 20 CF Compact Flash Card Mode 5 21 Stand Alone Mode 5 22 Menu Definition Tables 5 23 TROUBLESHOOTING Error Signal Troubleshooting 6 2 Warning Signal Troubleshooting 6 6 Troubleshooting Table 6 7 Interface Troubleshooting 6 9 Parallel Interface 6 9 RS232 Serial Interface 6 9 Universal Serial Bus USB Interface 6 9 LAN Ethernet Interface 6 10 Wireless LAN Interface 6 10 Centronics Interface 6 10 Performance Testing 6 11 Multimeter w Test Module 6 11 Multimeter Alone 6 12 Test Print Troubleshooting 6 13 Hex Dump Mode 6 13 Test Label Printing 6 14 Sample Test Label 6 15 S8400 Series Service Manual PN 9001161A REPLACEMENT PROCEDURES Replacement Procedures 1 2 Print Head 1 2 Platen Roller 1 3 Ribbon Rollers amp Belt Direct Load 7 4 Platen Drive Motor Belt Pulleys 7 6 Ribbon Spindle Drive Motors Belts Pulleys 7 8 Ribbon Saver Drive Motor amp Belt 7 10 Ribbon Cassette Timing Belt amp Rollers 7 11 Ribbon
57. X gt Figure 7 9 Ribbon Boss amp Torque Limiter Replacement Direct Load S8400 Series Service Manual 7 13 PN 9001161A Unit 7 Replacement Procedures RIBBON BOSS TORQUE LIMITER CASSETTE LOAD Each printer model incorporates the use of a ribbon supply spindle and a ribbon rewind spindle Whereas the ripbon spindle assemblies differ for different models both the supply and rewind spindles are identical in components and assembly as it relates to those addressed here This chapter covers the replacement of ribbon spindle components located on the printer s print side for those models that provide for casstte loading of ribbon stock 1 2 Shaft Tool 2 A Detach ribbon spindle assembly 1 Figure 7 10 from the ribbon cassette not shown Insert a small diameter shaft or tool into slot A and through to the opposite side NOTE Insert a screwdriver into screw 2 to rotate the spindle to align it with slot A so that the shaft or tool may pass through it Use the shaft or tool to loosen screw 2 then remove the tool Remove screw 2 boss extension 3 front boss 4 torque limiter 5 pin 6 rear boss 7 and torque limiter 8 from ribbon spindle 9 Leave pin 10 in place NOTE The two torque limiters have minor differences Keep them separate Using replacement parts as required insert torque limiter 8 rear boss 7 pin 6 torque limiter 5 front boss 4 boss extension 3 onto ribbon
58. YA 7 OD DCS amp Labeling Worldwide 58408 58412 58424 PRINTERS SERVICE MANUAL PN 9001161A SATO America Inc 10350A Nations Ford Road Charlotte NC 28273 Main Phone 704 644 1650 Technical Support Hotline 704 644 1660 Technical Support Fax 704 644 1661 E Mail satosales satoamerica com techsupport satoamerica com www satoamerica com WARNING THE EQUIPMENT REFERENCED IN THIS DOCUMENT COMPLIES WITH THE REQUIREMENTS IN PART 15 OF FCC RULES FOR A CLASS B COMPUTING DEVICE OPERATION OF THIS EQUIPMENT IN A RESIDENTIAL AREA MAY CAUSE UNACCEPTABLE INTERFERENCE TO RADIO AND TV RECEPTION PN 9001161A TABLE OF CONTENTS INTRODUCTION About This Manual 1 2 General Description 1 3 Theory Of Operation 1 4 Control Features 1 7 TECHNICAL DATA Physical Characteristics 2 2 Power 2 2 Enviromental 2 2 Processing 2 2 Command 2 2 Interface Modules 2 2 Regulatory Approvals 2 2 Print 2 2 Media 2 3 Ribbon 2 3 Sensing 2 4 Character Font Capabilities 2 4 Barcode Capabilities 2 5 INTERFACE SPECIFICATIONS Interface Specifications 3 2 RS232C High Speed Serial Interface 3 3 IEEE1284 Parallel Interface 3 6 Universal Serial BUS USB Adapter 3 7 Local Area Network LAN Ethernet 3 8 802 11G Wireless 3 9 All Interfaces 3 11 External Signal 3 14 ACCESSORIES INSTALLATION Interface Installation 4 2 Compact Flash Card 4 3 Remote Operator Panel 4 4 S8400 Series Service Manual PN 9001161A PRINTER CONFIGURA
59. a seal between two objects Oscillate To move back and forth along a span Pan Head Screw A threaded rod with a rounded flanged head used to attach multiple object together In printing applications the temporary backing for print media The paper is removed following Orifice An opening for which something is to pass through similar to a bore Paper printing so the label may be applied Parallel Objects extending in the same direction maintaining the same distance part An interface between computer and printer where the computer sends multiple bits of information to the printer simultaneously by sending each bit over a separate wire Parameter The span or area that something is allowed to exist or operate A simple form of error checking that is used in serial communication A parity bit is a binary digit that is added to a group of bits to detect the presence of an error The parity bit take on the value of an 0 or a 1 to satisfy a constraint on the overall parity of a binary number The parity scheme in use must be specified as even or odd Parity is even if there are an even number of 1 bits and odd otherwise None may also be chosen Passive RFID tags that do not contain an internal power source They are externally powered Passive Tags l i and typically derive their power from the carrier signal radiated from the scanner Personal Computer An electronic computing device that may be individually and independently used or c
60. after having the print head open When DISABLE is selected label pitch will not be redetect and the label must be manually positioned Allows the assignment of a function to the Function key The NONE setting disables the button It may also be assigned the REPRINT command or to enter the SEMBL mode Permits the determination of whether a password will be required to access and change principle configuration features Permits the assignment of a password Use the vertical arrow keys of the operator panel to scroll digit options and the horizontal arrow keys to move from one digit location to another Press the Enter key to record the four digit password chosen Determines whether or not the printer will be compatible with a previous printer model When the Compatibility Mode is ON the functions and settings that are unique to the printer will be disabled or modified to match the characteristics of older printer models of the same family This allows legacy or custom programmed labeling software to run on this printer without requiring modification 5 34 PN 9001161A Unit 5 Printer Configuration SERVICE MODE TABLE 5 9 Allows the maximum length of the label used to be defined The default value varies depending SE ECan on head density 8dot mm 0 to 2500mm 12dot mm 0 to 1500mm 24dot mm 0 to 400mm XXXX MM This screen will not appear if the Comaptibility Mode has been turned ON LISI Allows the determination of copying fir
61. an explanation of each menu screen PASSWORD Displayed if password feature is enabled ZA ONLINE QTY 000000 LAN CONFIGURATION BOARD LCD Disabled for Wireless OFFLINE LAN QTY 000000 Cancels CANCEL ENTER print job IP ADDRESS PROTOCOL STATUS3 zz STATUS4 STATUS5 SEMBL Mode CF Card Mode SUBNET MASK User 0o 0 0 0 STATUS RELAY TIMING INTERFACE MODE A ES TOT ENQ CYCLE ENTER ENTER INTERFACE BOARD ITEM NO CHECK SETTING YES NO WIRELESS MODE 802 11 Ad Hoc Ad Hoc Infrastructure ENABLE DISABLE ENTER ENTER DATA PORT INTERFACE BOARD BCC CHECK SETTING I F 1 I F 2 I F 1 I F 2 ik ib ENABLE DISABLE ENTER SENDER lt A gt CHANNEL IGNORE CR LF YES ENTER IGNORE CAN DLE ENTER Figure 5 8 Wireless LAN Interface Mode S8400 Series Service Manual 5 10 PN 9001161A SERVICE MODE Unit 5 Printer Configuration 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 Definition Tables in the following chapter to provide an explanation of each menu screen ZA ONLINE QTY 000000 LINE lit OFFLINE QTY 000000 ENTER ONLINE MODE za Te SO gt Service VA Fe Mode ENTER SENSOR LEVEL I MARK XXV LEVEL OFFSET XX SENSO
62. an otherwise pre printed label Without the ribbon saver feature ribbon would be exhausted during the entire length of the label as it is fed through the printer even if printing is not ocurring The ribbon saver feature allows the ribbon to remain stationary during areas where printing is not demanded while the media continues to advance Through a stepper motor designated for the ribbon saver feature torque is transfered by way of a belt and pulley configuration A sensor engaged with a toothed disc plate monitors and controls movement while a dampening lever is actuated by the same assembly to control print head vertical movement Paper guides within the chassis assembly ensure the media remains properly positioned beneath the print assembly and is fed unimpeded from the printer s rear through to the front A series of strategically located sensors and switches send signals to the processing unit Some sensors are two part consisting of transmitting and receiving components The transmitting component is mounted opposite of the receiving component so that media may pass between the two When present the media blocks sensor transmission from reaching the receiver The processing unit in turn sends response signals to the various features based on programmed and received data These signals are the controlling force of mechanical activities The print head through thermal heat inductively provided by electrical supply transfers print images onto th
63. and vice versa A setting of 0 0 to 3 2 volts is possible The default is 1 4 volts A setting of 0 0 volts causes the printer to automatically determine the slice level Allows sensitivity adjustment of the gap sensor for different label materials Increasing decreasing the level offset changes the sensor s voltage value within a factory set range The adjustment range is 1 to 99 The default value is 50 Refer to the Adjustment Procedures unit of this manual for detailed instructions Allows the sensor threshold slice level adjustment of the gap sensor Ideally the slice level setting is at or near the mid point between the low and high voltage readings from the previous screen low voltage reading high voltage reading 2 slice level setting A setting of 0 0 to 3 2 volts is possible The default value is 1 2 volts A setting of 0 0 volts causes the printer to automatically determine the slice level This feature allows one label to be fed upon the printer entering the online mode Enable or disable as desired Allows it to be determined if the printer will feed a label when an error condition is cleared and the printer goes online 5 33 PN 9001161A Unit 5 Printer Configuration SERVICE MODE TABLE 5 9 FORWARD BACKFEED DISTANCE DEFAULT XXX MM apr EXT 9PIN SELECT MODE1 MODE2 WEB ACCELERATION FAST NORMAL 4k EURO CODE XX a PRIORITY SETTING COMMAND INTERNAL RIBBON NEAR END ENABLE DI
64. anual 9 8 PN 9001161A IX Appendi Unit 9 Figure 9 7c Ribbon Loading Diagram Cassette Load Figure 9 7d Ribbon Loading Diagram Cassette Load PN 9001161A 9 9 S8400 Series Service Manual Unit 9 Appendix TYPICAL APPLICATOR PROCESS O 2 a QO lt I c je O A Packaging Figure 9 8 Typical Applicator Process S8400 Series Service Manual 9 10 PN 9001161A Unit 9 Appendix PRINTER PACKING amp UNPACKING DIAGRAM Figure 9 9 Printer Packing amp Unpacking S8400 Series Service Manual 9 11 PN 9001161A Unit 9 Appendix READY BUSY TIMING CHARTS 1 Normal process Power ON Press the LINE key Press the LINE key Printer side i Initial i td ER RD RS Printer status td Olt takes the printer 10s approx to recognize the end of item and to start controlling ER 2 Error process i l Head open Head close Press the LINE key Paper end occurred Press the LINE key Printer side N I I I I I I I I ER poo rt a1 a S ee I I loin ii RD I N T I Lesa RS i I i Online _ _ Offline _ i Online Printer status di I Figure 9 10a Single Item Buffer Timing Charts 1 Normal process Receive buffer Receive buffer Press the LINE key Press the LINE key Power ON near full occurred near full released Printer side N Initial ER RD RS Printer status
65. area in something In the case of a die set the core is one of two part with the core Cavity Li l being its mating half Circuit A network of wires resistors and other electronic devices over which electrical impulses travel Clockwise To rotate from left to right As it relates to RFID a system in which relevant data regarding the attributes of the object is stored in a common database accessible via data link by referencing the individual ID code Collar A sleeve applied to a rod shaft or pipe to prevent sideward motion Component A single part that may applied to others to form an assembly i An object that is comprised of or layered with two or more materials to achieve a desired Composite me Concave A curved recess or hollow the opposite of convex Concentric Multiple items that share a common center example a circle centered within a circle l l The arrangement of parts or components to operate in unison for a specific activity Configuration To program software to enable disable or specify how various features will function Devices for joining electrical and electronic circuits through coupling Typically one mating half is a plug male and the other is a socket female Convex A spherical shaped surface one that is curved outward The protruding portion of a die set The core is one of two parts and the cavity being its mating half The core is convexed and the cavity is concaved Closed Syste
66. at was previously registered is at least 0 8V greater than the low reading just read 6 Add these readings and divide them by two Record the result 7 Advance to the Slice Level menu screen Figure 8 14 SENSOR LEVEL GAP XXV SLICE LEVEL XXV Figure 8 14 Slice Level Menu Screen Read the slice level displayed to ensure the slice level is equal to this value Repeat steps 3 through 8 as required S8400 Series Service Manual 8 13 PN 9001161A Unit 8 Adjustment Procedures OPERATIONAL ADJUSTMENTS These operational adjustments are for fine tuning the printer as necessary following the configuration process and are largely confined to the four potentiometers located on the operator panel Refer to the table below for their function POTENTIOMETER PITCH OFFSET DARKNESS S8400 Series Service Manual DESCRIPTION PROCEDURE Is to be used in conjunction with the configuration adjustments Make course adjustments there and then fine tune here If unable to achieve the desired setting here the course adjustment must be reset Adjust this potentiometer as labels are being printed Allow two labels to be printed for each adjustment to ensure a desired setting Adjustment of the PITCH potentiometer will affect the print offset position The offset adjustment is used to reposition the media for printing following advancement for dispensing A label is printed it is fed forward for dispense the printer retracts the
67. balance Worn rollers Replace rollers as required Dirty print head MEANDERING MEDIA Incorrectly loaded media Clean print head Ensure correct loading Improperly adjusted media guides Adjust as required Unbalanced print head Adjust as required Worn rollers NO LABEL MOVEMENT Loose or broken timing belt Replace as required Replace or adjust as required Incorrect label sensor selected Check printer configuration for proper sensor selection No voltage output Replace fuse Test power supply and replace as required Drive motor not operating LCD FIELD ILLUMINATED BUT WITHOUT WORDS OR NO DISPLAY AT ALL Ensure cable properly connected Check replace power supply Ensure wiring harness connection Replace as necessary Power supply issues Incorrectly positioned display potentiometer Adjust as required S8400 Series Service Manual 6 7 PN 9001161A NO PRINTED IMAGE Print head is disconnected No voltage output Defective print head Damaged electronics Interface problems Data input error Ribbon incorrectly loaded PRINTER CREATES A BLANK LABEL Data input error Incorrect label sensor selection Disconnected print head Defective print head Defective main circuit board INCORRECT LABEL POSITIONING Incorrect label sensor selection Improper sensor adjustment Data input error Incorrect offset settings Incorrect applicator setup Poor media quality Foreign material on p
68. be required if the media is inclined to meander at the printer s rear to one side When all things are properly aligned and balanced the media will continuously feed from the printer s rear through to its front without lateral movement creating resistance on its left or right sides Before adjusting the pressure rollers ensure the media roll is harmoniously positioned and aligned so that it may flow perfectly parallel to the printer Next ensure the printer s print head is properly aligned and balanced If all other conditions are confirmed to be adequate and the media s edge is still dragging against either the printer s center wall or the media guide then adjust the pressure roller balance These pressure rollers are spring loaded on each end and embedded in the label sensor assembly By adjusting the setscrew on either end downward the pressure on that end is increased Likewise an adjustment of a setscrew upward on either end reduces pressure on that side To adjust pressure roller balance loosen the locknut on given side and adjust the relative setscrew to increase or decrease pressure as deemded appropriate When the desired outcome is achieved hold the setscrew in position while tightening its locknut Locknut Setscrew a N Figure 8 5 Media Pressure Roller Balance S8400 Series Service Manual 8 6 PN 9001161A Unit 8 Adjustment Procedures PRINTER BELT TENSIONING The printer incorporates the use of tim
69. before replacing it Switch off the printer and observe applicable lockout tagout procedures Remove ribbon stock and leave print head unlatched Remove screw 1 Figure 7 20a front boss 2 torque limiter 3 pin 4 rear boss 5 and torquelimiter 6 from ribbon rewind spindle 7 NOTE To dismantle the ribbon spindle assembly insert a small diameter shaft betwwen the front and rear ribbon bosses and through an orifice in the spindle Rotate the bosses as necessary for alignment Remove two screws 8 securing belt cover 9 Withdraw belt cover 9 Remove two screws 10 securing print head latch handle 11 Withdraw latch handle 11 Remove three screws 12 and two screws 13 from front plate 14 Leave front plate 14 in place Figure 7 20a Ribbon End Sensor Replacement Direct Load S8400 Series Service Manual 7 29 PN 9001161A 10 11 12 13 14 15 16 17 Unit 7 Replacement Procedures Remove one screw 15 Figure 7 20b and two screws 16 from rear plate 17 Withdraw ribbon roller assembly 18 from printer NOTE Manually hold the print head in the closed position to manipulate the roller assembly from the printer Remove one screw 19 securing defective ribbon end sensor 20 to printer Disconnect defective sensor 20 from wiring harness not shown Connect replacement sensor 20 to wiring harness not shown and secure to printer using screw 19 Hold ribbo
