CL608e/CL612e Printers

Service Manual

PN 9001079 Rev. B

SATO America, Inc. 10350-A Nations Ford Rd. Charlotte, NC 28273 Main Phone: (704) 644-1650 Technical Support Hotline: (704) 644-1660 Fax: (704) 644-1661 http:\\www.satoamerica.com

Copyright 2002

SATO America, Inc.
The information supplied in this manual was current at time of publication. If you come across procedures that need clarification or find errors or have suggestions contact us at qc@satoamerica.com
Warning: This equipment 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 requiring the operator to take whatever steps are necessary to correct the interference. All rights reserved. No part of this document may be reproduced or issued to third parties in any form whatever without the express permission of SATO America, Inc. The materials in this document are provided for general information and are subject to change without notice. SATO America, Inc. assumes no responsibility for any errors that may appear.
SATO CL608e/CL612e Service Manual

Table of Contents

Section 1. Overview and Specifications
Overview.... 1-1 Physical Characteristics.... 1-2 Printer Features... 1-3 Operation PanelDisplays... 1-5 Components.... 1-7 Switches and Sensors... 1-8 Ribbon.... 1-10 Installation Considerations... 1-10 Optional Accessories... 1-10 Environment & Approvals.... 1-11 General Printer Specifications... 1-11 Character Fonts... 1-14 Bar Codes.... 1-15

Section 2. Configuration

1 Dip Switch Settings... 2-Default Settings... 2-LCD Panel Printer Configuration... 2-8 Normal Mode.... 2-9 M8400 Compatible Mode... 2-12 Advanced Mode... 2-13 Card Mode.... 2-17 Service Mode.... 2-25 Counters Mode... 2-31 Test Print Mode... 2-32 Default Setting Mode.... 2-33 Maintenance Mode... 2-34 Clear Non-Standard Protocol... 2-36 Download User Defined Protocol Codes.. 2-36 Hex Dump Mode.... 2-37 Download Mode... 2-38 User Download Mode... 2-Sample Test Labels... 2-40
Section 3. Interface Specifications
Overview.... 3-1 Interface Types.... 3-1 Receive Buffer... 3-3 IEEE 1284 Parallel Interface... 3-4 Optional RS232C Serial Interface.. 3-6 Universal Serial Bus (USB) Interface... 3-9 Local Area Network (LAN) Interface.. 3-10 Bi-Directional Communications... 3-10 Accessory (EXT) Connector... 3-19 Overview.... Steps Prior to Some Procedures... DC Power Voltage Checks... Potentiometer Assignments & Adjustments.. Pitch Offset Adjustment....
Section 4. Electrical Checks and Adjustments

4-1 4-2 4-3 4-6 4-8

5b Pitch Offset Adjustment.... 4-Label Gap Adjustment... 4-Eye-Mark Adjustment... 4-Feed/Backfeed Adjustment (Tear-Off)... 4-Feed/Backfeed Adjustment (Cutter)... 4-Feed/Backfeed Adjustment (Dispenser).. 4-Ribbon Sensor Verification... 4-Ribbon Sensor Adjustment (Near End)... 4-LCD Display Adjustment... 4-Print Darkness Adjustment... 4-18
Section 5. Mechanical Adjustments
Overview.... 5-1 Ribbon Clutch Adjustments... 5-2 Print Head Position Adjustment... 5-5 Print Head Balance Adjustment... 5-7 Ribbon Roller Adjustment... 5-8 Feed Roller Adjustment (Label Tracking).. 5-9 Timing Belt Tension Adjustment.. 5-11 Head Latch Adjustment... 5-12 Notch/Gap Sensor Adjustment... 5-13
Section 6. Replacement Procedures
Overview.... 6-1 Replacing the Main Circuit Board... 6-2 Replacing the Fuses... 6-7 Replacing the Power Supply... 6-9 Replacing the Stepper Motor.. 6-12 Replacing the Timing Belts... 6-13 Replacing the Print Head... 6-16 Replacing the Platen... 6-19 Replacing the Ribbon Drive Clutch Washers... 6-23 Replacing the Ribbon Motion Sensor... 6-27 Replacing the Paper End Switch (Micro-Switch) and the Bottom Half of the Notch/Gap and Eye-Mark Sensors. 6-Replacing the Top Half of the Notch/Gap Sensor.. 6-Replacing the Display Panel or Keyboard... 6-37

.0033 in. -.083 mm 305 dpi - 12 dpmm 6.5 in. - 164 mm 32.8 in. - 833 mm
1.96 in. (50 mm).78 in. (20 mm) 7 in. (178 mm) Die Cut Labels, Fan-Fold, Tag Stock or Continuous.010 in. (.25 mm) 8.6 in. (218 mm), Face-in Wind 1.5 in. (38 mm) 3 in. (76 mm)

Page 1-11

General Printer Specifications
Specification Sensing Transmissive See-thru Reflective Eye-Mark Continuous Form Ribbon Maximum Width Length Thickness Controls and Signals On-Line LED Power LED Media Out LED Ribbon Out LED Error LED LCD Panel On/Off-Line Switch Label Feed Switch Power On/Off Switch Potentiometer Adjustments Print Darkness Pitch Offset Display Front Panel Front Panel Front Panel Front Panel Green Green Red Red Red 2 Line x 16 Character Front Panel Front Panel Rear Panel 6.75 in. (172 mm) 1345 ft. (410 m) 4.5 micron, Face in Wind Movable Fixed Sensor not used C L 608e C L 612e

Page 1-12

Specification Interface Modules Parallel Serial IEEE 1284 Parallel RS232C (9600 to 57,600 bps) RS422/485 (9600 to 57,600 bps) Hardware Flow Control (Ready/Busy) Software Flow Control (X-On/X-Off) Bi-directional Status 2,3 or 4 USB Version 1.1 10/100BaseT ASCII Format C L 608e C L 612e
Serial Protocol Universal Serial Bus Ethernet Data Transmission Processing C PU Flash ROM SDRAM Receive Buffer Optional Flash ROM Optional PCMCIA Memory
32 Bit RISC 2 MB 16 MB 2.95 MB 4 MB Up to 16 MB Flash or 4 MB SRAM

Page 1-13

1.12 Character Fonts
Specification Matrix Fonts U Font S Font M Font XU Font XS Font XM Font OA Font OB Font Auto Smoothing Fonts WB WL XB XL 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 B Font Downloadable Fonts Bit Mapped TrueType Fonts with Utility Program Character Control Expansion up to 12 X in either the X or Y coordinates Character Pitch control Line Space control Journal Print facility 00, 900, 1800 and 2700 Rotation CG Times, 8 to 72 pt CG Triumvirate, 8 to 72 pt WB Font (18 dots W x 30 dots H) WL Font (28 dots W x 52 dots H) XB Font (48 dots W x 48 dots H) Univers Condensed Bold XL Font (48 dots W x 48 dots H) Sans Serif (5 dots W x 9 dots H) (8 dots W x 15 dots H) (13 dots W X 20 dots H) (5 dots W x 9 dots H) Helvetica (17 dots W x 17 dots H) Univers Condensed Bold (24 dots W x 24 dots H) Univers Condensed Bold (15 dots W x 22 dots H) OCR-A (20 dots W x 24 dots H) OCR-B (22 dots W x 33 dots H) OCR-A (30 dots W x 36 dots H) OCR-B C L 608e C L 612e

Print Darkness Setting

There are three Darkness (or heat range) settings on the printer. The higher numbers represent darker settings. The current setting is indicated by a line under one of the range settings. To change the setting perform the following steps: STEP 1. PROCEDURE Use the LINE key to step the underlined cursor to the desired setting. 1 = Light 2 = Medium 3 = Dark 2.
PRINT DARKNESS 1(L) 2(M) 3(D)
Once the correct setting is underlined, press the FEED key to accept the setting and advance to the next adjustment.