70. ble Programmable Read Only Memory Are ROM chips that do not have to be removed to be rewritten Nor does the entire chip have to be completely erased to change a specific portion Changing the contents does not require additional dedicated equipment DRAM Eccentric EEPROM The localized application of an electric field to each cell erases the targeted cells which can be rewritten Since only 1 byte can be changed at a time EEPROM s are versatile but slow Electronic Label A label that has an electronic RFID tag embedded within Electromagnetic Coupling In RFID a system that uses a magnetic field as means of transferring data or power l In RFID a system which uses the induction of voltage on a plate as a means of transferring Electrostatic Coupling data or power Ellipse An oval shape that is symmetrical on either side of its center when divided into quadrants Embossed Characters or graphics that are raised above the remaining surface Enable To activate or make able to function Encompass To surround encircle or contain ECC In RFID supplemental bits in a data transfer used in conjunction with a polynominal Error Correcting Code algorithm in order to compute the value of missing or erroneous data bits Example for a 32 bit data transmission seven additional bits are required l Relative to RFID a mode of data communication in which missing or erroneous bits are Error Correcting Mode l automatically corrected
71. bracket 4 to motor plate 8 and secure the assembly 2 to printer frame 3 using two screws 1 Connect wiring harness not shown NOTE Ensure the motor spindle inserts within the free end of its respective belt 8 Close housing covers install interface cards restore power and test print to ensure proper function Figure 7 6 Ribbon Saver Drive Motor amp Belt Replacement S8400 Series Service Manual 7 10 PN 9001161A Unit 7 Replacement Procedures RIBBON CASSETTE TIMNG BELT amp ROLLERS REPLACEMENT The ribbon cassette feature allows the quick reloading of ribbon stock once an existing roll has been exhausted This is achieved by maintaining a loaded cassette on standby at all times Like the non cassette printer model the cassette is comprised of rollers and a single belt of the same type and in the same configuration Also like the non cassette model to replace these components the rear frame or plate that rests against the printer s center wall must be removed to gain access de e Switch off the printer and observe applicable lockout tagout procedures Detach the two ribbon bosses not shown from the cassette Remove five screws 1 Figure 7 7 two screws 2 and one screw 3 from rear plate 4 Separate rear plate 4 from front plate 5 and withdraw worn belt 6 Detach snap ring 7 and withdraw bearing 8 from ribbon roller 9 to replace Detach snap ring 10 and wi
72. c Identification Systems Systems that communicate over a radio link between a host computer and a data source RF DC enhances the capabilities of automatic ID Systems by providing the capabilities of hare wire data communications without the physical restrictions interconnecting wires Radio Frequency Identification A method of identifying unique items using radio waves Typically a reader communicates with a tag which holds digital information in a microchip But there are chipless forms of RFID tags that use material to reflect back a portion of the radio waves beamed at them 9 34 PN 9001161A GLOSSARY Unit 9 Appendix RFID Tags Ribbon Ribbon Core ROM RPM Route SAM SBPL Scale Scanner Screen Seat Secondary SEMBL Sensitivity Sensor Separation Sequential Serial Interface Set Screw Shaft u 00 N O O op D D N op D lt O D ie 5 E D A system of finding the position or location of assets A microchip attached to an antenna that is packaged in a way that it can be applied to an object The tag picks up signals from and sends signals to a reader The tag contains a unique serial number but may have other information and come in many forms such as smart labels that can have a barcode printed on it or can simply be mounted inside a carton or embedded in plastic RFID tags can be active passive or semi passive Each tag broadcasts a signal to b
73. cess the Work Shift Mode ENTER SHIFT TIME XX XX 45 Permits the entry of the begin time of the shift being configured This is in a 24 hour clock format Allows the establishment of the quantity of character to be used for the Shift Name in the screen ar to follow The first X depicts the shift number and is based upon what was selected in the Select Shift screen The XX has a valid range of 1 to 16 4p S8400 Series Service Manual 5 37 PN 9001161A Unit 5 Printer Configuration WORK SHIFT MODE TABLE 5 11 Allows the entry of the user defined shift name The quantity of characters used must be reflective of the quantity entered in the preceding screen x HIDDEN MODE TABLE 5 12 Used to enable or disable the label out sensor The YES option is enabled and the NO option is LABEL OUT SENSOR disabled YES NO aon Used to enable or disable the Shift Code menu parameters The YES option is enabled and the STES NO option is disabled Note the YES option must be selected to access the Work Shift Mode menu DOWNLOAD MODE TABLE 5 13 Is an informational screen only and confirms that the printer is ready to receive the data DOWNLOAD WAITING Screen confirms that downloading is in process and displays its progress status A tinted field will move laterally from the left toward the right as downloading progresses When the tinted bar reaches 100 on the scale downloading is complete This menu screen appea
74. cessor The processor in turn relays a signal to the panel board 1 Switch off the printer and observe applicable lockout tagout procedures 2 Open the printer s rear housing covers to access the printer s electrical side NOTE Figure 9 1 of the Appendix unit displays cover open or removal CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST 3 Remove two screws 1 Figure 7 18a and one screw 2 securing platen motor assembly 3 to frame 4 4 Withdraw platen motor assembly 3 from the printer and unlatch print head not shown Figure 7 18a Head Open Sensor Replacement Remove one screw 5 Figure 7 18b securing defective head open sensor 6 to frame 4 Disconnect wiring harness not referenced from defective sensor 6 and connect to replacement sensor 6 7 Secure replacement head open sensor 6 to frame 4 using screw 5 NOTE A properly installed sensor will be oriented so that it s directed upward 8 Latch and unlatch the print head to ensure unempeded movement S8400 Series Service Manual 7 26 PN 9001161A Unit 7 Replacement Procedures Xi ae NOS SIO R gt i y A gt N DS Pu EE FF N Figure 7 18b Head Open Sensor Replacement 9 Secure platen motor assembly 3 Figure 7 18a to frame 4 using one screw 2 and two screws 1 NOTE S
75. conforms to IEEE1284 specifications It automatically detects the IEEE1284 signals and operates in the high speed mode If the IEEE1284 signals are not detected it will operate in the slower standard Centronics mode For this reason an interface cable and host interface conforming to the IEEE1284 specification must be present to fully utilize the speed capabilities This interface also operates bi directionally and can report the status of the printer back to the host SPECIFICATIONS Printer Connector AMP 57 40360 DDK or equivalent Cable Connector AMP 57 30360 DDK or equivalent Cable 1 5 meter or less Signal Level High 2 4V to 5 0V Low OV to 0 4V Data Stream lt ESC gt A Job 1 lt ESC gt Z lt ESC gt A Job n lt ESC gt Z Figure 3 3 Parallel Connector Pin Assignments PIN ASSIGNMENTS SIGNAL DIRECTION DIRECTION Strobe To Printer Reference Data 1 Reference Data 2 Reference Data 3 Reference Data 4 Reference Data 5 Reference Data 6 Reference Data 7 Reference Data 8 Reference K Reference Busy Reference Ptr Error Reference Select From Host AutorD To Host Not Used Not Used Not Used Selectin1 From Host To Printer To Printer To Printer To Printer To Printer To Printer To Printer To Printer To Host To Host To Host To Host To Host gt O Not Used Logic Gnd F 5V z 24k ohm To Host 1 Signals required for ieee 1284 mode Frame Gnd i Eu Eu a e Eu O Io
76. corner is in the lower corner on the opposite side of the motor as its wiring harness connector _ ZN x Mf 1 gt NY Figure 7 5a Ribbon Spindle Motors Belts Pulleys Replacement S8400 Series Service Manual 7 8 PN 9001161A Unit 7 Replacement Procedures 6 Repeatsteps 3 and 4 for the second motor assembly 2 if belt and pulleys are to be replaced 7 Perform step 5 if the second motor is to be replaced NOTE Both motors are identical and their assemblies are assembled identically Their only difference is their orientation when mounted to the printer s frame 8 Detach snap ring 9 Figure 7 5b and remove two screws 10 securing pulley bracket 11 Lift away 11 9 Replace all belts not referenced and pulleys not referenced as deemed necessary in the orientation as was removed 10 Secure pulley bracket 11 to printer frame 3 using two screws 10 and snap ring 9 Figure 7 5b Ribbon Spindle Motors Belts Pulleys Replacement 11 Apply tension spring 5 Figure 7 5a motor bracket 4 to motor plate 8 and secure the assembly 2 to printer frame 3 using two screws 1 NOTE Ensure the motor spindle inserts within the free end of its respective belt and that the belt is properly routed 12 Repeat step 11 to install the second motor assembly and reconnect both motor wiring harnesses 13 Close housing c
77. d 8 Ensure panel board buttons 10 are properly placed within panel cover 6 NOTE To properly install the panel board insert its right end under the tab on the right end of the panel cover followed by the left end 10 Apply replacement panel board 8 to panel cover 6 and secure using four screws 7 Figure 7 15c Panel LCD Board Replacement 11 Apply mounting plate 5 Figure 7 15b to panel cover 6 and secure using four screws 4 Remove four screws 7 Figure 7 15c securing panel board 8 to panel cover 6 Lift away board 8 12 Reconnect wiring harness not referenced and secure board assembly 1 Figure 7 15a to frame 2 using two knurled thumbscrews 2 13 Restore power and test print labels to ensure proper function S8400 Series Service Manual 7 21 PN 9001161A Unit 7 Replacement Procedures INTERFACE BOARD REPLACEMENT Circuit boards generally have long lives due to the lack of moving parts Generally if a circuit board becomes defective it is contributable to a negative external condition If It is determined that the circuit board has become defective search the printer over for possible visual factors that may have led to the damage Switch off the printer and observe appilcable lockout tagout procedures Disconnect interface cable 1 Figure 7 16 from defective interface board 2 Remove two screws 3 securing defective interface board 2 to printer 4 Insert replacem
78. dustrial print engines The S8400 series can physically and electronically replace any of SATO s previous S type OEM print engines Additionally this printer utilizes the same SATO Barcode Printing Language SBPL as drives all current SATO OEM print engines The S8400 series print engine is available with many options including quick change ribbon cassette ribbon saver and RFID capability Power Switch Platen Roller x3 Ribbon Cassette Figure 1 1a Primary Components S8400 Series Service Manual 1 3 PN 9001161A Unit 1 Introduction THEORY OF OPERATION When activated media is fed past the print head by an integrated drive train The drive train is electric stepper motor driven and coupled to a gear pulley and belt configuration located on the electrical side of the printer s center frame A pulley is concentrically attached to the motor spindle and provides differential torque to a series of pulleys via three timing belts These pulleys with gears concentrically attached provide movement to the three platen roller spindles and provide media movement through treading contact with the roller Two separate stepper motors transfer torque to the ribbon supply and ribbon rewind spindles by way of a belt designated for each and engaged on the opposite end a pulley for each spindle The pulleys located on the printer s electrical side are directly attached to gears on the print side
79. e The most common format for text files in computers and on the internet In a ASCII file each alphabetic numeric or special character is represented with a 7 bit binary number a string of seven Os or 1s 128 possible characters are defined The fitting together of parts components or sub assemblies to form a complete unit A type of two way communication that occurs with a time delay allowing participants to respond at their own convenience This communication allows characters to be sent at irregular intervals by preceding each character with a start bit and following it with a stop bit The timing of the transmission is not determined by the timing of the previous character A sound loud enough to be heard A grouping of anything The number of signaling elements that occur each second or stated differently the number of changes to the transmission media per second in a modulated signal At slow speeds one bit of information signaling element is encoded in each electrical change The baud therefore indicates the number of bits per second bps that are transmitted Assuming asynchronous communication which requires 10 bits per character this translates to 30 characters per second cps For slow rates below 1200 baud the baud can be divided by 10 to see how many characters per second are sent At higher speeds it is possible to encode more than 1 bit in each electrical change Thusly 4800 baud may allow 9600 b
80. e media as it passes The print image may be manifested through either a direct process initiated through a chemical reaction to the heat from within the label media or transferred from the ink coated ribbon stock Predetermined voltage supply of alternating current from an independent souce is required for proper function The printer s integrated power panel transforms the supplied voltage to direct current which is mediated to the various circuitry This circuitry is comprised of properly positioned transformers relays diodes resistors and chips which sends receives and processes communication data throughout the system S8400 Series Service Manual 1 4 PN 9001161A Unit 1 Introduction Front Housing Cover Rear Housing Covers Ribbon Roller x2 Ribbon Guide Head Pressure Knob Head Balance Print Head Latch Figure 1 1b Primary Components S8400 Series Service Manual 1 5 PN 9001161A Unit 1 Introduction Ribbon Supply Motor Assy Ribbon Rewind Motor Assy Printer Center Frame Platen Motor Assy Ribbon Saver Motor Assy Figure 1 1c Primary Components S8400 Series Service Manual 1 6 PN 9001161A Unit 1 Introduction 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
81. e Replacement S8400 Series Service Manual 7 34 PN 9001161A Unit 7 Replacement Procedures FAN REPLACEMENT The fan assmbly is used to prevent the printer s internal components from overheating 1 Switch off the printer and observe applicable lockout tagout procedures 2 Open the printer s rear housing covers NOTE Figure 9 1 of the Appendix unit displays cover open or removal CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST Remove two screws 1 Figure 7 25 securing air deflector 2 and fan 3 to the printer Disconnect wiring harness not shown from defective fan 3 and connect replacement fan 3 Secure replacement fan 3 and air deflector 2 to the printer using two screws 1 NOTE A properly installed air deflector will be oriented upward 6 Close rear housing covers restore power and operate printer to ensure proper function Figure 7 25 Fan Replacement S8400 Series Service Manual 7 35 PN 9001161A Unit 7 Replacement Procedures FAN FILTER REPLACEMENT The fan filter prevents atmospheric debris from being drawn into the printer adversely affecting component performance The filter is adhesive on the contact side To install simply remove the contaminated filter peel away the adhesive paper backing and apply over the fan exhaust holes Refer to Figure 7 26 for
82. e received by three reader antennas The time each signal is received is passed on to a software system that uses triangulation to calculate the location of the asset A thin flexible strip with layers of material one of which contains ink used to produce an image on print media A thick cardboard sleeve onto which ribbon is wound Not flexible stiff Read Only Memory Also known as firmware is an integrated circuit programmed with specific data when it is manufactured There are five basic types ROM PROM EPROM EEPROM and Flash Memory Each type has unique characteristics but they all are types of memory that have two things in common the stored data is non volatile not lost when power is removed and the stored data is unchangeable or requires a special operation to do so ROM chips contain a grid of columns and rows A diode is used to connect the lines and gain access to the data if the value is 1 If the value is 0 the lines are not connected and access is denied Revolutions Per Minute The number of cycles within the time span of one minute The path or course taken to get from one location to another example the routing of a cable within a machine Serial Access Memory Stores data as a series of memory cell that can only be accessed sequentially Works very well for memory buffers where data is normally stored in the order in which they will be used SATO Basic Programming Language The units to
83. e the host s peripheral settings are set for Centronics output for faster throughput Refer to the computer manufacturer s documentation for details Ensure the printer is receiving information from the computer using the Receive Buffer Hex Dump mode Refer to that procedure within this manual for instructions The command stream should be continuous and possess ODhex and or OAhex carriage return and line feed characters throughout However there should not be either located between the start lt ESC gt A and the stop lt ESC gt Z commands Replace the interface board with another to isolate the problem permanently replace if defective S8400 Series Service Manual 6 10 PN 9001161A Unit 6 Troubleshooting PERFORMANCE TESTING This chapter explains how to troubleshoot circuitry using a multimeter These activities may be performed with or without test module assistance in conjunction with the multimeter MULTIMETER WITH TEST MODULE The following procedure provides in depth instruction on troubleshooting the DC power supply voltage If the voltage values measure outside the specified parameters the power board is deemed defective and must be replaced Those relative procedures may be found in the Replacement Procedures unit of this manual 1 Switch off the printer and open the exterior cover from the printer s mechanical side NOTE Refer to Figure 9 1a in the Addendum unit for guidance on cover opening Connect the Test
84. e the problem RS232 SERIAL INTERFACE Ensure the correct interface module is correctly installed Run self test to verify Ensure the serial cable Null Modem meets specifications and is correctly connected at each end Ensure the serial cable is not defective sent from the host computer Ensure the printer is receiving information from the computer using the Receive Buffer Hex Dump mode Refer to that procedure within this manual for instructions The command stream should be continuous and possess 0Dhex and or OAhex carriage return and line feed characters throughout However there should not be either located between the start lt ESC gt A and the stop lt ESC gt Z commands Replace the interface board with another to isolate the problem Replace the interface board permanently if determined to be the problem ne Ensure the communication parameters for the baud rate parity data bits and stop bits are consistent with those being UNIVERSAL SERIAL BUS USB INTERFACE If nothing prints during a test print verify the device drivers have been successively installed by performing the following 1 Olek on Ser setings and en Conte Panda OOOO BEE System within the new windon SSS O Telckon the Device manager OSS ensue thatthe View Device By type e hei I Scrolio SATO USB Device and ensure that errors do not exist Reinstall as regure O Rebootthe PC and ine pie SSS Contact Miroso technical suppor tor turner assistance as eau
85. e to align the scales reprint and then readjust as deemed necessary 4 Determine which end of alignment plate 2 should be adjusted and loosen its relative set screw 5 or 6 5 Adjust alignment plate 2 then retighten relative set screw 5 6 while maintaining plate 2 position NOTE There is an adjustment aperture C D in alignment plate 2 where an object may be inserted to assist in adjustment An appropriately sized Standard screwdriver works best 6 Test print a label to determine if print head 2 is properly aligned 7 Repeat this procedure until proper alignment is achieved Figure 8 3 Print Head Alignment S8400 Series Service Manual 8 4 PN 9001161A Unit 8 Adjustment Procedures RIBBON GUIDE ALIGNMENT If the print ribbon is not spread smoothly over the print head when it makes contact with the media print voids will occur at the point of the ribbon fold Typically this is the result of the axis of one of the following not being perfectly parallel with the platen roller ripbon spindle print head or ribbon guide The purpose of the adjustable ribbon guide is to compensate for the axis deviations of the other two By adjusting the ribbon guide proportionally to the degree of deviation the ribbon spreads smoothly as it travels from the ribbon supply spindle to the guide and beyond Ribbon guide adjustment i
86. eatures chapter of the Introduction unit for identification of specific interface features S8400 Series Service Manual 5 2 PN 9001161A Unit 5 Printer Configuration CONFIGURATION MODES This chapter provides an overview of the various configuration modes of the operation menu All of the configuration activities are performed via the use of the operator panel located on the printer s face However many settings may also be controlled via external software commands In the case of conflict between external software commands and internal software commands control panel settings the printer will always use the last valid setting unless a priority function is provided via the LCD menu USER MODE This mode allows configuration of printing features that are prone to change from job to job These are some of the most basic and common adjustments of all of the configuration modes Use the keys of the printer s operator panel to select and enter the required options Refer to the Menu Definition Tables in the following chapter to provide an explanation of each menu screen Za ONLINE QTY 000000 Sg OFFLINE QTY 000000 LINE CANCEL ENTER Cancels print job ONLINE MODE 2a D Jo SEMBL Mode CF Card Mode Interface Mode gt CANCEL ENTER OFFSET VOLUME Advanced PITCH X XX Mode OFFSET RR DARKNESS XX CANCEL ENTER PRINT SPEED PASSWORD Displayed if passwo
87. ect loading of ribbon stock Switch off the printer and observe applicable lockout tagout procedures Open the front housing cover to gain access to the print assembly Remove ribbon stock if presant to access ribbon spindle assembly 1 Figure 7 9 gt SP De Insert a small diameter shaft or tool into slot A and through to the opposite side NOTE Insert a screwdriver into screw 2 to rotate the spindle to align it with slot A so that the shaft or tool may pass through it Use the shaft or tool to loosen screw 2 then remove the tool Remove screw 2 front boss 3 torque limiter 4 pin 5 rear boss 6 and torque limiter 7 from ribbon spindle 8 Leave pin 9 in place NOTE The two torque limiters have minor differences Keep them separate 7 Using replacement parts as required insert torque limiter 7 rear boss 6 pin 5 torque limiter 4 front boss 3 onto ribbon spindle 8 and secure using screw 2 NOTE A properly installed torque limiter will be oriented so that its metal end is inserted onto the spindle first and will engage each respective pin Properly installed ripbon bosses will engage their respective torque limiters Rotate each while appliying forward pressure to ensure proper nesting Insert the shaft or tool into slot A of spindle assembly 1 and hold firmly to tighten screw 2 Repeat steps 4 through 8 for the second ribbon spindle 1 as necessary uf f Fa
88. ecure the three short ground cables to the platen motor bracket using the leftmost screw 1 and the two longer ground cables using the rightmost screw 1 10 Close rear housing covers restore power and latch unlatch print head to ensure proper function S8400 Series Service Manual 7 27 PN 9001161A Unit 7 Replacement Procedures RIBBON SENSOR REPLACEMENT The ribbon sensor monitors the revolutions of the ribbon supply spindle and sends a signal to the processor to control rewind timing This sensor has an integrated transmitter and receiver with each positioned on opposite sides of the supply spindle s toothed disk plate The toothed portion of the disk plate intermittantly interrupts and blocks the sensors transmission reception ATTENTION Before assuming the sensor is defective and replacing the assembly ensure that the condition is not the result of debris buildup Thoroughly clean the sensor before replacing it Switch off the printer and observe applicable lockout tagout procedures Open the printer s front cover and remove ribbon stock or remove ribbon cassette as applicable Remove two knurled thumbscrews 1 Figure 7 19 securing panel board assembly 2 to printer frame 3 Disconnect wiring harness not shown from panel board assembly 2 and set aside Remove one screw 4 securing defective sensor 5 to frame 3 and disconnect its wiring harness A Feed wiring harness A of replacement sensor 5 through
89. election of the receive buffer type Select MULTI for multiple item buffer and 1ITEM EEEO T for a single item buffer MULTI 1 ITEM This screen will only appear if one of the serial interface types is installed and the protocol is set to READY BUSY or XON XOFF WIRELESS LAN INTERFACE MODE TABLE 5 8 Is the premiere screen of the Interface Mode The Interface Mode allows the parameters to be set for the printer to communicate with a host and vice versa Select the YES option to configure an interface board for bi directional communication the menu sa will advance to multiple configuration screens depending on the type of interface borad installed SETTING RE Selecting the NO option will bypass those screens Allows the selection of which interface port will be assigned to receive print data Interface Port 1 I F 1 is the smaller card slot of the printer and Interface Port 2 I F 2 is the printer s middle card slot The default setting is I F 2 and accommodates a standard interface card F 1 is to be used a ii for the optional PCI interface cards DATA PORT Determines whether the print data code requires deletion Hexadecimal graphic data will not be E deleted Select YES to delete all carriage returns CR and line feed LF commands in the data stream including graphics and 2D bar codes This feature is primarily used to maintain compatibility with earlier models of SATO printers S8400 Series Service Manual 5
90. ent interface board 2 into printer 4 and secure using two screws 3 oe ee YS Connect interface cable 1 N IA N a Ke Figure 7 16 Interface Board Replacement S8400 Series Service Manual 7 22 PN 9001161A Unit 7 Replacement Procedures LABEL SENSOR REPLACEMENT The label sensor is a sensor complex comprised of the label out sensor gap reciever and eye mark sensor all contained within a single housing This sensor assembly is mounted to the printers center frame to protrude across the printer s chassis The label sensor assembly may be easily identified by its purple adjustment knob located behind the print assembly ATTENTION Before replacing the assembly assuming the sensor defective ensure that the condition is not the result of debris buildup Thoroughly clean the sensor before replacing it Switch off the printer and observe applicable lockout tagout procedures Open the printer s front cover or remove it s ribbon cassette as applicable Remove media from the printer to access the printer s chassis 1 Figure 7 17a AOA V a Remove two screws 2 securing upper label assembly 3 to center frame 4 Withdraw assembly 3 Figure 7 17a Label Sensor Replacement Remove two screws 5 Figure 7 17b securing lower cover 6 to upper cover 7 Detach defective upper sensor 8 from upper cover
91. entiometers on the Operator Panel Entry is not Son required for this screen The values will change as the potentiometers are adjusted PITCH X XX OFFSET X XX DARKNESS XX Permits the printer s print speed to be established based on inches per second IPS PRINT SPEED XX IPS Permits the adjustment of the print density Higher print density equates to darker print images PRINT DARKNESS The label pitch is the distance from the leading edge the edge that comes out of the printer first of a label and the leading edge of the next label The position of the label s leading edge can be adjusted relative to the print head in increments of 1mm Once the position has been set it can be fine adjusted using the PITCH potentiometer Positive digit selection on the display moves the leading edge forward and away from the print head while a negative selection moves the label s leading edge incrementally back into the mechanism ADVANCED MODE TABLE 5 2 Is the first menu screen of the Advanced Mode The Advanced Mode is provided to make advanced printer operational adjustments Typically once these adjustments or settings have been made they will not require additional address unless the application significantly changes This menu sets the darkness range used by PRINT DARKNESS screen in the User Mode Darkness range A is the default Darkness range B offers higher temperatures across the print darkness range and ma
92. er and configure printer for head change 13 Load printer with media and ribbon as applicable Test print a label to ensure proper function NOTE The print head configuration menu screens will appear when the printer is powered on S8400 Series Service Manual 8 11 PN 9001161A Unit 8 Adjustment Procedures EYE MARK PAPER END SENSOR SENSITIVITY This sensor adjustment regulates penetrating ability for media referencing For proper performance the sensor must have a voltage difference greater than 0 8V between high and low If performing the following procedure does not result in acceptable voltage levels clean the window over the sensor s eye 1 Load printer with label media so the white backing paper may be registered by the eye mark sensor Power on the printer Using the printer s operator panel access the Service Mode and then proceed to the Level Offset menu screen Figure 8 11 Using the printer s operator panel adjust the level offset so the sensor level reading is above 1 0V SENSOR LEVEL I MARK XXV LEVEL OFFSET XX ala 7 Figure 8 11 Level Offset Menu Screen Manually position the media so that its eye mark may be registered by the sensor Read the sensor level now displayed to ensure this reading is below 0 5V and the high value that was previously registered is at least 0 8V greater than the low reading just read Add these readings and divide them by two Record the result Advance to the Slice L
93. er the required options Refer to the Menu Definition Tables in the following chapter to provide an explanation of each menu screen S8400 Series Service Manual Displayed if password feature is enabled FH ONLINE QTY 000000 The screen that appears depends on the interface installed Sg OFFLINE QTY 000000 ENTER Cancels print job CANCEL BAUDRATE BAUDRATE 2400 4800 2400 4800 9600 19200 a 9600 19200 ONLINE MODE FH 38400 57600 PARITY BIT CF Card Mode a User NONE ODD EVEN 1BIT 2BIT ENTER INTERFACE BOARD CHARACTER BIT SETTING YES NO 7BIT 8BIT PROTOCOL STATUS5 READY BUSY DATA PORT INTERFACE BOARD SETTING I F 1 I F 2 I F 1 I F 2 ik ik ENTER IGNORE CR LF RS 232C 422 485 X On x Off CONFIGURATION ENTER a NO DIPSW LCD Ready Busy IVA Status3 Status4 ENTER ITEM NO CHECK BCC CHECK IGNORE CAN DLE ENABLE DISABLE ENABLE DISABLE ENTER RECEIVE BUFFER YES NO MULTI 1 ITEM ENTER Figure 5 4 Serial Interface Mode 5 6 PN 9001161A Unit 5 Printer Configuration LOCAL AREA NETWORK LAN INTERFACE MODE This chapter provides the programming sequences required for LAN setup Use the keys of the printer s operator panel to select and enter the required options Refer to the Menu Definition Tables in the following chapter to provide an explanation of each menu screen
94. ert replacement roller 5 in its place Insert bearing 3 onto the free end of replacement roller 5 to nest against chassis 4 Ni oe DI oS Rotate bearing clamp 2 onto bearing 3 and secure screw 1 NOTE Ensure the platen roller assembly is fully nested in the printer s center frame when screw 1 is secured 8 Repeat steps 3 through 8 for other rollers as required and restore power AF a O N x AQ 2 O J 3 W Figure 7 2 Platen Roller Replacement S8400 Series Service Manual 7 3 PN 9001161A Unit 7 Replacement Procedures RIBBON ROLLERS amp BELT DIRECT LOAD Following long periods of use a belt may become worn or excessively stretched beyond the printer s adjustment ability and require replacement It is at this time that the pulleys should be inspected for damage or wear 1 Switch off printer and observe applicable lockout tagout procedures Remove ribbon stock and label media from printer Leave print head unlatched Remove screw 1 Figure 7 3a front boss 2 torque limiter 3 pin 4 rear boss 5 and torque limiter 6 from ribbon rewind spindle 7 NOTE To dismantle the ribbon spindle assembly insert a small diameter shaft between the front and rear ribbon bosses and through an orifice in the spindle Rotate the bosses as necessary for alignment 4 Remove two screws 8 securing belt cover 9 Withdraw belt cover 9 5 Remove two
95. et this feature to enable or disable an external signal for other printer s communication port If the port is enabled an external print start signal can be sent and received using an appropriate device plugged into the EXT port Appears only if the printer s external signal feature has been enabled to allow selection of the output signal For information on which type to choose refer to the printer s Programming Reference for guidance Allows configuration as to whether the reprint function may be activated via the external signal port Allows for selection of specific SEMBL program to be stated when SEMBL mode AUTO START selection is YES This menu allows for the printer to be configured to print zeros with or without a diagonal slash through them This will apply to all printer font types The printer can be set to go into the online mode when powered on Otherwise the printer starts in the offline state and must be manually placed online before it is ready to print Print offset refers to the vertical and horizontal shifting of the entire print area relative to the label and the print start position The movement is incremental by dots in the positive or negative direction Positive and negative vertical adjustment is toward or away from the print head respectively Positive and negative horizontal adjustment is to the left or right of the reference point respectively 5 24 PN 9001161A Unit 5 Printer Configuration
96. eturned signalling to the host that the received transmission contained errors and must be resent If the returned Status byte indicates a command structure error the error must then be corrected before the print data is resent to the printer A valid transmission to the printer must be bounded by an STX ETX pair with the STX 02H signifying the start of the Print Data and ending with an ETX 03H signifying the end STATUSS RETURN This communication protocol is designed for the purpose of monitoring and controlling print data status in the host and featuring various functions INTERFACE SIGNALS PIN DIRECTION SIGNAL DEFINITION 1 Reference FG Frame Ground 2 ToHot TD Transmit Data Data from the printer to the host computer 3 ToPrinter RD Receive Data Data to the printer from the host computer SG Signal Ground CABLE REQUIREMENTS Depending on the host used it may need to loop CS and RS maintaining at high level on the hose side For additional information refer to the host computer documentation peo pes Host DIRECTION ozs printer G SG Signal Ground Bi Directional SG Signal Ground S8400 Series Service Manual 3 11 PN 9001161A Unit 3 Interface Specifications RECEIVE BUFFER CONTROL Causes For Receive Buffer Near Full Receive buffer near full occurs when the remaing free space of the buffer drops to 0 95MB of 2 95MB capacity or when the remaining free space is available for