Page 2-9

Print Speed Adjustment
There are three Speed settings on the printer. The setting is listed on the bottom line of the display. The current setting is indicated by an underline under one of the speed settings. To change the setting: STEP 1. PROCEDURE Use the LINE key to step the underlined cursor to the desired speed setting. 4 = 4 in/s (100mm/s) 6 = 6 in/s (150mm/s) 8 = 8 in/s (200mm/s) 2.

PRINT speed 8

Pitch Offset Adjustment
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 leading edge position of the label can be adjusted relative to the print head +/- 49mm in increments of 1mm. Once the position is set, it can be fine adjusted +/- 3.75mm using the PITCH potentiometer on the adjustment panel. STEP 1. PROCEDURE The underline cursor will initially be positioned underneath the Pitch Direction setting. Use the LINE key to step the underline to either the positive (+) or negative (-) selection. A position selection moves the leading edge of the label forward (away from the print head) while a negative selection moves the leading edge of the label back into the mechansim. Once the correct setting is underlined, press the FEED key to accept the setting and advance to the Offset adjustment. Use the LINE Key to step the first digit of the counter to the desired setting. The display will increment one step each time the LINE key is pressed. The reading will advance to a setting of 4 after which it will automatically wrap and start at 0 again.

pitch offset +00mm

Page 2-10
STEP 4. PROCEDURE Press the FEED key to accept the setting and advance the cursor to the second digit. Again use the LINE key to step to the desired setting. Once it is correct, press the FEED key to advance to the next adjustment. Print a test label after completing the adjustments to ensure it is correct. Leading Edge of Label Moved with negative (-) offset to print on leading edge of the label Original (0 offset) first line position Moved with positive (+) offset to print on trailing edge of the label

Auto online feed yes no

This selection specifies whether or not the printer will automatically feed a blank label when it is placed in the Online mode. STEP 1. PROCEDURE Use the LINE key to step the underlined cursor to the desired setting. IF Yes is selected, the printer will feed a blank label anytime it enters the Online mode. If No is selected, the display will advance to the mode display.

Feed on Error Yes No

feed on error yes no
This selection specifies whether or not the printer will feed a blank label automatically when an error condition is cleared. STEP 1. PROCEDURE Use the LINE key to step the underlined cursor to the desired setting. IF Yes is selected, the printer will feed a blank label anytime an error condition is cleared. If No is selected, the display will advance to the mode display.

Reprint W/Feed Yes No

reprint w/feed yes no
This selection specifies whether or not the printer will print the last printed label stored in memory when the FEED key is pressed in the Normal Online mode. STEP 1. PROCEDURE Use the LINE key to step the underlined cursor to the desired setting. IF Yes is selected, the printer will reprint the last label when the FEED key is pressed when the printer is Online. If the printer is Offline, pressing the FEED key will feed a blank label. If No is selected, the display will advance to the mode display.

Page 2-28

Forward/Backfeed Distance Default
forward/backfeed distance default
This display will only appear when Backfeed is enabled (DSW3-4 = OFF). The maximum backfeed distance is 255mm. STEP 1. PROCEDURE Press the FEED key to use the default distance. This setting will be appropriate for use with standard labels with a 1/8" gap between labels and most tag stock applications. Press the LINE key to set your own backfeed distance up to 255mm. Each time you press the LINE key, the distance is advanced 1mm. CAUTION: A backfeed distance over 40mm may cause ribbon wrinkle and require ribbon tension adjustments.
forward/backfeed distance XXXmm
3. Press the FEED key to accept the selected backfeed distance.

Ext Port Pin 9 Select

EXt pin9 mode 1

select mode2

This selection allows user selection of when Pin #9 of the 14 pin EXT connector goes HIGH, to allow printer status to be determined without using Bi-Directional Communication Select Mode1 or Mod2, using the Line key. Press FEED key to save and exit. MODE 1 = On-Line print job waiting. MODE 2 = On-Line

Page 2-29

Euro Code D5

euro code d5

This selection allows the user to specify the hexadecimal code for the character which is replaced with the Euro Character. The default is D5 Hex. STEP 1. 2. 3. 4. PROCEDURE The underline cusor should be positioned underneath the first digit selection. Use the LINE key to step to the desired setting. Press the FEED key to advance the underline cursor to the second digit of the desired hexadecimal code. Press the LINE key to step to the desired setting. When the setting is correct, press the FEED key to accept the setting and advance to the next display.
Select LCD Display Language

select language english

This selection allows the user to select the language used in the LCD menu and error messages. The selections are English, French, German, Spanish, Italian and Portuguese. STEP 1. 2. PROCEDURE Press the LINE key to advance to the desired language setting. When the setting is correct, press the FEED key to accept the setting and advance to the next display.

Page 2-30

Priority Setting LCD Command
priority setting lcd command
This selection allows the user to assign a priority for Print Darkness, Print Speed and Print Offset. STEP 1. PROCEDURE Use the LINE key to step to the desired priority. If LCD is selected, the setting established via the LCD display/menu system will be used for an incoming label job, regardless of any different command settings. If Command is selected, any commands in the label job will take precedence and be used for printing the job and the LCD Display will reflect the new setting. Once the desired setting is selected, press the FEED key to accept the setting and advance to the next display.

ignore yes

can/dle no
This function allows the user to disable: <DLE> (Hex 10) the print stop command and <CAN> (Hex 18) the cancel command. Used for compatibility with some third party hardware and software. It is only displayed and functional when RS-232C HS serial interface is installed and configured for Status 4 Bidirection operation.
ribbon near end enable disable
This function is only displayed when a RS232 HS serial interface card is installed and configured for Status 3 Bi-direction operation. The disable function was added for compatibility with older non "e" version printers, where ribbon near end was not reported. Use the LINE key to select Enable or Disable and press FEED to save and exit.

Page 3-1

Interface Types
In order to provide flexibility in communicating with a variety of host computer systems, CL608e/612e printers use a Plug-In Interface Module. The IEEE1284 Interface module is shipped with the printer unless another interface type is specified at the time of the order. The other interfaces available are a high speed (to 57.6K bps) serial interface, an Ethernet interface or an optional Universal Serial Bus (USB) interface. The Parallel interface will probably be the most useful in communicating with IBM PCs and compatibles. The RS232C Serial interface allows connectivity to a number of other hosts. The USB interface allows the printer to be connected to a computer that supports peripherals attached to a USB bus. 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 warranty.
CENTRONICS PARALLEL INTERFACE

RS232C SERIAL INTERFACE

USB INTERFACE

ETHERNET INTERFACE

Available Interfaces

Page 3-2

3.3 The Receive Buffer
The CL608e/CL612e printers have the ability to receive a data stream from the host in one of two ways. The receive buffer may be configured to accept one print job at a time or multiple print jobs. The single job print buffer is generally used by software programs that wish to maintain control of the job print queue so that it can move a high priority job in front of ones of lesser importance. The multiple job buffer on the other hand prints all jobs in the order they are received by the printer and the order of printing cannot be changed. Single Job Buffer The printer receives and prints one job at a time. Each job must not exceed 2.95MB. Multi Job Buffer The printer is able to continuously receive print jobs, compiling and printing other jobs at the same time. It acts much like a "print buffer" ot maximize the performance of the host and the printer. When using the RS232 Serial interface, the Multi Job Buffer uses either the Ready/ Busy with DTR (pin 20) or X-On/X-Off flow control protocols. See these sections for more details. With an empty receiving buffer, the status of DTR is "high" (or an XOn status if using X-On/X-Off), meaning the printer is ready to receive data. When the receive buffer is holding 2.0MB of data (1MB from being full), DTR will go "low" (or an X-Off is sent) indicating the printer can no longer receive data. This condition is called "Buffer Near Full."