97. evel menu screen Figure 8 12 SENSOR LEVEL I MARK XXV SLICE LEVEL XX Figure 8 12 Slice Level Menu Screen Read the slice level displayed to ensure the slice level is equal to this value Repeat steps 3 through 8 as required S8400 Series Service Manual 8 12 PN 9001161A Unit 8 Adjustment Procedures GAP SENSOR SENSITIVITY This sensor adjustment regulates penetrating ability for media referencing To establish penetration upper and lower voltage levels must be set and the difference between the two voltage levels should be maximized for optimum performance For proper performance the sensor must have a voltage difference greater than 0 8V between high and low If performing the following procedure does not result in acceptable voltage levels clean the window over the sensor s eye 1 Load printer with label media backing label so as to be registered by the gap sensor Power on the printer 2 Using the printer s operator panel access the Service Mode and then proceed to the Level Offset menu screen Figure 8 13 3 Using the printer s operator panel adjust the level offset so the sensor level is above 1 0V SENSOR LEVEL GAP XXV LEVEL OFFSET XX ala 7 Figure 8 13 Level Offset Menu Screen 4 Peel a label from the paper backing and place the backing paper so that its gap may be registered by the sensor 5 Read the sensor level now displayed to ensure this reading is below 0 5V and the high value th
98. f those oscillations A numbering system composed of six letters A F and ten numbers 0 9 used to condense binary numbers A threaded rod having a flanged head that is comprised of six sides a type of hardware used Hex Screw to attach two or more objects Hexidecimal In engineering a recess that does not penetrate completely through as a bore or orifice Term Hole Di may be casually used in lieu of a bore or orifice Horizontal On a level plane ninety degrees from vertical Hertz Radio waves or other electromagnetic radiation resulting from oscillations of electricity afe N in a conductor Also the measurement of those oscillations Icon An image or picture that has a specific meaning I D Filter In RFID software that compares a newly read ID with those in a database or set Idle Gear A toothed wheel that is not directly driven but instead receives motion from another Idle Roller A non toothed wheel that is not driven in the case of printers it is typically used to provide tension on a timing belt Also referred to as tension roller Illuminate To give or emit light In RFID systems that use the inducing of a current in a coil as a means of transferring data or Inductive Coupling power Intermittent Stopping and starting again at intervals In Use Programming The ability to read from and write to an RFID tag while attached to its object Junction A place or point of joining or crossing Ki
99. ge The windings are wrapped around a magnetic core affecting magnetic induction Transformer A device used to amplify a signal or open and close a circuit Is constructed of a semiconductive material and is comprised of three terminals where one can be used to control the flow of current through the other two Translucent When a medium is of a condition so as to allow light to filter Transparent When a medium is of a condition so one can see through it unfettered Relative to RFID the transmitter receiver pair of transceiver plus the information storage mechanism attached to the object Also referred to as Tag Tread The act of an object making repetitive contact upon another that is in motion Transistor Transponder S8400 Series Service Manual 9 36 PN 9001161A Unit 9 Appendix GLOSSARY Troubleshoot The act of locating the source of a problem or problems Two of the projectories of an object X axis is the distance left and right and the Y axis is the Two Dimensional l I Be distance up and down In a two dimensional perspective the Z axis is not recognized The state of multiple objects being the same Any fixed quantity measure etc Universal Serial Bus An external peripheral interface standard for communication between a USB Interface i Lu computer and external peripherals over a cable using bi serial transmission The quantity for which a symbol stands A plane or axis that is plum the Y axis Voltage The
100. heir commencement The pages of this manual have embedded headers and footers to assist the user in identifying his or her exact position within the manual The header provides the unit number followed by its name The footer identifies the product on the left the page number in the center and the manual s part number to the right side of the page Page enumeration is two part with each separated by a hyphen The first character set references the Unit and the second identifies the page number within that unit Page numbers begin with the numeral one 1 at the beginning of a new unit and ascend sequentially ATTENTION The illustrations and graphics provided in this manual may display components assemblies and purchase options that may not be present on idividual printers However where those instances arise they are not revalent to the topic discussed S8400 Series Service Manual 1 2 PN 9001161A Unit 1 Introduction GENERAL DESCRIPTION The S8400 series print engines are specifically designed for use in high volume automated print apply labeling applications demanding unparalleled reliability and around the clock operation These print engines offer four inch wide printing ability and are available in 203 305 and 609 dpi print resolution However more compelling is their user friendly design and application flexability These OEM print engines follow the design concepts and principles of SATO s previous market leading in
101. hen STATUSS is set for the protocol ENABLE DISABLE JE Allows BCC check to be enabled or disabled Will only appear if STATUS5 is set for protocol When the printer driver is set for GAP sensor printing transmissive mode BCC CHECK will be switched to DISABLE BCC CHECK ENABLE DISABLE S8400 Series Service Manual 5 30 PN 9001161A Unit 5 Printer Configuration CENTRONICS INTERFACE MODE TABLE 5 7 Is the premiere screen of the Interface Mode The Interface Mode allows the parameters to be set for the printer to communicate with a host and vice versa Select the YES option to configure an interface board for bi directional communication the menu ser will advance to multiple configuration screens depending on the type of interface borad installed SETTING E Selecting the NO option will bypass those screens Determines whether the print data code requires deletion Hexadecimal graphic data will not be Rm deleted Select YES to delete all carriage returns CR and line feed LF commands in the data stream including graphics and 2D bar codes This feature is primarily used to maintain compatibility with earlier models of SATO printers Allows the determination of whether the Cancel CAN and Data Link Escape DLE codes will be e processed or ignored Select the YES option to ignore the codes and NO to process them This screen will only appear when the communication protocol is STATUS4 Allows the s
102. ice Manual 3 10 PN 9001161A Unit 3 Interface Specifications 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 to maintain control of the job print queue so that it can move a high priority job in front of ones of lesser importance A multiple job buffer allows the printer to continuously receive print jobs while compiling and printing other jobs at the same time It acts much like a Print buffer to maximize the performance of the host and the printer The printer receives and prints one job at a time If a print job exceeds the buffer size transmission will be rejected by the printer Error conditions that occur during the Print Data transmission will cause the printer to return a NAK ACKINAK PROTOCOL Bi Directional ACK NAK protocol is used for error control In a normal transmission sequence when the transmission is received the printer will return an ACK 06H signifying that it was received without a transmission error After the transmission command structure has been analyzed a status byte is returned to the host This status byte informs the host of the validity of the command structure If the command structure is error free the printer proceeds with the print operation When the print operation is completed a Printer Status message is returned to the host If an error was detected during the initial transmission sequence a NAK 15H will be r
103. ide an explanation S8400 Series Service Manual of each menu screen Printer beeps BOOT DOWNLOADER INTERFACE CARTRIDGE Scrolls options Interface ENTER SELECT INTERFACE PROGRAM DOWNLOAD SET CARTRIDGE I F 2 I F 1 Printer PROGRAM DOWNLOAD waiting for download to begin READY PROGRAM DOWNLOADING Receiving downloaded data Kenne PROGRAM DOWNLOAD Displays COMPLETED when download is PRESS ENTER complete ENTER Figure 5 14 Boot Download Mode 5 16 PN 9001161A Unit 5 Printer Configuration PRINT CANCEL MODE Figure 5 15 provides the specific sequence of events required by the operator the printer and the printer s software to cancel a print job once initiated Use the printer s operator panel to select and enter the required options Refer to the Menu Definition Tables in the following chapter to provide an explanation of each menu screen Printing in process ONLINE QTY 000000 Sg OFFLINE QTY 000000 CANCEL PRINT JOB CANCEL YES NO ENTER CANCEL PRINT JOB CURRENT ALL Current All ENTER e ENTER Am CANCEL PRINT JOB COMPLETED Figure 5 15 Print Cancel Mode S8400 Series Service Manual 5 17 PN 9001161A Unit 5 Printer Configuration DEFAULT SETTINGS MODE Figure 5 16 provides the specific sequence of events required by the operator the printer and the printer s software to return
104. ik ik ENTER IGNORE CR LF PROTOCOL ITEM NO CHECK YES STATUS4 ENABLE DISABLE STATUS5 ENTER Status4 ENTER IGNORE CAN DLE F Status5 ENTER ENTER e pe BCC CHECK ENABLE DISABLE IR YES NO ENTER Figure 5 6 USB Interface Mode S8400 Series Service Manual 5 8 PN 9001161A Unit 5 Printer Configuration 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 Definition Tables in the following chapter to provide an explanation of each menu screen Displayed if password feature is enabled PASSWORD ONLINE QTY 000000 z A OFFLINE QTY 000000 LINE CANCEL ENTER Cancels print job IGNORE CAN DLE ONLINE MODE ea aD GOT r CANCEL spl ENTER NO Advanced Mode ENTER INTERFACE MODE seno AOT RECEIVE BUFFER ZANCE MULTI 1ITEM CANCEL ENTER INTERFACE BOARD SETTING YES NO Mn CANCEL ENTER Figure 5 7 Centronics Interface Mode S8400 Series Service Manual 5 9 PN 9001161A Unit 5 Printer Configuration 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 Definition Tables in the following chapter to provide
105. ing belts that transfer torque from various drive motors to individual print mechanisms Each timing belt has a spring loaded adjustment feature so that manual adjustment is not required Simply loosen the applicable screws to allow spring torsion to determine the degree of tension then retighten the loosened screw to secure their position The colorized screws in Figure 8 6 identify the setscrews to be loosened and retightened for belt tensioning of the mechanisms identified NOTE Figure 9 1 of the Appendix unit displays cover removal and installation CAUTION EXCESSIVE BELT TENSION WILL CREATE UNDESIRABLE DRAG ON THE DRIVE TRAIN A PROPERLY ADJUSTED BELT WILL POSSESS JUST ENOUGH TENSION TO PREVENT SLIPPAGE Ribbon Saver Motor Figure 8 6 Printer Belt Tensioning S8400 Series Service Manual 8 7 PN 9001161A Unit 8 Adjustment Procedures 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 tension then retighten the loosened screw to secure its position The colorized screw in Figure 8 7 identifies the setscrew to be loosened and retightened for belt tensioning Figure 8 7 Ribbon Cassette Belt Tensioning S8400 Series Service Manual 8 8 PN 9001161A Unit 8 Adjustment Procedures PRINT HEAD BALANCE Print head balance is the equal
106. inter and observe applicable lockout tagout procedures 2 Remove all interface cards and open rear housing covers to access printer s electrical side NOTE Figure 9 1 of the Appendix unit for displays housing cover open or removal CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST 3 Remove two screws 1 Figure 7 13 securing main circuit board 2 to the printer Withdraw main circuit board 2 along with defective flash memory board 3 from printer Remove two screws 4 securing defective flash memory board 3 to main circuit board 2 Detach defective flash memory board 3 and attach replacement flash memory board 3 Secure using two screws 4 Insert main circuit board 2 into printer and secure using two screws 1 Insert flash card not shown close rear housing covers restore power and test print to ensure proper function CAUTION ENSURE THAT WIRING HARNESSES ARE NOT PINCHED DURING INSTALLATION AND THAT ALL REMAIN AWAY FROM MOVINGS COMPONENTS WITHIN THE PRINTER Figure 7 13 Flash Memory Board Replacement S8400 Series Service Manual 7 18 PN 9001161A Unit 7 Replacement Procedures POWER BOARD REPLACEMENT The power board contains the printers transformers relays etc for transferance of electrical current from the source supply to the printer s control circuits Circuit boa
107. inter is in the Maintenance Mode If an error signal occurs the sensor is functioning properly If an error signal does not occur the sensor must be replaced Used to test Ribbon End sensor on the feed side RE1 Measurement must be made while the printer is in the Maintenance Mode If an error signal occurs the sensor is functioning properly If an error signal does not occur the sensor must be replaced Not applicable to this printer Not applicable to this printer Table 6 1 Test Reference Chart MULTIMETER ALONE Testing of circuitry and sensor adjustment may be performed by using a multimeter without the assistance of the Test Module To perform this task the multimeter probes must be attached to the correct connector pins of the test connector Refer to the Table 6 1 to correlate the desired testing or adjustment function with its relative connector pin Afterward refer to Figure 6 2 to locate the required pins SENSOR SENSITIVITY VALUES VALUES Eye mark Low Level 1 0 VDC or less High Level low level 0 8 VDC minimum Gap Low Level 0 2 VDC to 1 0 VDC High Level low level 0 8 VDC minimum Ribbon End Refer to Table 6 1 S8400 Series Service Manual 6 12 PN 9001161A Unit 6 Troubleshooting 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
108. its to be sent each second At high data transfer speeds data transmission rates are usually expressed in bits per second bps rather than baud Capable of operating in two directions along the same plane or medium In the case a communication cable or an RFID tag one that transmits as well as receives read and written A numeral system that represents numeric values using two symbols typically O and 1 A binary number can be represented by any sequence of bits binary digits which in turn may be represented by any mechanism capable of being in two mutually exclusive states Refers to a single digit in the binary numeral system A bit can either be on or off a 1 or 0 A byte is a collection of eight bits Shows the interconnections between system components by using a pictorial representation of a system and sub systems linked to illustrate their relationships A threaded metal rod with a flanged head that is used with a nut to hold parts together A hole in or through something 9 28 PN 9001161A Unit 9 Appendix GLOSSARY Bytes A collection of 8 bits used in the binary system As it relates to RFID the number of bits or bytes that can be programmed into a tag This may Capacity represent the bits accessible to the user or the total number including those reserved to the manufacturer e g parity or control bits Capture Window Field Region of the scanner field in which an RFID tag will operate A recessed
109. ization of pressure against the platen roller from one end to the opposite If the print head balance is out of adjustment the printed image will be darker on one side of the label than the other and the media will be prone to travel in the direction of least resistance The adjustment of print head balance on the label can be subjective One will know when balance is achieved by the disappearance of prevailing negative characteristics To adjust the balance begin test printing slightly loosen set screw 1 Figure 8 8 and slightly move the adjustment plate 2 upward or downward as necessary Retighten set screw 1 while holding the adjustment plate 2 when proper printing is achieved Figure 8 8 Print Head Balance Adjustment S8400 Series Service Manual 8 9 PN 9001161A Unit 8 Adjustment Procedures PRINT HEAD DPI CHANGE The alteration of the printer to accomodate a print head with a different DPI Dots Per Inch a mechanical adjustment is required in addition to a configuration change through the printer s operator panel The mechanical adjustment required is the alternate routing of some timing belts of the platen motor assembly To achieve this the platen motor assembly must be removed to gain access to the relative timing belts 1 Swtichoffthe printer and observe applicable lockout tagout procedures 2 Remove all interface cards and open the rear housing covers NOTE Figure 9 1 of the Appendix u
110. l be deleted and then the printer will go offline If the NO een option is selected the printer will go offline without deleting data YES NO This menu screen allows the selection of whether to only delete the current print job or all that have been received CANCEL PRINT JOB CURRENT ALL This screen confirms the received data has been deleted Will display for 3 seconds then the Da printer will go offline CANCEL PRINT JOB COMPLETED DEFAULT SETTING MODE TABLE 5 16 Is the first menu screen of the printer s Default Setting Mode The Default Setting Mode allows the printer to be reset to the programmed condition as received from the factory This may include PRINTER SETTING all printer settings or just protocol ALT PROTOCOL The selection of YES confirms the operator wants to proceed and the selection of NO allows for exit without default reset If YES is selected resetting will immediately begin DEFAULT PRINTER SETTING YES NO is This screen will only appear if PRINTER SETTING was selected from the first screen S8400 Series Service Manual 5 39 PN 9001161A Unit 5 Printer Configuration DEFAULT SETTING MODE TABLE 5 16 The selection of YES confirms the operator wants to proceed and the selection of NO allows for exit without default reset If YES is selected resetting will immediately begin This screen will only appear if ALT PROTOCOL was selected from the first screen Is an
111. letion Hexadecimal graphic data will not be CORRE deleted Select YES to delete all carriage returns CR and line feed LF commands in the data stream including graphics and 2D bar codes This feature is primarily used to maintain compatibility with earlier models of SATO printers Allows the selection of which interface board will be set up in subsequent menus Interface Port 1 TN I F 1 is the smaller card slot of the printer and Interface Port 2 I F 2 is the printer s middle card SETTING slot The default setting is I F 2 and accommodates a standard interface card F 1 is to be used es aii for optional PCI interface cards Allows the determination of whether the Cancel CAN and Data Link Escape DLE codes will be TENDE processed or ignored Select the YES option to ignore the codes and NO to process them This screen will only appear when the communication protocol is STATUS4 S8400 Series Service Manual 5 28 PN 9001161A Unit 5 Printer Configuration LAN INTERFACE MODE TABLE 5 5 Allows the deternination of whether the interface will be configured on the interface board or the a LCD This screen will only appear if the LAN Wireless LAN or Mini LAN interface board has CONFIGURATION been installed Power off the printer then on again to enable the changes BOARD LCD Sets a unique static IP Address using the TCP IP Protocol The format of an IP Address is a 32 IP ADDRESS bit numeric address written as four nu
112. ly 4 O A O N ana Find label sensor adjustment knob 7 located behind print assembly 1 NOTE The label sensor adjustment knob is purple colored ABS plastic 6 Manually rotate knob 7 to the left or right as required to properly position label sensor 8 NOTE Sensor positioning may also be achieved by measuring from the printers center frame outward to the specified distance for sensor reference mark alignment Refer to Figure 9 3 in the Appendix unit of this manual for applicable dimensions 7 Test print a label to determine if label sensor 8 is properly aligned Figure 8 1 Label Sensor Positioning S8400 Series Service Manual 8 2 PN 9001161A Unit 8 Adjustment Procedures PRINT HEAD PRESSURE Print head pressure is the equalization of pressure against the platen roller from one end to the opposite If the print head balance is out of adjustment the printed image will be darker on one side of the label than the other and the media will be prone to travel in the direction of least resistance The adjustment of print head pressure is achieved through the adjustment of a four position dial located within the print assembly just above the print head The end of the dial is inumerated 1 through 4 To adjust the pressure begin test printing and slightly loosen set screw 1 Figure 8 2 Then rotate dial 2 to each position and monitor printing characteristics for each position Optimum pressure is achieved
113. mbers separated by periods See your network administrator for available IP Addresses ar Specifies which segment of the network the printer will reside The format of Subnet Mask is a 32 SUBNET MASK bit numeric address written as four numbers separated by periods See your network administrator to find out your Subnet Mask CIEL Specifies the IP Address of the main router on the host network The format of a Gateway smo Address is a 32 bit numeric address written as four numbers separated by periods See your ADDRESS network administrator to find out your default Gateway Address When the priority setting is set to BOARD this screen will not appear Power off the printer then on again to enable the changes Allows setting of the sequence of control characters to ensure correct data transference See your network administrator to find out which Status number will be used for the control characters being sent to and from the printer Allows reply timing of status information to the host to be set Select the ENQ option to return status after receiving Status Request ENQ and CYCLE to return status from the printer to the RELAY TIMING host at 500ms intervals ENQ CYCLE STATUS This screen will only appear when LAN or Wireless LAN is installed and when protocol is set to STATUS4 Allows the item number check to be enabled or disabled Will only appear when STATUSS is set for the protocol When performing a test print of any LA
114. ms Connector Core Central Processing Unit A programmable device that performs all the instruction logic and mathematical processing in a computer is the brains of the computer The CPU is a microchip that is installed on a motherboard primary board that coordinates hardware components Also referred to as processor Counter Clockwise To rotate from right to left Couple Two mating halves that are connected example a plug or receptacle CPU Cubic The X Y and Z axis all being equal in size a three dimensional object that is equally proportioned Current The flow or rate of flow of electric force A single revolution of a potentially reoccurring activity in the case of printer one label being Cycle printed O Direct Current Electrical current flowing in a single direction Density The quantity within a given or specific area or unit Deviation A change in course or the measurement of that change A straight line from the outer edge of a circle through the center and onward to the opposite Diameter edge Also the measurement of that distance dimension Dimension Any measurable distance S8400 Series Service Manual 9 29 PN 9001161A Unit 9 Appendix GLOSSARY Allows current to flow in one direction but not the other to protect sensitive electronics A diode functions by compositing two conductive materials with one possessing low resistance to electrical current on
115. mware data to and from the ROM and optional CF Card The default setting is NO meaning that copying is not desired YES NO Appears if the YES option was chosen on the preceding screen and allows the direction of sn information flow to determined CF CARD gt ROM ROM gt CF CARD This screen confirms the selection from the preceding screen and allows the option of initiating CF CARD gt ROM the copy or to abort COPY START YES NO am This screen confirms the selection from the preceding screen and allows the option of initiating ROM gt CF CARD the copy or to abort COPY START YES NO ik If Trace Mode is enabled three different icons will appear on the LCD to trace the processing of a TRACE MODE label The first identifies data reception the second displays after receiving lt ESC gt A 1BH and the third displays following a print operation Permits determination of whether a record of print activity will be maintained on the CF Card SAVE PRINT LOG ENABLE DISABLE 48 CLEAR PRINT LOG YES NO 4 8 OUTPUT PRINT LOG FROM SUBPORT ENABLE DISABLE i k Allows the record of print activity to be cleared if a log has been maintained Allows the print log to be output to the printer s sub port port not used for print data in real time The default is DISABLE By default the I F 2 card is set to be a sub port for status monitoring purposes only The main I F card is by default the data port for printing p
116. n roller assembly 18 together while inserting into the printer and secure using two screws 16 one screw 15 Figure 7 20b Ribbon End Sensor Replacement Direct Load Secure front plate 14 Figure 7 20a to the print assembly using two screws 13 and three screws 12 Secure print head latch handle 11 to the latch using two screws 10 Secure belt cover 9 to the printer using two screws 8 Insert torque limiter 6 rear boss 5 pin 4 torque limiter 3 front boss 2 onto spindle 7 and secure using screw 1 NOTE Ensure all loose components are properly positioned before assembly Reload printer restore power and test print to ensure proper function S8400 Series Service Manual 7 30 PN 9001161A Unit 7 Replacement Procedures RIBBON END SENSOR REPLACEMENT CASSETTE LOAD The ribbon end sensor informs the operator when ribbon stock has been exhausted and reloading is required ATTENTION Before assuming the sensor is defective and replacing the assembly ensure that the condition is not the result of debris buildup Thoroughly clean the sensor before replacing it Switch off the printer and observe applicable lockout tagout procedures Remove ribbon cassette and label media Remove screw 1 Figure 7 21 securing defective ribbon end sensor 2 to printer frame Disconnect wiring harness not referenced from defective sensor 2 and connect to replacement sensor 2 Secure replacement ribb
117. nable by dedicated socket protocol NOTE In the TCP IP protocol enviroment LPD and FTP are provided for printing TELNET for variable setup ARP RARP and BOOTP DHCP for address setup LPD protocol complies with RFC1179 and handles the list of logical printer name as queue name such as Ip sjis euc In addition a banner page can be printed by a proper setup When sending the job by LPR the transmission order of data file control file within the job will not affect print operation In addition if the banner page is specified it will be added to each data file Job deletion by LPR is not available FTP protocol complies with RFC959 and handles the list of logical printer name as a transfer directory File transfer to this directory executes print operation It is possible to specify ASCII A Binary l and TENEX L8 as transfer mode although the mode difference is dependent on the client A banner page may be printed with a proper setup TELNET Complies with RFC854 This operation consists of interactive menu form and enables change and reference of internal setup and to display status To change the setup enter root user and password at the time of login Default of root pasword is set as null linefeed only 1 Printing by socket Port1024 print data Port1025 status 2 Printing by LPR and FTP LPR and FTP print data Port1025 status Figure 3 4 Socket Connection Diagram S8400 Series Serv
118. ne quantity divided by another of the same kind Relative to RFID a device containing the digital electronics which extract and separate the information from the format definition and error management bits Relative to RFID many applications require that new data or revisions to data already in the tag be entered while it remains on the object Some items with this capability of being re programmable are read write tags memory cards or memory modules An area of temporary data storage to help compensate for differences in the transfer rate and the processing ability of the printer A female connector to which a male connector may be inserted typically for electrical current A simple electro mechanical switch made up of an electromagnet and a set of contacts Relays use a small amount of power to energize things that require a greater amount of energy Sometimes relays are serial connected so that one smaller relay activates a larger relay which in turn activates another larger still and so on until the thing that is desired to be activated is To keep or to hold in place To withdraw the opposite of advance A two terminal electrical or electronic component that resists the flow of current producing a voltage drop between its terminals in accordance with Ohm s law This electrical resistance is equal to the voltage drop across the resistor divided by the current that is flowing through it Radio Frequency Automati
119. netic The science dealing with the motion of masses in relation to the forces acting on them S8400 Series Service Manual 9 31 PN 9001161A GLOSSARY Unit 9 Appendix Key Keyed Kilo Bytes Knob Knurled Label LAN Interface Latch Lateral LCD LED Lever Laminate Life Linear Linerless Media Link z DJ un z z O S z op D D v 09 D lt O D lt Q Cc Media Megabytes Menu Meter Millimeter Module Multimeter Memory Card Memory Modules Mobile Inventory Vehicle The button on a panel that may be pressed to send an electrical signal to influence a predetermined activity A physical object shaped in a manner so as to prevent unwanted movement or to ensure desired movement Kilogram A unit of weight measure within the metric system Used to describe data transfer rates or storage capacity of approximately 1000 bytes A rounded handle to facilitate the manual opening closing securing or otherwise movement of the object to which it is attached An item that has recessed grooves or elevated areas on its surface to increase manual grip Print media that has been used or printed upon that has adhesive on one side Local Area Network A computer network limited to the immediate area consequently capable of transmitting data at a very fast rate Usually the computer is limited to the same building or floor of a building as the periphery
120. nit displays opening the rear housing covers CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST 3 Remove two screws 1 Figure 8 9 and one screw 2 securing platen motor asembly 3 to frame 4 4 Move aside five ground cables not shown and withdraw platen motor assembly 3 from printer 5 Loosen set screw 5 to release belt tensioner 6 Figure 8 9 Print Head DPI Change S8400 Series Service Manual 8 10 PN 9001161A Unit 8 Adjustment Procedures 6 Move timing belt 7 Figure 8 10 to the orientation applicable for the desired print head resolution 203 DPI 305 amp 609 DPI Figure 8 10 Print Head DPI Change 7 Adjust and hold belt tensioner 6 Figure 8 9 while tightening set screw 5 CAUTION A PROPERLY TENSIONED BELT WILL BE JUST ENOUGH TO PREVENT SLIPPAGE AN OVERLY TENSIONED BELT WILL EXCESSIVELY INCREASE DRAG ON THEIR PULLEYS AND INCREASE COMPONENT WEAR 8 Insert platen motor assembly 3 to printer frame 4 9 Secure the assembly 3 and five ground cables not shown using one screw 2 and two screws 1 NOTE The three shorter ground cables are to be secured using the leftmost screw and the two longer ground cables are to be secured using the middle screw 10 Close the rear housing covers 11 Relpace the print head as directed in the Replacement Procedures unit 12 Restore pow
121. ns Standard Direct Load 9 22 Printer Dimensions Opposite Direct Load 9 25 Glossary 9 28 S8400 Series Service Manual PN 9001161A INTRODUCTION About This Manual e General Description Theory Of Operation e Control Features S8400 Series Service Manual 1 1 PN 9001161A Unit 1 Introduction ABOUT THIS MANUAL This manual is laid out consistent with the product discussed and provides all of the information required for printer maintenance and repair by SATO approved personnel For the repair technician this manual is intended to compliment and to be used as an extension of owner operator literature This manual also incorporates the use of special information boxes Examples of these boxes and the type of information provided in each are below WARNING PROVIDES INFORMATION THAT IF UNHEEDED MAY RESULT IN PERSONAL INJURY CAUTION PROVIDES INFORMATION THAT IF UNHEEDED MAY RESULT IN EQUIPMENT DAMAGE ATTENTION Provides information that is deemed of special importance but will not result in personal injury or product damage if unheeded NOTE Provides helpful hints to assist in performing the tasks at hand LCD DISPLAY Provides the specific display that should be visible on the LCD at that point A comprehensive Table Of Contents provided at the front of this manual facilitates rapid movement within The contents identify the different Units Chapters and some Sections Each references the page number of t
122. nting Figure 6 4 Test Print Mode S8400 Series Service Manual 6 14 PN 9001161A Unit 6 Troubleshooting NOTE The only print problem that the following sample test label does not display is fading of print image from one side of the label to the other This is the result of improper print head balance Compare this scale on each side to ensure the print is evenly spaced horizontally Visually inspect INN UN these rows for voids INN UNNA indicating defective NINE UN EEE EEEEEEEEEEEENE head elements SAMPLE TEST LABEL Label Contents Will Vary Depending on Test Label Type Displays the dip switch settings at the time of print DSWI DSwe DSWS NONE CEN Line sharpness is determined by print speed and darkness Clear line in print indicates the ee Compare this scale on each was wrinkled during side to ensure the print is printing evenly spaced vertically Figure 6 5 Sample Test Label S8400 Series Service Manual 6 15 PN 9001161A S8400 Series Service Manual REPLACEMENT PROCEDURES Print Head Platen Rollers Ribbon Rollers Belt Direct Load Platen Drive Motor Belts Pulleys Ribbon Spindle Drive Motors Belts Pulleys Ribbon Saver Drive Motor Belt Ribbon Cassette Timing Belt Rollers Ribbon Boss Torque Limiter Direct Load Ribbon Boss Torque Limiter Cassette Load Main Board Secondary Board Flash Board Power Board Panel LCD Board Interface Board Label
123. nus Interface Port 1 o I F 1 is the smaller card slot of the printer and Interface Port 2 I F 2 is the printer s middle card SETTING slot The default setting is I F 2 and accommodates a standard interface card 1 F 1 is to be used pe Ae gue for optional PCI interface cards Selection of the DIPSW option will use settings on the serial interface card The LCD option ae advances the operator to menus that allow the DIPSW settings to be over written CONFIGURATION DIPSW LCD Allows the selection of the receive buffer type Select MULTI for multiple item buffer and 1ITEM an for a single item buffer MULTI 1 ITEM This screen will only appear if one of the serial interface types is installed and the protocol is set to READY BUSY or XON XOFF Allows selection of the baud rate Wil only appear when the RS422 or RS485 interface is installed and the LCD option is chosen from the prior menu Allows selection of the baud rate Will only appear when the RS232 interface is installed and the ne LCD option is chosen from the prior menu 2400 4800 9600 19200 38400 57600 __ Allows setting of the parity bit for the serial interface Will not display if the dipswitch priority option is chosen The interface board must be installed NONE ODD EVEN Allows stop bit selection for the serial interface Will not display if the dipswitch priority is chosen STOP BIT 1BIT 2BIT Allows selection of the data length for serial in