Page 4-11

4.8 Offset Label Stop Position Adjustment
Used for fine adjustment of label stop position for Tear Off, Cutter and Dispense Modes. The Label Stop Position is adjusted with the Offset potentiometer on the Front Panel. VR 2 Note: The stop position only is changed with the VR2 (OFFSET). The print position is changed with the VR3(PITCH). POTENTIOMETERS ARE LOCATED UNDERNEATH A FLIP - DOWN COVER OF THE FRONT PANEL STEP 1. 2. 3. 4. PROCEDURE Flip down the cover on the front panel for access to the potentiometers. TurnVR2(OFFSET) to the center position. Press the FEED key while simultaneously turning ON the power switch. When the printer beeps, release the key. The following screens will appear. The VR2(OFFSET) adjustment range is +/- 3.75mm.
Adjust the stop position using VR2 and feed another label. When the adjustment is correct, turn the printer off. If the print position can't be adjusted replace the Keyboard PCB. Refer to Section 6.

Page 4-12

4.9 Ribbon Sensor Operation Verification
No adjustment is provided for this sensor SEE PAGE 1-8 FOR SENSOR LOCATION
PLACE DSW2-1 IN THE OFF POSITION STEP 1. 2. 3. 4. PROCEDURE
Flip down the cover on the front panel for access to the dip switches. Record all dip switch positions, then place DSW2-1 in the OFF position and the power switch OFF. Remove the ribbon from the printer and close the Head Open Lever. Turn the power switch ON to initialize the printer. The following screens will display.

online qty:000000

Press the LINE key to place the printer off-line. Press the FEED key. The printer will beep and the following screen will display to confirm that the ribbon is not in position and confirm the sensor is functioning.

Ribbon end

Turn off the printer and reinstall the ribbon. Turn ON the printer. The printer will initialize as in Step 4. Be sure to place the printer off line. Press the FEED key to generate a blank label and confirm ribbon has been installed and is in position.

Page 4-13

4.10 Ribbon Sensor Adjustment
Turn VR4 potentiometer on the main PCB all the way to the right. Refer to Section 4.3. Set the digital multimeter to DC voltage measurement mode. Attach the connector from the TP Test Module to the test port on the main PCB. Note correct positioning of connector. Set the dial to 7. Connect (+) probe of the multimeter to Sig+ and (-) probe to pin GND. Refer to Section 1-6 to locate the ribbon sensor. For Low level adjustment, rotate the ribbon unwind shaft to align one of the "slots" with the sensor. Then adjust the electrical level with VR4 on the main PCB so that it will measure less than +1.0. For High level adjustment, rotate the ribbon unwind shaft to align one of the "tabs" with the sensor. Check the electrical level. If the level difference is + 2.3 V more than the Low level, it is acceptable. If not, return to STEP 4 and readjust. Standard values: Low level (slot): +1.0 V or less. High level (tab): Low level +2.3 V or higher NOTE: Adjust low level to achieve the biggest difference between each level by repeating the process If these values do not result, try the following: a) Repeat the process b) Clean the sensor c) Replace the sensor

Page 6-3

DISCONNECT CABLES

REMOVE (2) SCREWS

Figs. 6-3

REMOVE SCREW

Page 6-4

PRESS OUTWARD
MEMORY MODULE PCB IN THE MAIN PCB MEMORY FRAME

* PRESS OUTWARD

Figs. 6-4

INDEXING NOTCHES

* CAREFULLY PRESS OUTWARD
ON TABS ON BOTH ENDS OF THE FRAME TO RELEASE THE MEMORY PCB.

Page 6-5

NO NOTCH ON THIS SIDE

APPROXIMATELY 450 ANGLE

INDEXING NOTCH INDEXING NOTCHES FLASH MEMORY MODULE
INSERT THE FLASH MEMORY MODULE INTO THE MAIN PCB MEMORY FRAME AT APPROXIMATELY 450. NOTE THE INDEXING NOTCH ON THE MODULE. GENTLY PUSH DOWN TO SNAP INTO POSITION

Figs. 6-5

Page 6-6

6.3 Replacing the Fuses

Fuse replacement is described in the following section. 6.3.1 Removing and Replacing the Main Power Fuse 6.3.2 Removing and Replacing the Internal Fuse NOTE: Before replacing a fuse, determine the cause of the overload condition. 6.3.1 Removing and Replacing the Main Power Fuse Required: STEP 1. 2. 3. 4. PROCEDURE Switch the printer OFF and disconnect the power cable. Locate the fuse cap on the back of the printer. Unscrew the cap and remove the defective fuse. Fig. 6-6 Replace the fuse with one of equal rating (3A, 250V). Do not use a fuse with a higher rating. Screw the fuse cap back and connect the power cable. F3A, 250V Fuse Fuse
BACK OF PRINTER FUSE (UNDER COVER)

Fig. 6-6

Page 6-7

Replacing the Fuses

Required: T3.15A, 250V Fuse or T1 Amp 250V Fuse
To remove and replace these fuse(s) do the following: STEP 1. 2. PROCEDURE Switch the printer OFF and disconnect the power cable. Remove (3) screws holding the left side cover to the printer. Raise the access door and loosen the (2) screws on the inside top of the printer. Lift off the left side cover to expose the main PCB. Fig. 6-1 Refer to Fig. 6-7 and locate the appropriate fuse on the PCB. Remove and replace the fuse(s) with one of equal rating. Do not use a fuse with a higher rating. Replace the cover and replace the screws. Return the printer to service by reconnecting the power cable.

3. 4. 5. 6.

FUSES MAIN PC BOARD

Figs. 6-7

Page 6-8
6.4 Replacing the Power Supply
The Power Supply is a non-repairable component with no servicable parts and is to be replaced as a complete assembly. STEP 1. 2. PROCEDURE Switch the printer OFF and disconnect the power cable. Remove (3) screws holding the left side cover to the printer. Raise the access door and loosen the (2) screws on the inside top of the printer. Lift off the left side cover to expose the main PCB. Fig. 6-1 Remove (2) screws holding the I/O PCB Interface from the back end of the unit. Pull away to detach the connector on the interface from the main PCB. Figs. 6-8 Remove (2) screws to detach the main circuit board. Figs. 6-9 Remove (2) screws to which secures the board mounting plate to the back side of the unit. Fig. 6-9 Remove (2) screws to detach the Board Mounting Plate and carefully move out of the way of the Power Supply Assembly. Figs. 6-10 & 6-11 Remove (2) screws to which secures the power supply to the back side of the unit. Fig. 6-12 Lower the Media Holder in the mechanical section of the printer for access to (2) screws holding the power supply. Remove the screws. Figs. 6-13 & 6-14 Detach (2) cable connections and remove the defective Power Supply. Fig. 6-15 Install a replacement Power Supply reversing steps 1 through 9. Check the DC power voltages. Refer to Section 4.3.