124. o cease printing Figure 5 17 Test Print Mode S8400 Series Service Manual 5 19 PN 9001161A Unit 5 Printer Configuration HEX DUMP MODE The contents of the print buffer and the data received before it is placed into the print buffer may be examined through the use of the Hex Dump Mode Each line of the printed data is enumerated in the first column the second column contains the data in hexadecimal format and the right column contains the same data in ASCII format The options of data to be printed are receive data receive buffer and internal data However only one type of data may be printed on a single label Repeat the dump process to print the other data types as desired Use the keys on the printer s operator panel to select and enter the required options Refer to the Menu Definition Tables in the following chapter to provide an explanation of each menu screen Displayed if password feature is enabled HEX DUMP MODE LINE AO ao Go yE ln T H OFFLINE QTY 000000 Service ENTER LUNE ia Sec ENTER D CANCEL SELECT DUMP DATA RECEIVE DATA RECEIVE BUFFER INTERNAL DATA User Internal Data Receive Data Receive Buffer SEMBL MODE ENTER ENTER ENTER za a0 WOT 2 Dump is printed ADVANCED MODE Te EMO T Figure 5 18 Hex Dump Mode S8400 Series Service Manual 5 20 PN 9001161A Unit 5 Printer Configuration CF COMPACT FLASH CARD MODE Use the printer s operator
125. o round off the sharp edges of the angle Flange The projecting rim of an object used to keep another object or objects in place A form of rewritable memory chip that allows multiple memory locations to be erased or written in one programming operation Flash Memory is very high speed and non volatile does not need power to maintain the stored information Its information is stored in an array of floating gate transistors called cells Font A type or style of letter or numeral characters used in written text The number of times a signal executes a complete excursion through its maximum and minimum values and returns to the same value The number of vibration cycles Flash Memory Frequency Print media with a space between each label where only the paper backing exists The Gap Media printer s sensor uses this gap to identify when the printed label ends and to properly position the next label for printing A unit of measurement used to describe the nominal thickness of wire The higher the gauge Gauge number the smaller the diameter Gear A system of toothed wheels meshed together so that the motion of one is passed on to the others Gigabytes Used to describe data transfer rates or storage capacity of 1 billion bytes Groove An elongated slot cut into an object Radio waves or other electromagnetic radiation resulting from oscillations of electricity in a Hertz conductor Also the measurement o
126. on end sensor 2 to printer frame o od a w N Reload printer restore power and test print to ensure proper function Figure 7 21 Ribbon End Sensor Replacement Cassette Load S8400 Series Service Manual 7 31 PN 9001161A Unit 7 Replacement Procedures RIBBON SAVER SENSOR REPLACEMENT The ribbon saver sensor is attached adjacent to and is engaged with a toothed disc plate The disc plate rotates in response to the ribbon saver motor The toothed portion of the disc plate intermittantly interrupts and blocks sensor transmission reception ATTENTION Before assuming the sensor is defective and replacing the assembly ensure that the condition is not the result of debris buildup Thoroughly clean the sensor before replacing it 1 Switch off the printer and observe applicable lockout tagout procedures 2 Remove all interface cards and open rear housing covers to access the printer s electrical side NOTE Figure 9 1 of the Appendix unit displays cover open or removal CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST Remove screw 1 securing defective ribbon saver sensor 2 to printer frame 3 Disconnect wiring harness not referenced from defective sensor 2 and connect to replacement sensor 2 Secure replacement ribbon saver sensor 2 to printer frame 3 using screw 1
127. onate spacing A circular clip that may be applied to a shaft etc to prevent another object from moving used Snap Ring to retain objects in position l An item that is not porous Solid An item that is not transparent or translucent Any object of purpose to maintain a specific distance from two other objects example a Spacer sleeve or washer A shaft or rod that is fixed on one or both ends and spins on its axis while maintaining its apnee projection Static Random Access Memory A type of memory that is faster and more reliable than the more common DRAM The term static is derived from the fact that it doesn t need to be refreshed like DRAM Stainless Steel A shiny mirror like carbon steel alloyed with chromium to inhibit rust Metal that contains a specific percentage of carbon The percentage of carbon determines its Steel l n e strength in addition to how prone it is to rust SRAM Stepper Motor An electrical motor designed to rotate in both directions and to move in incremented distances Sub Assembly A group of components assembled to form a complete unit that is a part of a larger unit A small mechanical device when altered sends an electrical signal to influence a predetermined activity Unlike a button or key switches may have multiple positions Relative to RFID the transmitter receiver pair of transceiver plus the information storage mechanism attached to the object Also referred to
128. ontrols motor movement and may require replacement if a motor is no longer properly functioning Test the motor first followed by its wiring harnesses then replace secondary board as necessary Circuit boards generally have long lives due to the lack of moving parts Typically if a circuit board becomes defective it is contributable to a negative external condition If it is determined that the circuit board has become defective search the printer over for possible visual factors that may have led to the damage 1 Switch off the printer and observe applicable lockout tagout procedures 2 Remove all interface cards and open rear housing covers to access secondary circuit board 1 Figure 7 12 NOTE Figure 9 1 of the Appendix unit for displays housing cover open or removal CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST Figure 7 12 Secondary Board replacement S8400 Series Service Manual 7 17 PN 9001161A Unit 7 Replacement Procedures FLASH MEMORY BOARD REPLACEMENT Circuit boards generally have long lives due to the lack of moving parts Typically if a circuit board becomes defective it is contributable to a negative external condition If it is determined that the circuit board has become defective search the printer over for possible visual factors that may have led to the damage 1 Switch off the pr
129. operly connected 2 Replace main circuit board as necessary Ensure work environment does not exceed specification Ensure fan filter is not clogged Replace as necessary Ensure internal fan is operational Replace as necessary Replace main circuit board as necessary Ensure correct communication protocols Check cables cycle printer power and resend Replace board as necessary Ensure correct communication parameters Check cables cycle printer power and resend Replace board as necessary Check and correct communication cables and settings Ensure host system and interface settings match 2 Check and correct communication cables null modem serial cable required Size of received data exceeds size of receiving buffer 2 Establish the correct communication protocol Properly latch the print head 2 Replace the head open switch Ensure media is properly loaded Clean sensor transmit receive surfaces Ensure correct sensor configuration PN 9001161A Unit 6 Troubleshooting ERROR DISPLAYS 10 Ribbon End Error 11 Sensor Error 12 Head Related Error 15 Download Data Error 17 Item Number Error 18 Head Mismatch Error 19 Kanji ROM Error POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE
130. option to configure an interface board for bi directional communication the menu rr will advance to multiple configuration screens depending on the type of interface board installed SETTING Selecting the NO option will bypass those screens S8400 Series Service Manual 5 26 PN 9001161A Unit 5 Printer Configuration SERIAL INTERFACE MODE TABLE 5 4 IENE o DESCRIPTION Allows the selection of which interface port will be assigned to receive print data Interface Port 1 I F 1 is the smaller card slot of the printer and Interface Port 2 I F 2 is the printer s middle card slot The default setting is I F 2 and accommodates a standard interface card F 1 is to be used ala e for the optional PCI interface cards DATA PORT Determines whether the print data code requires deletion Hexadecimal graphic data will not be ENOESTEIE deleted Select YES to delete all Carriage Returns CR and Line Feed LF commands in the data stream including graphics and 2D bar codes Select the NO option to process them This feature is primarily used to maintain compatibility with earlier models of SATO printers Allows the determination of whether the Cancel CAN and Data Link Escape DLE codes will be TSE processed or ignored Select the YES option to ignore the codes and NO to process them This screen will only appear when the communication protocol is STATUS4 Allows the selection of which interface board will be set up in subsequent me
131. ore printing labels high after completion of print and low 20 miliseconds later Type Il Print end signal PREND is high before printing labels low after completion of print and high 20 miliseconds later Type III Print end signal PREND is low before printing labels high from start to end of print and low upon completion of print Type IV Print end signal PREND is high before printing labels low from start to end of print and high upon completion of print 14 PIN CONNECTOR ASSIGNMENTS DIRECTION LEVEL MAX CURRENT Low Print Start PRIN Input High high impedance Low 15mAor more OV Print End PREND Output 5V 400mA Reprint PRIN2 Input High high impedance Low 15mAor more OV SIGNAL NAME Paper End Ground Ribbon End Machine Error Online 5V 400mA Ribbon Near End 5V 400mA Output Output 24V O1 lt a 2 Eu Eu 5 EH maz Ro o EE O BER ca FG II A Choose from Type to Type IV for PREND the output signal for Pin 6 S8400 Series Service Manual 3 14 PN 9001161A Unit 3 Interface Specifications 25 PIN CONNECTOR ASSIGNMENTS DIRECTION LEVEL MAX CURRENT Machine Error Output Low 5V 400mA Print End PREND Output Low 5V 400mA Input High high impedance Low 15mA or more OV SIGNAL NAME Frame Ground V O1 Online O1 Reprint PRIN2 EXT_GND V 24V GND EXT GND Ribbon End Pa
132. otocols Receive Data Data to the printer from the host computer To Host RTS Request to Send Used with Ready Busy flow control to indicate an error condition RTS is high and remains high unless the print head is open in this case RTS would return to the high state after the print head is closed and the printer is placed back on line or an error condition occurs during printing e g ribbon out label out To Printer CTS Clear to Send When this line is high the printer assumes that data is ready to be transmitted The printer will not receive data when this line is low If this line is not being used it should be tied high to pin 4 To Printer DSR Data Set Ready When this line is high the printer will be ready to receive data This lime must be high before data is transmitted If this line is not being used it should be tied high to pin 20 To Host DTR Data Terminally Ready This signal applies to Ready Busy flow control The printer is ready to receive data when this pin is high It goes low when the printer is off line either manually or due to an error condition and while printing in the single job buffer mode It will also go low when the data in the buffer reaches the buffer near full level READY BUSY CABLE REQUIREMENTS Kunz HOST DIRECTION DB25 PRINTER FG Frame Ground Frame Ground Bi Directional FG Frame Ground arte DA Clear To a To Printer DB9 6 RTS ee To S 4 2 DTR Data Terminal
133. oupled to other similar devices Perforation A series of through holes in a material to facilitate tearing apart At right angles to a given line or plane a vertical line is perpendicular to a horizontal one and Perpendicular Wine genes A black synthetic material used in manufacturing that is purchased in blocks and machined to the desired shape resembles plastic Pinion Gear A smaller gear meshed with a larger one Pitch Physical top of form of media placed under the print head elements in the feed direction Parallel Interface Parity 4 O Phenolic Material A synthetic material typically rigid in nature that is molded to its useful shape Plastic is Plastic typically injection molded along with its color additive and may be of any color chosen Post A pin or shaft to which an object may be tethered or latched A variable resistor used to adjust voltage to affect various mechanical activities This electronic component is comprised of two terminals connected to either end of an resistive element and a conductor that can be moved between the two ends thus allowing the creation of a resistor or voltage divider Primary Something first in order or importance Print Assembly The sub assembly of a printer that comprise the printing components Potentiometer S8400 Series Service Manual 9 33 PN 9001161A GLOSSARY Unit 9 Appendix Print Head Processor Profile Program Proportional Proximit
134. overs install interface cards restore power and test print to ensure proper function S8400 Series Service Manual 7 9 PN 9001161A Unit 7 Replacement Procedures RIBBON SAVER DRIVE MOTOR amp BELT REPLACEMENT The ribbon saver feature is an electronically controlled mechanical function that incorporates the use of a motor transferring torque to a belt and pulley configuration mobilizing the saver lever attached to the print assembly 1 Switch off the printer and observe applicable lockout tagout procedures 2 Remove all interface cards and open the rear housing covers NOTE Figure 9 1 in the Appendix unit displays cover open or removal CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST Remove two screws 1 Figure 7 6 securing motor assembly 2 to printer frame 3 Lift away motor bracket 4 tension spring 5 and disconnect motor wiring harness not shown Perform steps a and b if the motor requires replacement a Remove two screws 6 securing defective motor 7 to plate 8 b Secure plate 8 to replacement motor 7 using two screws 6 NOTE A properly installed plate will be oriented so that its notched corner is aligned with the motor s lower corner on the same side as its wiring harness connector Withdraw worn timing belt 9 from pulley 10 and insert replacement belt 9 in its place Apply tension spring 5 motor
135. panel to select and enter the required options Refer to the Menu Definition Tables in the following chapter to provide an explanation of eachmeny screen Displayed if password feature is enabled PASSWORD ONLINE QTY 000000 Sg OFFLINE QTY 000000 Cancels ENTER print job CANCEL ONLINE MODE aa E a SEMBL Mode di P i Interface Mode Service Mode CF CARD FORMAT FORMAT START Lo FORMATTING o SS aaa CF CARD FORMAT COMPLETE PRESS ENTER ENTER Figure 5 19 CF Card Mode S8400 Series Service Manual 5 21 PN 9001161A Unit 5 Printer Configuration STAND ALONE MODE The Stand Alone Mode allows the printer to function independently from a host computer once a fixed format has been sent and saved to the flash memory card The data may be saved to the flash memory card while in the print buffer and then recalled later with a new print quantity indicated The flash memory card will only hold a single format at a time new formats will overwrite the existing saved format The host computer must be reconnected to the printer to overwrite an existing format Figure 5 20 Stand Alone Mode S8400 Series Service Manual 5 22 PN 9001161A Unit 5 Printer Configuration MENU DEFINITION TABLES USER MODE TABLE 5 1 Is the entrance screen to the User Mode The User Mode allows various print parameters to be set This screen shows the adjusted value for the pot
136. per End Ribbon Near End Print Start PRIN Input Low High high impedance Low 15mA or more OV 17 lt EXT5V_IN GND Choose from Type I to Type IV for PREND the output signal for Pin 5 PREND will not be output when the command is O in the cutter mode Connect EXT_GND Pins 11 15 to external equipment GND Supply EXT5V_IN Pin 24 5V from the external power supply Input Peripheral device Printer 5V Open collector O 5V Open collector Figure 3 6 Input Output Circuit Diagram S8400 Series Service Manual 3 15 PN 9001161A Unit 3 Interface Specifications GSGSSSGSS e e e e SGG Figure 3 8 25 Pin Connector Assignments INPUT SIGNAL WAVE FORM START PRINTING Figure 3 9a Completed the print of 1 label Start printin PRIN Reprint PRIN2 Print operation End of 1 print PREND A REPRINTING Figure 3 9b Completed the print of 1 label Start printing PRIN rr i Reprint PRINS Print operation End of print PREND S8400 Series Service Manual 3 16 PN 9001161A Unit 3 Interface Specifications OUTPUT SIGNAL WAVE FORM BASIC OPERATION Figure 3 10a Figure 3 10b Figure 3 10c Completed the print of 1 label operation End of print PREND 1 2 3 4 Paper end Ribbon end Print operation End of print 1 PREND 3 4 Paper end Ribbon end Print operation End of print 1 2
137. peration It is possible to specify ASCII A Binary I and TENEX L8 as transfer mode although the mode difference is dependent on the client A banner page may be printed with a proper setup TELNET Complies with RFC854 This operation consists of interactive menu form and enables change and reference of internal setup and to display status To change the setup enter root user and password at the time of login Default of root pasword is set as null linefeed only S8400 Series Service Manual 3 8 PN 9001161A Unit 3 Interface Specifications 802 11G WIRELESS The wireless print server provides easy printer interface with 802 11g Wi Fi compliant networks free of wired connections Each printer is shipped with an integrated driver and interface installed The driver must be loaded onto the host computer and configured to run one of the supported protocols typ AAWGN 8E 2 PER 91dBm at 1Mbps 88dBm at 2 Mdps 87dBm at 5 5Mbps Sensitivity 84dBm at 11Mbps Range 100m indoors 300m outdoors enviromentally dependent Protocols TCP IP IPX SPX Direct Mode IPX IP DLC LLC NetBEUI NetBIOS IP Protocol Status3 return Protocol for Driver cyclic response mode Protocol for Driver ENQ response mode Status5 return Channels 01 to 11 DIPSWITCH SETTINGS The dipswitches serve to initialize the configuration saved on the Wireless LAN board print the configuration and make a self diagnosis To communicate with