6. 7. 8. 9.

REMOVE THE RIBBON AND LABEL STOCK

Fig. 6-19

Page 6-13
Replacing the Timing Belts

BELT "A"

BELT "B"

REWIND SPINDLE

Fig. 6-20
BELT "A" GEAR TO ENGAGE FEED ROLLER IDLER FRONT PLATEN ROLLER

REAR PLATEN ROLLER

TENSION ADJUSTMENT IDLER

Fig. 6-21

Page 6-14

BEARING

DO NOT DISTURB THESE TWO SCREWS

Figs. 6-22

REMOVE SCREW (ATTACHES TO REWIND SPINDLE) BEARING REMOVE & REPLACE BELT "A"
PULL REWIND SPINDLE FORWARD TO DISLODGE BELT "A"
DISLODGE BELT "B" FROM MOTOR SHAFT AND GEARS
LOOSEN ADJUSTMENT IDLER SCREWS

Figs. 6-23

Page 6-15
6.7 Replacing the Print Head
If the print head becomes damaged, it can be easily removed and replaced. No critical adjustments are required. Before you replace the print head, check the head counter values by printing a test pattern (Refer to Page 2-32). STEP 1. 2. 3. 4. 5. 6. 7. 8. PROCEDURE Switch the printer OFF and disconnect the power cable. Raise the access door and remove the ribbon and label stock if installed. Fig. 6-24 Close the Head Latch Lever to facilitate removal of the Print Head. Remove (2) stud screws. Fig. 6-24 & 6-25 Carefully open the Head Latch Lever so that the Print Head will drop down. Fig. 6-26 Dislodge and remove the Ribbon Guide Plate from the Print Head. Fig. 6-26 Carefully disconnect the cables and remove the Print Head. Fig. 6-27 Set the switch setting on the new Print Head to the right side position. Fig. 6-28 Install the Print Head by reconnecting the Print Head Data Cable and Print Head Power Cable to the Print Head. Attach the Ribbon Guide Plate. Fig. 6-26 & 6-29 Position the Print Head so it aligns properly with the alignment pins and Ribbon Guide Plate. Fig. 6-26 & 6-29 Close the Head Latch Lever and reinstall the two stud screws.
Before you return the printer to normal service, you should perform the following procedures. Clear Counter Heads (Refer to Section 7.3). Confirm that head cables are connected and that they do not touch the head opening spring. Also confirm that you can open and close the head without restriction. Print test pattern (Refer to Page 2-32).

Page 6-16

Replacing the Print Head
REMOVE THE RIBBON AND LABEL STOCK REMOVE (2) STUD SCREWS

HEAD LATCH LEVER

Fig. 6-24

Fig. 6-25

DISLODGE AND REMOVE RIBBON GUIDE PLATE
DISCONNECT CABLES PLATEN RIBBON GUIDE PLATE

Fig. 6-26

Fig. 6-27

Page 6-17

FOR THIS MODEL PRINTER SET SWITCH TO THE RIGHT

Fig. 6-28

ALIGNMENT PINS

RECONNECT CABLES

Fig. 6-29

Page 6-18

6.8 Replacing the Platen
PROCEDURE Switch the printer OFF and disconnect the power cable. Remove (3) screws holding the left side cover to the printer. Raise the access door and loosen the (2) screws on the inside top of the printer. Lift off the left side cover. Fig. 6-1 Remove the ribbon and label stock if installed. Fig. 6-30 Loosen but do not remove the screw holding clamp and platen to the frame. Fig. 6-31 Slightly loosen screw holding eccentric adjustment. Fig. 6-31 In the electronics compartment loosen (2) screws on tension idler to release tension on timing belts. Slide belt off platen gear. Fig. 6-32 If unit is CL612, remove pulley from end of platen by loosening two set screws and sliding off shaft Fig. 6-33, 6-34 Remove (2) screws holding the platen retainer to the frame. Fig. 6-35 Displace platen by tilting up and away from the holding clamp in the mechanical section and pull forward through the hole in the frame and out the electronics compartment. Figs. 6-36 & 6-37 Remove old bushings and replace with bushings from new platen. Install new platen by reversing removal procedure above. NOTE: It is important to verify that spring on head release lever is not under bushing holding plate but is properly positioned alongside it. Fig. 6-38, 6-39

3. 4. 5. 6. 7. 8. 9.

10. 11.

12. 13. 14. 15. 16.

Reinstall platen pulley if applicable after inspecting for wear and replacing if necessary. Reinstall belts. Refer to Section 5.8 to adjust belts. Perform Print Head Balance adjustment Section 5.4. Replace the left side cover and reconnect the power cable.

Page 6-19

Replacing the Platen
REMOVE THE RIBBON AND LABEL STOCK PLATEN
LOOSEN CLAMP AND SCREW HOLDING PLATEN TO FRAME

Fig. 6-30

SLIGHTLY LOOSEN ECCENTRIC SCREW

Fig. 6-31

REMOVE BELT
LOOSEN IDLER SCREWS TO RELEASE BELT TENSION

Fig. 6-32

Page 6-20
LOOSEN (2) SET SCREWS AND REMOVE PULLEY FROM END OF SHAFT
ELECTRONIC COMPARTMENT SIDE

Windows NT/LAN Server Troubleshooting
If you are having trouble printing with Windows NT or LAN Server, check the following: 1. Make sure that you can ping the SATO enhanced ethernet adapter using the DOS or OS/2 command PING ipaddress, where ipaddress is the IP address of the SATO enhanced ethernet adapter. If you cannot ping the print server, you will not be able to print.

Page 8-8

2. Make sure that TCP/IP and lpr printing are installed and running on the Windows NT system or the LAN Server file server. 3. If you are having problems printing to the SATO enhanced ethernet adapter from a client PC that is connected to a Windows NTAS or LAN Server file server, verify that you can print a job directly from the DOS or OS/2 prompt on the file server. If you can print from the file server but not from the client, then the problem is probably with the NetBEUI communications rather than with the TCP/IP link to the SATO enhanced ethernet adapter. Check your file server network setup (for example, make sure that you can print from the client to other printers on the network. 4. If you have problems with Windows NT queues locking up when the active print job is deleted, try setting the IP timeout to one minute with the console command SET IP TIMEOUT 1.
Windows 95/98 Peer-to-Peer Troubleshooting
If you are having trouble printing on a Windows 95 Peer-to-Peer network, check the following: 1. If the print server does not show up under HP JetAdmin on a Windows 95/98 Peer-to-Peer network, try removing all of the Windows 95 network software from the Network Control panel and then reinstalling them as follows: First install the IPX/SPX-Compatible Protocol, the Client for Microsoft Networks, and the network adapter card driver. Restart the system, and then add the HP JetAdmin service.
2. Because of the many changes that have been incorporated in Windows 95/98 Peer-toPeer printing since its introduction, it is a good idea to upgrade to the latest version of JetAdmin (available on the HP web site at http://www.hp.com).
Resetting the Print Server
Press the Factory button for at least 5 seconds. Please wait approximately 1 minute before trying the factory test print. Factory Button

Test LED

Link LED

Page 8-9

8.7 Error Signals
The LCD display, Front Panel LED Indicators and Buzzer provide a visual/audio indication of the type of error encountered.
LE D Error On Error On Error On Error On LCD Message Machine Error EEPROM Error Head Error Sensor Error Audible B eep 1 Long 1 Long 1 Long 3 Short 1 Long 1 Long 3 Short 3 Short 3 Short 3 Short 3 Short Error Condition Machine Error EEPROM Read/Write Print Head is damaged Sensor Memory Card Read/Write Memory Card Battery Low Head Open RS232 Parity Error RS232 Overrun Error RS232 Framing Error Buffer Overflow Media End or Misselected Media Type To Clear Cycle Power ON/OFF Cycle Power ON/OFF Replace Print Head Cycle Power ON/OFF Cycle Power ON/OFF Format Memory Card Cycle Power ON/OFF Replace MC Battery Cycle Power ON/OFF Close Head Lever Correct parity to match system Verify RS232 Settings Verify RS232 Settings Verify RS232 Settings Replenish Media Select Correct Media Type Open/Close Head Lever Open/Close Media Hold Down Replace Ribbon Open/Close Head Lever Open/Close Media Hold Down Open/Close Head Lever Replace ribbon with full roll Slow down transmission rate

Page 10-17

10.4 Print Head Assembly

Page 10-18

Print Head Assembly

Page 10-19

NO. 30 CODE PA1721700 MA0301221 MT1300522 PA1721800 PA1721200 PL2720100 MD4300821 PD1720400 MD3401021 PA1721500 MD4300821 PB2720100 MD3401021 PR1720100 ND0060030 PR0720700 PL2720400 PE8720100 ND0040030 PE1720100 PB0720600 ND0040030 PE1720200 PE6720500 MD4300821 PV9720100 PC0720100 DESCRIPTION Head frame (LH) Pan head screw Hex nut Head frame (RH) Plate (adjust C) Adjust collar Pan head screw Stay Pan head screw Support plate (B) Pan head screw Collar Pan head screw Roller E-Ring Feed roller Bush Gear E-Ring Cam (head pressure) Shaft (head pressure) E-Ring Knob Protecter (B) Pan head screw Bush Spring (open) QTY 1

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NO. 56
CODE PA1727100 PA1727200 PC1720100 PB2720200 PB2720300 PB2720400 MD4402021 MD4401021 PR1720200 MD4300821 PR1721400 PA1721400 MD4300621 PC1690201 MN1301630 RH1727700 RH1775201 GH000661A PB0723400 PR4721000 PR4721100 PA1721900 PA1722000 PC1720400 GH000511A
DESCRIPTION Head Bracket (A) (CL608) Head Bracket (B) (CL608) Spring (head) (CL608) Collar Collar Collar Pan head screw Pan head screw Head sub holder (CL608) Pan head screw Head sub holder(CL612) Head cable cover Pan head screw Spring Hex hole bolt Power & Head Power Cord Set Print Head Cable Assy Print Head (CL608) Post (Head) Plate(Ribbon) (CL608) Plate(Ribbon) (CL612) Head bracket (A) (CL612) Head bracket (B) (CL612 Spring (head) (CL612) Print Head (CL612)

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10.5 Ribbon Assembly

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Ribbon Assembly

Page 10-23

Page 10-24
NO. CODE PE4720100 PE2720100 PA4690900 MH0300521 PT2301020 PA0680400 PC1730100 PE2730100 PB5730100 MA0303022 PB0720400 PE4720200 MA0301821 MA0302522 MT1300522 MH1250621 PA0680300 PC0730100 PE1681100 PE7720100 PE6720100 MD4300821 PA0730100 PA0730200 PA1720700 MD4400821 PA1731000 MD4300621 MD4400821 PT1114080 PT1112080 PR1720400 ND0060030 PT8131064 DESCRIPTION Ribbon boss Collor Spring P tight screw Oilless dry metal Disc Spring Stopper collar Adjust screw Pan head screw Shaft (ribbon) Plate holder boss Pan head screw Pan head screw Hex nut P-tight screw Lining Spring (back) Guide plate (B) Disc plate (A) Disc plate cover Pan head screw Guide plate Hold plate Ribbon frame Pan head screw Adjust plate Pan head screw Pan head screw Ball supporter Ball supporter Pulley E-Ring Timing belt QTY 1 1

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NO. CODE PR1770100 PC0760500 NA1030022 MH0300821 MT1400722 MD3401221 DESCRIPTION Pulley Spring (ribbon) Plain washer P tight screw Hex nut Pan head screw QTY 1 1

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10.6 Feed Roller Assembly

Page 10-27

Feed Roller Assembly

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NO. 36 CODE PR3720500 PR4721300 PA1720400 PA1720500 PE2730300 PC1720601 MA0301221 MT1300522 MD4300821 PB0720500 PE3720200 PE3720500 ND0040030 MD4300821 MA7300625 PV3720100 PA1729400 MA0300622 PB2720800 MJ9300622 MD4300821 PA1720300 PC2740200 PA3742100 PC2740300 PB0741100 ND0020030 MD4401621 RH1724300 DESCRIPTION Paper lid Paper lid cover Roller bracket (A) Roller bracket (B) Stopper collar Spring (pressure) Pan head screw) Hex nut) Pan head screw) Shaft (pressure) Roller Roller E-Ring Pan head screw Truss screw PCB bracket (A) PCB Bracket (D) Pan head screw Collar Thin head screw Pan head screw) Lid bracket Spring (open) Latch handle Spring (latch) Shaft (lid) E-Ring Pan head screw Pitch sensor cord(SEN2) QTY 1

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10.7 Main PCB Assembly

NO. 5 8

CODE RJ1771200 PC9730100 PA3739900 MD4300621 RJ7770200 RJ7770300
DESCRIPTION Main PCBA Spring (Lock) Connector lock Pan head screw Memory PCB Assy-B Memory PCB (4 MB Memory Option)

QTY 1 1

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10.8 Interface Option

NO. 5 6
CODE MD3300622 WCL404070 WCL404051 WCL404060 11S000158 11S000136
DESCRIPTION Screw IEEE-1284 Parallel Interface Serial Interface USB Interface Ethernet Interface CX/TX Interface

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10.9 Dispenser Assembly Option

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Dispenser Assembly Option

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Page 10-34

Page 10-35

NO. CODE PH0720400 MH0300821 PA1724701 PB0721600 PB0721700 MD4300621 PA1724600 PA1724500 MD4300621 MD4301021 MD4300821 MA7300625 PA1724800 MD4300621 PB0721400 ND0030030 PE1720400 PE1570300 MH0250621 PA1724400 PR1340500 PR1520200 PB0721200 ND0040030 PC1010200 PE2730300 DESCRIPTION Dispense cover P tight screw Dispense frame Post (latch) RH Post (latch) LH Pan head screw Dispense bar Adjust plate Pan head screw Pan head screw Pan head screw Truss screw Dispense cover bracket Pan head screw Shaft (Guide) E-Ring Dispense bracket Dispense sensor bracket P-tight screw Roller bracket Brush Pressure roller sub assy Shaft (Pressure roller) E-Ring Head spring Stopper collar QTY 2 2

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NO. 59 CODE MD4300821 MH0300821 PB0721300 PE3520600 ND0020030 PE8720800 PB2720100 MD4401421 PR0720300 PE8720700 PT1112060 PA1680200 ND0040030 MD4300821 PA1725200 MD4300821 PA1725100 MD4300621 PE8721000 PB0721800 PR4720600 PR1720700 PB0721900 PB4720100 PL2720200 DESCRIPTION Pan head screw P tight screw Shaft (Dispense roller) Dispense roller E-Ring Gear Collar Pan head screw Feed roller Gear Ball supporter Ball supporter clamp E-Ring Pan head screw Rewind frame Pan head screw Side frame Pan head screw Gear pulley Shaft (Idle gear) Rewind belt Rewind handle Shaft (rewind) Rewind core Bush QTY 1

SECTION 6. TROUBLESHOOTING
Initial Checklist. Using the IEEE1284 Parallel Interface Using the RS232C Serial Interface. Error Signals.