138. r s middle card slot The default setting is I F 2 and accommodates a standard interface card I F 1 is to be used poe NE for the optional PCI interface cards DATA PORT Determines whether the print data code requires deletion Hexadecimal graphic data will not be ENGE SIE deleted Select YES to delete all carriage returns CR and line feed LF commands in the data stream including graphics and 2D bar codes This feature is primarily used to maintain compatibility with earlier models of SATO printers Allows the determination of whether the Cancel CAN and Data Link Escape DLE codes will be ae E processed or ignored Select the YES option to ignore the codes and NO to process them This screen will only appear when the communication protocol is STATUS4 Allows the selection of which interface board will be set up in subsequent menus Interface Port 1 st I F 1 is the smaller card slot of the printer and Interface Port 2 I F 2 is the printer s middle card SETTING slot The default setting is I F 2 and accommodates a standard interface card I F 1 is to be used foe Were ate for optional PCI interface cards Allows setting of the sequence of control characters to ensure correct data transference See your network administrator to find out which Status number will be used for the control characters STATUS4 being sent to and from the printer STATUS5 Allows the item number check to be enabled or disabled Will only appear w
139. rd feature is enabled PRINT DARKNESS 1 2 345 Ur CANCEL ENTER PITCH OFFSET XX MM i CANCEL ENTER Figure 5 1 User Mode S8400 Series Service Manual 5 3 PN 9001161A Unit 5 Printer Configuration ADVANCED MODE The Advanced Mode is provided to make advanced printer operational adjustments Typically once these adjustments or settings have been made they will not require additional address unless the application changes significantly Use the keys of the printer s operator panel to select and enter the required options Refer to the Menu Definition Tables in the following chapter to provide an explanation of each menu screen ZERO SLASH Displayed if password feature is enabled PASSWORD YES ENTER QTY 000000 PRINT METHOD AUTO ONLINE TRANSFER DIRECT YES NO OFFLINE ENTER QTY 000000 Cancels PRINT OFFSET print job ENTER CANCEL Vi XXXX H XXXX ash HEAD CHECK SET CALENDAR ENABLE DISABLE YES NO a lt gt ENTER ENTER CALENDAR HEAD CHECK NORMAL BARCODE XXIXXIXX XX XX EXTERNAL SIGNAL CALENDAR CHECK ENABLE DISABLE Disable ENTER ENABLE DISABLE ENTER Enable ENTER CHARACTER PITCH EXTERNAL SIGNAL TYPE1 TYPE PROPORTIONAL FIXED INDES INCRE re Mid ENTER ENTER Vi Mi _ PRINTER TYPE PROTOCOL CODE EXTERNAL REPRINT DISPENSER CONTINUOUS STANDARD EN
140. rds generally have long lives due to the lack of moving parts Generally if a circuit board becomes defective it is contributable to a negative external condition If It is determined that the power board has become defective search the printer over for possible visual factors that may have led to the damage 1 2 o m 2 Switch off the printer observe applicable lockout tagout procedures and disconnect power cord Remove all interface cards and open rear housing covers to access power board 1 Figure 7 14 NOTE Figure 9 1 of the Appendix unit displays cover open or removal CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST Disconnect all wiring harnesses from defective power board 1 Remove four screws 2 securing defective power board 1 to rear housing cover 3 Withdraw defective power board 1 and insert replacement power board 1 to housing cover 3 Reconnect all relative wiring harnesses previously disconnected NOTE Each of the printer s wiring harness connectors are different from all others to ensure proper mating Mate each matching half for connection Close rear housing cover restore power and test print to ensure proper function Vi N Le DI ee e a as S Si a 1 si per m 7 A a ee i J ai g nig a Figure 7 14 Power Board Replacement S8400 Series Service Manual 7 19 PN 90011
141. re properly positioned before assembly Secure print head latch handle 11 to the latch using two screws 10 Secure belt cover 9 to the printer using two screws 8 Insert torque limiter 6 rear boss 5 pin 4 torque limiter 3 front boss 2 onto spindle 7 and secure using screw 1 Reload printer restore power and test print to ensure correct installation S8400 Series Service Manual 7 5 PN 9001161A Unit 7 Replacement Procedures PLATEN DRIVE MOTOR BELT PULLEYS REPLACEMENT The stepper drive motor transmits kinetic energy to the platen roller assemblies via a timing belt and gear configuration for precise print positioning and media advancement 1 Switch off the printer and observe applicable lockout tagout procedures 2 Remove all interface cards and open rear housing covers NOTE Figure 9 1 of the Appendix unit displays housing cover opening or removal CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS INSTALLED WILL RESULT IN COMPONENT DAMAGE ALWAYS REMOVE FIRST 3 Removetwo screws 1 Figure 7 4a and one screw 2 securing platen motor assembly 3 to frame 4 4 Move aside five ground cables not shown and disconnect motor wiring harness not shown from secondary board 5 5 Withdraw platen motor assembly 3 from printer frame 4 Figure 7 4a Platen Drive Motor Belt Pulley Replacement S8400 Series Service Manual
142. re the printer is receiving information from the computer using the Receive Buffer Hex Dump mode Refer to that procedure within this manual for instructions The command stream should be continuous and possess ODhex and or OAhex carriage return and line feed characters throughout However there should not be either located between the start lt ESC gt A and the stop lt ESC gt Z commands If using TCP IP ensure a valid IP address is specified and that all parameters are correct subnet mask gateway etc Attempt to PING the IP address assigned to the network interface Also ensure the SSID channel and security matches that of the network Install the IPX SPX protocol on a workstation to determine if the network device can be discovered via the MAC address If able configure the appropriate protocols and retest connectivity Replace the interface board with another to isolate the problem Ensure the interface has been correctly configured Wait two minutes and run self test to verify If a test label does not print there may be a hardware problem Replace the interface board permanently if determined to be the problem Also reset the interface card CENTRONICS INTERFACE TROUBLESHOOTING STEP EEE Ensure the interface module is correctly installed Run self test to verify Ensure the printer cable is connected to the appropriate LPT port on the host computer If using a Windows printer driver ensure the correct port is selected Ensur
143. remaining media offset to print the next label To perform this adjustment Power On the printer Press the LINE key to place printer offline Advance to the User Mode and press FEED Adjust the OFFSET potentiometer Press the FEED key to feed another label Repeat steps 3 and 4 until desired offset is achieved Press the LINE key to bring the printer back online Is used to adjust the darkness or lightness of the printed image and should be used in conjunction with the configuration adjustments Make course adjustments there and then fine tune here If unable to achieve the desired setting here the course adjustment must be reset Adjust this potentiometer as labels are being printed Allow two labels to be printed for each adjustment to ensure a desired setting 8 14 PN 9001161A S8400 Series Service Manual APPENDIX Cover Open Diagram Block Diagram e Print Setup Dimensions e Label Reference Position Diagram e Label Adjustment Diagram e Printer Connection Diagram e Printer Loading Diagram e Typical Applicator Process e Printer Packing amp Unpacking Diagram e Ready Busy Timing Charts e X On X Off Timing Charts e Session Connect Disconnect Diagram Printer Mounting Diagram e Printer Dimensions LH w Cassette e Printer Dimensions RH w Cassette e Printer Dimensions LH Direct Load e Printer Dimensions RH Direct Load e Glossary 9 1 PN 9001161A Unit 9 Appendix COVER OPEN DIAGRAM CAUT
144. rint head and platen roller Foreign material on labels Excessive print head energy Excessive print speed S8400 Series Service Manual Unit 6 Troubleshooting Ensure ribbon is properly loaded Replace main board as required I SMEARED PRINT IMAGES 6 8 PN 9001161A Unit 6 Troubleshooting INTERFACE TROUBLESHOOTING This chapter provides a checklist for the various interface types Locate the checklist relative to the interface used and perform each of the troubleshooting tasks until the problem has been isolated PARALLEL INTERFACE TROUBLESHOOTING STEP Ensure the printer cable is connected to the appropriate LPT port on the host computer If using a Windows printer driver ensure the correct port is selected Ensure a IEEE1284 printer cable is being used Ensure the host s peripheral settings are set to ECP for faster throughput Refer to the computer manufacturer s documentation for details Ensure the printer is receiving information from the computer using the Receive Buffer Hex Dump mode Refer to that procedure within this manual for instructions The command stream should be continuous and possess ODhex and or OAhex carriage return and line feed characters throughout However there should not be either located between the start lt ESC gt A and the stop lt ESC gt Z commands Replace the interface board with another to isolate the problem Replace the interface board permanently if determined to b
145. rk enviroment does not exceed specifications ONLINE F Ensure fan filter is not clogged Replace as necessary LABEL Ensure internal fan is operational Replace as necessary RIBBON Replace main circuit board as necessary 05 Overheat Warning WARNING ICONS E i S8400 Series Service Manual 6 6 PN 9001161A Unit 6 Troubleshooting 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 quality Use higher quality media Ribbon stock and media are mismatched RIBBON WRINKLING Poor head alignment Consult with media supplier Adjust head balance and alignment Excessive temperature setting Adjust temperature Poor ribbon tension Adjust tension as required Worn roller Replace as necessary Foreign material on print head and or rollers Clean as required Foreign material on labels Use higher quality media Damaged print head LIGHT PRINT IMAGES Low print head energy darkness Replace print head as required Adjust darkness level Low print head pressure Adjust head pressure and or balance Foreign material on print head Clean print head and rollers Improper head alignment Align print head as required Excessive print speed UNEVEN PRINT DARKNESS Unbalanced print head Reduce print speed setting Adjust head
146. rs when all of the data has been received and the process is complete DOWNLOAD COMPLETE BOOT DOWNLOAD MODE TABLE 5 14 Allows the selection of location of download via the INTERFACE or CF Card BOOT DOWNLOADER INTERFACE CARTRIDGE Permits the sub port to be used for the download process The I F 1 port is for the PCI interface type and I F 2 is the standard interface type This screen only appears if INTERFACE was selected in the first screen 1 F 2 I F 1 S8400 Series Service Manual 5 38 PN 9001161A Unit 5 Printer Configuration BOOT DOWNLOAD MODE TABLE 5 14 This screen only appears if CARTRIDGE was selected in the first screen and prompts to confirm PO ARAN DA that the CF Card has been installed and setup for use SET CARTRIDGE YES NO 4 PROGRAM DOWNLOAD READY Confirms theprinter is on standby for receiving data Screen confirms that downloading is in process and displays its progress status A tinted field will Sn move laterally from the left toward the right as downloading progresses When the tinted bar DOWNLOADING reaches 100 on the scale downloading is complete i This menu screen appears when all of the data has been received and the process is complete SESCRANTONNIGAD Also prompts the operator on how to proceed COMPLETED PRESS ENTER PRINT CANCEL MODE TABLE 5 15 Print data that has been previously received can be cleared If the YES option is En selected the print data wil
147. s a trial and error activity that requires the pause of printing unlatching of the print head adjusting the guide relatching the print head and printing once again Several labels must be printed following each adjustment to determine if the adjustment was effective The ribbon guide is secured to the face of the print assembly by a screw on each end Before adjusting the guide visually inspect that its axis is parallel with that of the print assembly If not adjust accordingly ensure the set screws are secure and once again commence printing By starting in a neutral position either end may be adjusted vertically as necessary to remedy the wrinkling problem 1 Test print a label to ensure the print head is properly balanced and aligned NOTE Refer to their relative procedures within this manual for guidance on Print Head Balance and Print Head Alignment Disengage the print head latch Loosen one of the two set screws 1 Figure 8 4 and move the free end of ribbon guide 2 upward or downward as necessary until the ribbon appears to unwrinkle Retighten loose set screw 1 while holding ribbon guide 2 in place Engage print head latch close cover and test print a label Repeat steps 2 through 5 until proper alignment is achieved Figure 8 4 Ribbon Guide Alignment S8400 Series Service Manual 8 5 PN 9001161A Unit 8 Adjustment Procedures MEDIA PRESSURE ROLLER BALANCE Pressure roller balance adjustment may
148. sen an image is saved to the Flash Card If NO is chosen an image is not saved Only a single image may be saved at a time and will be overwritten by a new image Allows the data saved in the Flash Card to be read and to specify the print quantity Use the arrow keys to change the print quantity then press ENTER The print will beep if print data is not stored S8400 Series Service Manual 5 41 PN 9001161A TROUBLESHOOTING Error Signal Troubleshooting e Warning Signal Troubleshooting Troubleshooting Table e Interface Troubleshooting e Performance Testing Test Print Modes S8400 Series Service Manual 6 1 PN 9001161A Unit 6 Troubleshooting ERROR SIGNAL TROUBLESHOOTING ERROR DISPLAYS POWER 01 Machine Error 02 Machine Error 03 Flash ROM Error 04 Parity Error 05 Overrun Error 06 Framing Error 07 Buffer Overflow Error 08 Head Open Error 09 Paper End Error ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON POWER ONLINE LABEL RIBBON S8400 Series Service Manual MACHINE ERROR TEMPERATURE RISE 0 BUFFER OVER ERROR LED DISPLAY LCD DISPLAY DESCRIPTION On 6 2 Ensure all wiring harnesses are pr
149. spindle 9 and secure using screw 2 NOTE A properly installed torque limiter will be oriented so that its metal end is inserted onto the spindle first and will engage each respective pin Properly installed ribbon bosses will engage their respective torque limiters Rotate each while appliying forward pressure to ensure proper nesting Insert the shaft or tool into slot A of spindle assembly 1 and hold firmly to tighten screw 2 Repeat steps 2 through 6 for the second ribbon spindle 1 as necessary Figure 7 10 Ribbon Boss amp Torque Limiter Replacement Cassette Load S8400 Series Service Manual 7 14 PN 9001161A Unit 7 Replacement Procedures MAIN BOARD REPLACEMENT The main circuit board is the primary brain center for all printer activities Circuit boards generally have long lives due to the lack of moving parts Generally if a circuit board becomes defective it is contributable to a negative external condition If it is determined that the circuit board has become defective search the printer over for possible visual factors that may have led to the damage 1 2 2 p p Switch off the printer and observe applicable lockout tagout procedures Remove all interface cards and open the rear housing covers to access main circuit board 1 Figure 7 11 NOTE Figure 9 1 of the Appendix unit for displays housing cover open or removal CAUTION OPENING THE REAR HOUSING COVERS WITH INTERFACE CARDS
150. t OCR A 305dpi 12dots mm 22 dots W x 33 dots H 609dpi 24dots mm 44 dots W x 66 dots H 203dpi 8dots mm 20 dots W x 24 dots H OB Font OCR B 305dpi 12dots mm 30 dots W x 36 dots H 609dpi 24dots mm 60 dots W x 72 dots H AUTO SMOOTHING FONTS x DJ 48 dots W x 48 dots H Univers Condensed Bold 48 dots W x 48 dots H Sans Serif VECTOR FONT Proportional or Fixed Spacing Font Size 50 x 50 dots to 999 x 999 dots Helvetica 10 Font Variations AGFA RASTER FONTS A Font CG Times 2 to 99 pt 4 999 dots B Font CG Triumvirate 2 to 99 pt 4 999 dots DOWNLOADABLE FONTS Compact Flash Card required CHARACTER CONTROL Expansion up to 12 x in either the X or Y coordinates Character Pitch Control Line Space Control Journal Print Facility 0 90 180 and 270 Degree Rotation S8400 Series Service Manual 2 4 PN 9001161A Unit 2 Technical Data BAR CODE CAPABILTIES UPC A E EAN 8 13 Code 39 Code 93 Code 128 Interleaved 2 of 5 Industrial 2 of 5 Matrix 2 of 5 Bookland RSS 14 Linear Bar Codes MSI POSTNET UCC EAN 128 NW 7 Codabar QR Code Data Matrix ECC200 Two Dimemsional Maxi Code PDF417 Composite Symbology Form Overlay Form overlay for high speed editing of complex formats S8400 Series Service Manual 2 5 PN 9001161A INTERFACE S8400 Series Service Manual SPECIFICATIONS RS232C High Speed Serial Interface e IEEE1284 Parallel Interface e Universal Serial Bus U