7-1 7-1 7-3 7-4

APPENDICES
APPENDIX A: Optional Accessories Label Rewinder, All Models. A-1 Label Cutter, All Models. A-2 Label Dispense Option. A-3 CL608e and CL612e. A-3 CL408e and CL412e. A-4 Memory Cards, All Models. A-7 CL608e and CL612e. A-7 CL408e and CL412e. A-8 Interface Cards, All Models. A-10 Calendar, All Models. A-10

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Preface This page left intentionally blank.

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PN 9001044 Rev. B

INTRODUCTION

The SATO CL Series e Thermal Transfer Printers are complete, high-performance on-site labeling systems. All printer parameters are user programmable using the front panel controls and the DIP switches. All popular bar codes and 14 human-readable fonts, including a vector font, are resident in memory providing literally thousands of type styles and sizes. The Operators Manual will help you understand the basic operations of the printer such as setup, installation, configuration, cleaning and maintenance. The major differences in the CL408e and the CL412e printers is the resolution of the head. The CL408e with its 203 dpi head provides an economical labeling solution for most applications. It can print labels up to four inches wide. If a wider label is needed, the CL608e can print labels up to six inches wide at the same resolution. The CL412e provides a higher print resolution, 305 dpi, to give laser-quality printing. It is useful when higher resolution is needed for detailed graphic images. The six inch wide companion printer to the CL412e is the CL612e. All of the CL Series e printers use the same command codes. The only differences are the allowable values representing the print positions on the label. These values are specified in dots and will vary depending upon the resolution of the printer and the amount of memory available for imaging the label. The allowable range for each printer is specified in a table for those command codes. This commonalty makes it very easy to convert labels from one CL printer to another without having to create an entirely different command stream. There are some caveats that must be observed though to compensate for the different resolution print heads. The effect of the different printer resolutions are best illustrated by taking a label designed for a 203 dpi printer and sending the command stream to the its 305 dpi counterpart. The label printed will be an exact two-thirds scale, including the fonts, bar code dimensions and line lengths/widths. The only exception is the PostNet bar code which has only one legal size and the printer resolution is automatically compensated for by the printer. Conversely, a label designed for a 305 dpi printer and sent to its 203 dpi cousin will be one-third larger. It probably will be truncated if the label size is larger than the maximum allowable for the printer. The following general information is presented in this section: General Printer Specifications Optional Accessories

WB Font (18 dots W x 30 dots H) WL Font (28 dot W x 52 dots H) XB Font (48 dots W x 48 dots H) Univers Condensed Bold XL Font (48 dot W x 48 dots H) Sans Serif
Proportional or Fixed Spacing Font Size 50 x 50 dots to 999 x 999 dots Helvetica, 10 Font Variations AGFA RASTER FONTS A Font B Font DOWNLOADABLE FONTS Bit Mapped TrueType Fonts with Utility Program CHARACTER CONTROL Expansion up to 12X in either the X or Y coordinates Character Pitch control Line Space control Journal Print facility 0, 90, 180 and 270 Rotation
CG Times, 2 to 99 pt CG Triumvirate, 2 to 99 pt

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Section 1. Printer Overview BAR CODES
SPECIFICATION SYMBOLOGIES
Bookland (UPC/EAN Supplemental) EAN-8, EAN-13 CODABAR Code 39 Code 93 Code 128 Interleaved 2 of 5 Industrial 2 of 5 Matrix 2 of 5 MSI POSTNET UCC/EAN-128 UPC-A and UPC-E Data Matrix Maxicode PDF417 Micro PDF417 Truncated PDF417 QR Code Ratios Bar Height Rotation OTHER FEATURES Sequential Numbering Custom Characters Graphics Form Overlay
1:2, 1:3, 2:5 User definable bar widths 4 to 600 dots, User programmable 0, 90, 180 and 270
Sequential numbering of both numerics and bar codes RAM storage for special characters Full dot addressable graphics, SATO Hex/Binary,.BMP or.PCX formats Form overlay for high-speed editing of complex formats.

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Section 1. Printer Overview PHYSICAL
SPECIFICATION DIMENSIONS Wide Deep High WEIGHT POWER REQUIREMENTS Voltage 110 V (10 %) 220V (10 %) 50/60 Hz (1%) 50W Idle 130W Operating 50W Idle 210W Operating 10.7 in. (271 mm) 16.9 in. (430 mm) 12.6 in. (321 mm) 28.7 lbs (13 Kg) 13.8 in. (352 mm) 16.9 in. (429 mm) 11.7 in. (298 mm) 41.9 lbs (19 Kg) CL408e CL412e CL608e CL612e
Power Consumption ENVIRONMENTAL Operating Temperature Storage Temperature Operating Humidity Storage Humidity Electrostatic Discharge REGULATORY APPROVALS Safety RFI/EMI
41 to 104F (5 to 40C) -0 to 104F (-20 to 40C) 15-85 % RH, non-condensing Max 90% RH, non-condensing 8KV

UL, CSA FCC Class A

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Section 1. Printer Overview OPTIONAL ACCESSORIES
ACCESSORY MEMORY EXPANSION CL408 CL412 CL608 CL612
One slot for PCMCIA Memory Cards (up to 16 MB Flash or 4 MB SRAM) and/or 4MB internal Flash ROM. Can be used for Graphic File storage, print buffer expansion, format storage and downloaded TrueType fonts. An internally mounted Date/Time clock that can be used to date/time stamp labels at the time of printing. Internal attachment allowing labels to be cut at specified intervals. Controlled through programming. Internal attachment allowing labels to be peeled from backing for immediate (on demand) application. Internal backing take-up. Internal attachment allowing labels to be peeled from backing for immediate (on demand) application. Backing take-up mounted externally to rear of printer.

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Section 2. Installation LOADING LABELS, TAGS AND RIBBON
LOADING LABELS OR TAGS 1. Open the Side Access Door by swinging it up and to the left. The hinge system automatically dampens the movement to prevent the door from inadvertently falling and possibly causing injury to the operator. 2. Open the Print Head Assembly by pushing the Head Latch toward the rear of the printer. The Print Head Assembly is spring-loaded and will automatically open as soon as the Head Latch is disengaged.

CL608e and CL612e

Head Latch
3. Push the Label Supply Guide to the outside of the printer to give the maximum label width. 4. Release the Label Roll Support by pulling outward at the top and swing it down and out of the way. 5. If using roll labels (or tags), load the roll onto the Label Supply Spindle so that the printing side of the labels faces upwards as it unwinds from the roll. The labels should be wound face-in. Push the roll all the way to the inside of the printer and push the Label Supply Guide snugly against the outside of the label roll. 6. If using fanfold labels (or tags) set them on a flat surface behind the printer. Pass the labels (printing side up) through the slot and under the Label Supply Spindle. 7. Open the Label Hold-Down by squeezing the green tab and the release tab together. The Label Hold-down is spring loaded and will open automatically when the latch is disengaged. Feed the labels under the Label Guide, under the Label Hold-Down, through the Print Head Assembly and out the front of the printer. 8. Inspect the label routing and verify that the path matches that illustrated in the Label Loading
Sensor Adjust Cap Screw Sensor Adjust Tab

Label Hold-Down

Page 2-4
diagram. Set the Adjustable Label Guide to keep the labels against the inside of the printer. 9. Close the Label Hold-Down by pushing downward on the green tab until it latches closed. NOTE: If the Label Dispenser option has been purchased, see Appendix A, for proper label routing instructions. 10. Adjust the Label Sensor Assembly to the correct position by loosening the Sensor Adjust Cap Screw located on the front side of the Label Hold-Down and moving the Sensor Adjust Tab to the correct position. After it is correctly positioned, retighten the Sensor Adjust Cap Screw. 11. If the ribbon is already loaded, close the Print Head Assembly by pushing downward on the green tab until it latches closed. 12. If the ribbon is not loaded, see the following description for loading instructions.

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LOADING THE RIBBON 1. Open the Top and Front Access Doors. 2. Open the Print Head Assembly by rotating the green the Head Latch counter clockwise. The print head is spring loaded and will raise to the open position as soon as the latch is released. 3. Locate the Extra Ribbon Core supplied with the printer. Place the core on the Ribbon Rewind Spindle, pushing it all the way to the inside of the spindle. Note that the new empty core of each subsequent roll becomes the next rewind core. 4. Load the ribbon onto the Ribbon Supply Spindle, pushing it all the way to the inside of the spindle. The dull side of the ribbon should be facing down as it travels through the Print Head Assembly. 5. Feed the leader portion of the ribbon through the Print Head Assembly and up to the Ribbon Rewind Spindle following the routing shown in the diagram. 6. Load the ribbon behind and over the top of the Ribbon Rewind Spindle and tape it to the Extra Ribbon Core. Make sure it matches the ribbon path shown in the diagram. 7. Manually turn the Ribbon Rewind Spindle to wrap the ribbon onto the core one to two turns to secure it. 8. If the labels or tags are already loaded, close the Print Head Assembly by rotating the green Head Latch clockwise until it latches closed and close the Front and Top Access Doors. NOTE: Run a test print to ensure that the labels and ribbons were loaded correctly. See the Test Print section on page 3-22 for instructions on how to run test prints.

Ribbon Supply Roll

Empty Core

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Ribbon Supply Spindle

Ribbon Roll

Ribbon Path Label Supply Spindle
Ribbon Rewind Spindle Print Head Assembly

Label Path

LABEL SENSOR ADJUSTMENTS
The Gap (transmissive) sensor on the CL608e and CL612e can be adjusted over a limited range. It is located in the Label Hold-Down Assembly and can be adjusted by loosening the Sensor Adjust Cap Screw on the front of the Label Hold-Down and sliding the Sensor Adjust Tab to the desired position. The Gap sensor can be adjusted from a minimum of 1.0 in. (25mm) to a maximum of 3.5 in. (90mm). The Eye Mark sensor is fixed at 0.33 in. (9mm).
Both the Eye-Mark (refelective)and Gap (transmissive) sensors on the CL408e and CL412e can be adjusted over a limited range. They are both located in the Label Sensor Unit. The assembly can be adjusted by loosening the green Sensor Adjust knob located underneath the Label Transport Assembly and sliding the Label Sensor Unit to the desired position. The Gap sensor can be adjusted from a

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minimum of 0.67 in. (17mm) to a maximum of 2.5 in. (64 mm), and the Eye-Mark from a minimum of 0.25 in. (6mm) to a maximum of 2.1 in. (53mm).

OPERATOR PANEL

LCD DISPLAY PANEL

RIBBON

DISPLAY PITCH
PRINT Reserved DSW2 DSW3 OFFSET
The CL608e/CL612e Operator Panel consists of five LED indicators, two momentary contact switches, three DIP switches, four adjustment potentiometers and one LCD Display. All of these are accessible from the front of the printer. They are used to set the printer operating parameters and to indicate the status of the printer to the operator. After you power on the printer, familiarize yourself with the keys and indicators as it will help you understand the configuration process. PRINT: OFFSET: Potentiometer to adjust print darkness (fine tuning). Potentiometer to adjust amount of back/forward feed for dispenser/cutter/tear-off bar position (+/-3.75 mm) Potentiometer to adjust home position of the label (+/- 3.75 mm). Affects stop position of label feed, print position and dispense position. Potentiometer to adjust the contrast of the LCD. LED, illuminated when the power is on.
PN 9001074 Rev. B SATO CL Series e Printers

PITCH:

DISPLAY: POWER:

Page 2-12

LABEL: RIBBON: LED, illuminated when label supply is out. LED, illuminated when ribbon motion sensor does not detect any ribbon motion. LED, illuminated when there is a system fault such as an open print head. LED, illuminated when printer is ready to receive data. It is turned on and off by toggling the LINE key. This indicator will blink while the printer is receiving data. Momentary switch. Pressing this key toggles the printer between the on-line and off-line mode. When the printer is on-line, it is ready to receive data from the host. This key acts as a pause during a print job by taking the printer off-line. It can also be used as a Pause function key to stop label during the printing process. Momentary switch. Pressing this key feeds one blank label through the printer when it is off-line. When the printer is on-line, another copy of the last label will be printed (can be disabled via the LCD panel). Located behind the Front Access Door. DIP switch array to set operational parameters of the printer. DSW1 is used to set the RS232 parameters and is located on the RS232 interface board. 2 Line x 16 Character LCD display. Used for setting operational parameters of the printer.

DSW1-7 Off Off On On DSW1-8 Off On Off On SETTING Rdy/Bsy Xon/Xoff Bi-Com 3 Bi-Com 4* ON OFF DSW1
Printer Set Up Print Mode Selection (DSW2-1). Selects between direct thermal printing on thermally sensitive paper and thermal transfer printing using a ribbon.
DSW2-1 Off On SETTING Therm Xfr Direct Therm DSW2 ON OFF 7 8
Sensor Type Selection (DSW2-2). Selects between the use of a label gap or a reflective Eye-Mark detector.
DSW2-2 Off On SETTING Gap Eye-Mark DSW2 ON OFF 7 8

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Head Check Selection (DSW2-3). When selected, the printer will check for head elements that are electrically malfunctioning.
DSW2 DSW2-3 Off On SETTING Disabled Enabled ON OFF 7 8
Hex Dump Selection (DSW2-4). Selects Hex Dump mode.
DSW2-4 Off On SETTING Disabled Enabled DSW2 ON OFF 7 8
Receive Buffer Selection(DSW2-5). Selects the operating mode of the receive buffer. See Section 6: Interface Specifications for more information.
DSW2-5 Off On SETTING Single Job Multi Job DSW2 ON OFF 7 8
Firmware Download (DSW2-6). Places the printer in the Firmware Download mode for downloading new firmware into flash ROM.
DSW2-6 Off On SETTING Disabled Enabled DSW2 ON OFF 7 8
Protocol Code Selection (DSW2-7). Selects the command codes used for protocol control. Refer to Appendix E for more information.
DSW2-7 Off On SETTING Standard Non-Std DSW2 ON OFF 7 8
M8400 Emulation Mode (DSW2-8). For emulating earlier series software commands. Should be used only if problems are encountered when using existing software. This switch will also affect the settings selected by DSW1-7 and DSW1-8.
DSW2-8 Off On SETTING Disabled Enabled DSW2 ON OFF 7 8