151. t head 3 NOTE Each of the printer s wiring harness connectors are different from all others to ensure proper mating Mate each matching half for reconnection 6 Insert replacement print head 3 into the print assembly and lift upward into position until latched CAUTION EXCERCISE CARE WHEN INSTALLING THE PRINT HEAD TO ENSURE THAT ITS ELEMENTS ARE NOT DAMAGED DURING INSTALLATION 7 Restore power reload the printer reset the head counter and test print to ensure proper function Figure 7 1 Print Head Replacement S8400 Series Service Manual 7 2 PN 9001161A Unit 7 Replacement Procedures PLATEN ROLLER REPLACEMENT The printer s platen roller is considered to be a high wear component due to constant treading of the print media and ribbon stock against its contact surface This constant contact will eventually wear grooves into the rubber material and negatively effect print output This procedure applies to all three rubber rollers 1 Switch off the printer and observe appropriate lockout tagout procedures Remove label media as required Loosen screw 1 Figure 7 2 sufficiently to rotate bearing clamp 2 from bearing 3 NOTE Figure 7 2 shows screw 1 and bearing clamp 2 as being removed for display purposes only It is not necessary to remove those components for roller replacement Withdraw bearing 3 from chassis 4 and worn roller 5 Withdraw worn roller 5 from the printer and ins
152. terface Will not display if the dipswitch priority REISE option is chosen 7BIT 8BIT S8400 Series Service Manual 5 27 PN 9001161A Unit 5 Printer Configuration SERIAL INTERFACE MODE TABLE 5 4 Lee DESCRIPTION Allows setting of communication protocol Will not display if the dipswitch priority option is chosen Allows the item number check to be enabled or disabled Will only appear when STATUSS is set for the protocol ENABLE DISABLE 4 k Allows BCC check to be enabled or disabled Will only appear if STATUS5 is set for protocol BCC CHECK ENABLE DISABLE LAN INTERFACE MODE TABLE 5 5 Is the premiere screen of the Interface Mode The Interface Mode allows the parameters to be set for the printer to communicate with a host and vice versa Select the YES option to configure an interface board for bi directional communication the menu E will advance to multiple configuration screens depending on the type of interface borad installed SETTING en d Selecting the NO option will bypass those screens Allows the selection of which interface port will be assigned to receive print data Interface Port 1 I F 1 is the smaller card slot of the printer and Interface Port 2 I F 2 is the printer s middle card slot The default setting is F 2 and accommodates a standard interface card 1 F 1 is to be used i for the optional PCI interface cards DATA PORT Determines whether the print data code requires de
153. that provides the printed length of media using the existing print head Eb COUNTER The head counter should be reset each time the print head is replaced X X M X X M X X M Enables view of the printer s dispense counter identifying the quantity of times the printer has DISPENSE COUNTER dispensed a label X X M Enables the printer s serial number to be recorded within its memory SERIAL NO S N XXXXXXXX r S8400 Series Service Manual 5 36 PN 9001161A Unit 5 Printer Configuration FACTORY MODE TABLE 5 10 Enables the revision number of the main circuit board to be recorded within its memory MAIN PCB REVISION REV X X 456 Enables the revision number of the interface board to be recorded within its memory INTERFACE BOARD REVISION REV XX 4 or TEST PRINT YES NO i E Allows the determination of whether to test print or not If the YES option is selected from the previous screen this menu allows the test print type to be TEST PRINT MODE selected Allows the selection of large 10cm or small 4cm media width These are the only two options PRINT SIZE SMALL LARGE TEST PRINT PRESS ENTER KEY WORK SHIFT MODE TABLE 5 11 This screen is used to select the shift that will be configured in the screens to follow Up to three shifts can be configured Initiates test printing activity SELECT SHIFT 12 3 Bar Note the shift code must be installed from within the Hidden Mode below to ac
154. thdraw set screw not shown from gear 11 to replace ribbon roller 12 Insert replacement ribbon roller 12 into its respective orifice of rear plate 4 apply gear 11 and secure using set screw not shown and snap ring 10 Insert replacement ribbon roller 9 into its respective orifice of rear plate 4 and secure using snap ring 7 Apply replacement timing belt 6 to ribbon roller 9 Apply rear plate 4 to front plate 5 and secure using one screw 3 two screws 2 five screws 1 NOTE Ensure the timing belt is properly routed and all protruding components insert into their respective slots when assembling the front and rear plates Refer to Figure 7 8 for proper timing belt routing Figure 7 7 Ribbon Cassette Belt amp Roller Replacement S8400 Series Service Manual 7 11 PN 9001161A Unit 7 Replacement Procedures Figure 7 8 Ribbon Cassette Belt Route Diagram S8400 Series Service Manual 7 12 PN 9001161A Unit 7 Replacement Procedures RIBBON BOSS TORQUE LIMITER DIRECT LOAD Each printer model incorporates the use of a ribbon supply spindle and a ribbon rewind spindle Whereas the ripbon spindle assemblies differ for different models both the supply and rewind spindles are identical in components and assembly as it relates to those addressed here This chapter covers the replacement of ribbon spindle components located on the printer s print side for those models that provide for dir
155. the host set the communication mode by through switches 5 and 6 then set the remaining switches to the OFF position Print of configuration and self diagnsis are operable only on the screen after turning on the printer Ensure all switches are in the OFF position when operating the printer SWITCH SETTING o 1 oF Normal operating setting Normal operating setting Initialization Reset to factory default upon power up Normal operating setting Configuration report upon power up prints diagnostic report upon powering up Wireless Mode setting NOTE The communication mode may be set within the printer s Interface Mode Go to Communication of the Interface Mode to enable setup by either the dipswitches or through the Interface Mode WIRELESS LAN SIGNAL STRENGTH 010 50 weak Network Port Link LED Blinking 50 to 75 medium 75 to 100 strong S8400 Series Service Manual 3 9 PN 9001161A Unit 3 Interface Specifications LED INDICATOR STATUS Link LED green Blinking Waiting for link Front Panel On Status LED orange Front Panel Blinking Receiving packet l Blinking Ad hoc mode Wireless LED green Front Panel On Infrastructure mode SOFTWARE SPECIFICATIONS Corresponding Protocol TCP IP Network Layer ARP RARP IP ICMP Session Layer TCP UDP Application Layer LPD FTP TELNET BOOTP DHCP NOTE Print data can be sent by LPR and FTP of TCP IP and dedicated socket protocol Printer status is obtai
156. the printer to the configuration as received from the factory Use the printer s operator panel to select and enter the required options Refer to the Menu Definition Tables in the following chapter to provide an explanation of each menu screen S8400 Series Service Manual Printer beeps DEFAULT MODE PRINTER SETTING ALT PROTOCOL Alt Protocol ENTER Printer Set ENTER DEFAULT DEFAULT PRINTER SETTING ALT PROTOCOL YES NO YES NO 4 E i P DEFAULT SETTING COMPLETED PLEASE POWER OFF Printer waiting to be powered off Figure 5 16 Default Settings Mode 5 18 PN 9001161A Unit 5 Printer Configuration TEST PRINT MODE Figure 5 17 provides the specific sequence of events required by the operator the printer and the printer s software for a test label to be printed Test labels are designed to identify failures in configuration adjustment problems and mechanical defects Use the keys on the printer s operator panel to select and enter the required options Refer to the Menu Definition Tables in the following chapter to provide an explanantion of each menu screen Printer beeps TEST PRINT MODE CONFIGURATION BARCODE HEAD CHECK MEMORY FONT FACTORY Scrolls options Barcode Head Check Memory Factory ENTER ENTER ENTER ENTER TEST PRINT SIZE Configuration ENTER 10 cm TEST PRINT PRESS ENTER KEY TEST PRINT SIZE LARGE SMALL Power off t
157. to be enabled or disabled Will only appear if STATUS5 is set for protocol When the printer driver is set for GAP sensor printing transmissive mode BCC CHECK will be switched to DISABLE When performing a test print of any LAN type of interface set this to DISABLE 5 32 PN 9001161A Unit 5 Printer Configuration WIRELESS LAN INTERFACE MODE TABLE 5 8 This menu screen allows for the setting of the wireless LAN communication method See your network administrator for the proper setting Allows the unique wireless LAN SSID name to be configured in the printer See your network administrator for proper SSID settings Allows the wireless LAN channel to be set in the printer The valid range is 01 to 14 See your network administrator for the wirelss network channel SERVICE MODE TABLE 5 9 The Service Mode allows the programming of various dimensional settings sensor thresholds and language options Permits sensitivity adjustment of the eye mark sensor The adjustment range is 1 to 99 The SENSOR LEVEL I MARK XXV LEVEL OFFSET XX a SENSOR LEVEL I MARK XXV SLICE LEVEL SENSOR LEVEL GAP XXV LEVEL OFFSET SENSOR LEVEL GAP XXV SLICE LEVEL XXV AUTO ONLINE FEED YES NO ask FEED ON ERROR YES NO i k S8400 Series Service Manual default value is 50 Permits adjustment of the sensor s slice level The slice level is the voltage at which the printer determines media change from label to gap
158. tten as four numbers separated by periods See your network administrator for available IP Addresses Specifies which segment of the network the printer will reside The format of Subnet Mask is a 32 bit numeric address written as four numbers separated by periods See your network administrator to find out your Subnet Mask Specifies the IP Address of the main router on the host network The format of a Gateway Address is a 32 bit numeric address written as four numbers separated by periods See your network administrator to find out your default Gateway Address When the priority setting is set to BOARD this screen will not appear Power off the printer then on again to enable the changes Allows setting of the sequence of control characters to ensure correct data transference See your network administrator to find out which Status number will be used for the control characters being sent to and from the printer Allows reply timing of status information to the host to be set Select the ENQ option to return status after receiving Status Request ENQ and CYCLE to return status from the printer to the host at 500ms intervals This screen will only appear when LAN or Wireless LAN is installed and when protocol is set to STATUS4 Allows the item number check to be enabled or disabled Will only appear when STATUSS is set for the protocol When performing a test print of any LAN type of interface set this to DISABLE Allows BCC check
159. units of electrical force the ampere current that flows through a conductor vet The amount of space occupied in three dimensions cubic contents olume The strength or loudness of sound The amount of electrical power to operate an electrically powered device arrived by Wattage ae multiplying amperage by voltage To diminish in quality by repetitive activity Operates with electromagnetic waves and not with conducting wire Multiple electrical wires bundled together A protocol for controlling the flow of data between computers and other devices on an asychronous serial connection A flat disk of metal rubber etc used to make a seat for the head of a bolt screw or nut X ON X Off For example a computer typically sends data to a printer faster than the printer can print The printer contains a buffer where data is stored until it catches up a small microprocessor in the printer sends back an Xoff signal to stop sending data When enough data is printed and the buffer storage becomes free the printer sends an Xon signal to resume sending data S8400 Series Service Manual 9 37 PN 9001161A
160. urposes However the roles of those two slots may be exchanged at the DATA PORT menu screen Screen confirms that copying is in process and displays its progress status A tinted field will move laterally from the left toward the right as copying progresses When the tinted bar reaches 100 on the scale copying is complete This screen confirms the completion of the copy process and prompts for action to exit the PROGRAM COPY prog ram COMPLETE PRESS ENTER KEY S8400 Series Service Manual 5 35 PN 9001161A Unit 5 Printer Configuration SERVICE MODE TABLE 5 9 Allows the language of the menu screens to be selected SELECT LANGUAGE ENGLISH FRENCH GERMAN SPANISH ITALIAN PORTUGESE FACTORY MODE TABLE 5 10 Is the first menu screen of the Maintenance Mode that includes the Service Mode and Factory Mode Provides a prompt on the action required to proceed to the Factory Mode MAINTENANCE MODE SERVICE MODE FACTORY MODE Counter Clear permits the operator to select individual counters to be reset to zero or by selecting FR ALL to entirely clear all of the printer s internal counters or EEPROM data Allows view of the recorded linear meters of printed media by the printer s internal counters Is an informational screen that provides the length of media used since printer setup Enables view of the printer s cutter counter identifying the quantity of cut cycles by that cutter Is an informational screen
161. wo screws 3 NOTE The interface slot identified EXT is assigned for peripheral device connection The center slot is asigned for standard interface card connection And the remaining slot is for use with PCI interface cards 4 Repeat steps 2 and for additional interface cards as applicable NOTE Dependent on individual setup and operational requirements multiple interface cards may be required 5 Connect interface cable not shown NOTE The interface cable to be used is dependent upon the type of card and the device to be connected Refer to this printer s operator manual for specific printer connection instructions Refer to peripheral device s documentation for its connector identification Figure 4 1 Interface Installation S8400 Series Service Manual 4 2 PN 9001161A Unit 4 Accessories Installation COMPACT FLASH CARD The compact flash card provides an expanded storage location to enhance the capabilities and functionality of the printer This area may be used to store fonts graphics and formats It can alos be used to store custom programs put the in Stand Alone Mode or to simply copy printer settings 1 Switch off the printer and and observe applicable lockout tagout procedures 2 Remove all interface cards and open rear housing covers to access flash memory card 1 Figure 4 2 NOTE Figure 9 1 ofthe Appendix unit provides guidance on
162. y Sensor Pulley Quadrant Radial Radius RAM Ratio Reader Read Write Receive Buffer Receptacle Relay Retain Retract Resistor RF AIS RF DC RFID u 00 N O O op D D N op D lt O D lt ie 5 E D The device on a direct thermal or thermal transfer printer containing the heating elements that causes an image to be transferred to print media A programmable device that performs all the instruction logic and mathematical processing in a computer is the brains of the computer The processor is a microchip that is installed on a motherboard primary board that coordinates hardware components Also referred to as CPU A side view of an item To enter or send to the processor the control parameters for electronic equipment to operate To be equal A device that detects and signals the presence of a selected object at or near the sensor s location A toothed wheel for providing movement to a belt One quarter of the circumference of a circle Branching out in equal distances from a common center A straight line from the center of a circle or sphere to its periphery also the measurement of its distance Random Access Memory A network of electrically charged points in which a computer stores quickly accessible data in the form of Os and 1s Each storage or memory cell can be directly accessed if the intersecting row or column is known The quotient of o
163. y be necessary when using high resin content ribbons Allows choice of continuous feed or dispenser operation PRINTER TYPE DISPENSER CONTINUOUS Allows the determination of whether a backfeed motion will be applied Is so the selection of ESSO before or after the printing of each label S8400 Series Service Manual 5 23 PN 9001161A Unit 5 Printer Configuration ADVANCED MODE TABLE 5 2 PRINT METHOD TRANSFER DIRECT SENSOR TYPE GAP TOP I MARK BOTTOM I MARK HEAD CHECK ENABLE DISABLE HEAD CHECK NORMAL BARCODE EXTERNAL SIGNAL ENABLE DISABLE EXTERNAL SIGNAL TYPE1 TYPE2 TYPE3 TYPE4 4s EXTERNAL REPRINT ENABLE DISABLE START PROGRAM NONE ZERO SLASH YES NO i E AUTO ONLINE YES NO i E PRINT OFFSET V XXXX H XXXX Ih S8400 Series Service Manual Allows the printer to be switched to operate in the thermal transfer or direct thermal mode as desired Allows the pitch sensor mode to be selected relative to the media type being used This feature determines the intensity of the print head elements when enabled The printer will go into error mode when a malfunctioning print head element is detected This screen will appear if the print head check feature has been enabled Choose for the head check to be performed unconditionally or only when barcodes are being printed Previously printed barcodes should be scanned following an error to determine their functionality S
164. y i ES J N Screw x2 Figure 3 1 Interface Installation S8400 Series Service Manual 3 2 PN 9001161A Unit 3 Interface Specifications 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 communication Bi Directional Communication Transmission Form Start b1 b2 b3 b4 b5 b6 b7 b8 Stop b8 will be omitted if using 7 bit oriented Control Codes STX 02H ETX 03H ACK 06H NAK 15H Connector Printer Side DB 25S Male equivalent 9 pin Serial Interface PCI Cable Connector DB 25P Female equivalent 9 pin Serial Interface PCI Signal Levels High 5V to 12V Low 5V to 12V Protocol Ready Busy X On X Off Protocol for Driver Status4 Status5 DIPSWITCH SETTINGS SWITCH COMPONENT SETTINGS ON Data Bit OO OFF OFF ON EVEN OFF NONE ON Stop Bit ON Reserved Status2 amp 3 when compatible mode is OFF OFF Protocol for Driver Status5 7 ON Protocol ON ON ON 57600 bps Baud Rate ON OFF 38400 bps OFF ON 19200 bps OFF OFF 9600 bps S8400 Series Service Manual 3 3 PN 9001161A Unit 3 Interface Specifications READY BUSY INTERFACE SIGNALS DIRECTION SIGNAL DEFINITION To Host TD Transmit Data Data from the printer to the host computer Sends X On X Off characters or status data bi directional pr

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