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Backfeed Sequence (DSW3-1). Backfeed is used to correctly position the label for application and then retract the next label to the proper print position. This operation can be performed immediately after a label is printed and used, or immediately prior to the printing of the next label.
DSW3-1 Off Off On On DSW3-2 Off On Off On SETTING Continuous Tear-Off Cutter Dispenser ON OFF DSW3
Label Sensor Selection (DSW3-3). Enables or disables the Label Sensor. If the Sensor is enabled, it will detect the edge of the label and position it automatically. If it is disabled, the positioning must be under software control using Line Feed commands.
DSW3-3 Off On SETTING Sensor Used Not Used DSW3 ON OFF 7 8
Back-Feed Selection (DSW3-4). When Back-Feed is enabled, the printer will position the last printed label for dispensing and retract it before printing the next label. The amount of backfeed offset is adjustable.
DSW3 DSW3-4 Off On SETTING Enabled Disabled ON OFF 7 8

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Section 3. Configuration POTENTIOMETER ADJUSTMENTS
PITCH After the pitch has been set with the LCD Control Panel, it is sometimes desirable to make minor adjustments. This can be done using the PITCH potentiometer on the front panel. This potentiometer is set at the factory so that it has a range of +/- 3.75 mm. The midpoint setting should have no effect on the pitch. Turning the potentiometer all the way clockwise should move the print position 3.75 mm up towards the top edge of the label. Turning it all the way counterclockwise should move the print position down 3.75 mm. 1. While depressing the FEED key on the front panel, power the printer on. 2. When you hear one beep from the printer, release the FEED key and the printer will display on the LCD panel a message asking what type of Test Label you want to print. 3. Use the LINE key to step to the Configuration selection and press the FEED key to accept the selection. 4. Use the LINE key to select the Test Label Size. After the size is selected, press the FEED key to accept the selection and the printer will begin to print test labels continuously. 4. Adjust the PITCH potentiometer on the front panel until the first print position is at the desired location on the label. If the potentiometer does not have enough range, then you will have to change the pitch setting using the front panel display. 5. Press the FEED key to stop the printer. 6. To exit the Test Label mode, power the printer off andthen back on. Adjusting the PITCH potentiometer will affect the stop position of the label. BACKFEED OFFSET When a label is printed it must be correctly positioned for dispensing and application. The Backfeed adjustment is used to position the label so that it is fully dispensed and ready for application. It may then be necessary to reposition the next label before printing. The Backfeed (repositioning of the label)operation is enabled if DSW3-4 is in the Off position. If Backfeed is enabled, placing DSW3-1 is in the Off position will cause the backfeed operation to be performed immediately before each label is printed. If DSW3-1 is in the On position, the backfeed operation is performed as soon as the dispensed label has been printed and taken from the printer. The amount of backfeed is controlled by the OFFSET potentiometer on the DIP Switch Panel inside the cover. When turned all the way counterclockwise, the amount of backfeed is +3.75 mm, and -3.75 mm when turned all the way counterclockwise. 1. Turn the printer on. 2. Press the LINE key to place the printer in the Off Line status.
SATO CL Series e Printers PN 9001074 Rev. B Page 3-7
3. Press the FEED key to feed out a blank label. 4. Adjust the position using the OFFSET potentiometer on the front control panel and feed another label by depressing the FEED key. Repeat this procedure until the label is fully released from the liner. DISPLAY This potentiometer is used to adjust the contrast of the LCD display for optimum viewing under various lighting conditions. PRINT The PRINT potentiometer is used to adjust the amount of heat (i.e., power) applied to the head for printing. It provides a continuous range of adjustment. Maximum print darkness is obtained by turning the potentiometer all the way clockwise and a maximum counterclockwise setting will give the lightest print. NOTE: The PRINT potentiometer adjustment will affect the darkness in all of the command code speed and darkness ranges.

CARD->MEMORYCOPY PROGRAM Y/N
This selection allows the user to copy printer firmware from the PCMCIA Memory Card to the printer. 1. Use the LINE key to step the cursor to desired setting. If Yes is selected, the printer will enter the Card Copy mode. If No is selected, the display will advance to the mode display.
COPY START YES NO CARD->MEMORY COPY COPYING CARD->MEMORYCOPY COMPLETED CARD COPY/FORMAT XXXXXXX ERROR
2. Confirm your selection by stepping the underline cursor to the Yes selection. If you select No, the display will return to the previous selection. 3. Press the FEED key to accept the selection. If Yes was selected the copy process will start
4. Once the copy process is completed, press the FEED key to step the display. 5. If an error is encountered in the copy process, one of the following messages will be displayed on the second line: R/W Error No Card Error Mem Full Error Indicates a Read/Write error occured Indicates no card was regognized Indicates that there is insufficient memory available.
MEMORY->CARDCOPY PROGRAM Y/N
This selection allows the user to copy the current firmware installed in the printer to a PCMCIA Memory Card. 1. Use the LINE key to step the cursor to desired setting. If Yes is selected, the printer will enter the Card Copy mode. If No is selected, the display will advance to the mode display.

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2. Press the FEED key to accept the selection. If Yes was selected the copy process will start. If you select No, the display will return to the previous selection. 3. Once the copy process is completed, press the FEED key to step the display. 4. If an error is encountered in the copy process, one of the following messages will be displayed on the second line: R/W Error No Card Error Mem Full Error CARD FORMAT YES NO Indicates a Read/Write error occured Indicates no card was regognized Indicates that there is insufficient memory available.
COPY START YES NO MEMORY->CARDCOPY COMPLETED CARD COPY/FORMAT XXXXXXX ERROR
Before a PCMCIA card can be used, it must be formatted. Note: Formatting a card destroys all data currently stored on the card. 1. Use the LINE key to step the cursor to desired setting. If Yes is selected, the printer will enter the Card Format mode. If No is selected, the display will advance to the mode display.

MEMORY FORMAT YES NO

Before the internal Expanded Memory can be used, it must be formatted. Note: Formatting the Memory will destroy any stored data. 1. Use the LINE key to step the cursor to desired setting. If Yes is selected, the printer will enter the Memory Format mode. If No is selected, the display will advance to the mode display.

GAP INPUT

[X.XV] [X.XV]
EYE - When setting the eye threshold, the voltage must be measured with nothing but the label under the sensor and then again withthe printed eye mark under the sensor. The formula for this is: (High Voltage Level + Low Voltage Level) x 0.5 = Start Value 1. Insert a label into the sensor and close the Label Hold-Down. Make sure the printed eye mark is not under the sensor. Record the voltage shown on the top line of the LCD panel. This line should have the message EYE on the top line (DIP switch DSW2-2 = ON). 2. Now pull the label forward until the eye mark is positioned under the sensor (the voltage reading should be at its highest point). Record the voltage shown on the top line of the LCD panel. The voltage ranges measured should be within the following ranges: Label Only = 0.3 to 0.7V Eye-Mark 1.2V above low value If the measured values are outside this range, you may have trouble in finding a value that will work properly under all conditions. If this is the case, a higher quality label may be needed to get adequate performance. 3. Calculate the starting point voltage using the formula. 4. Use the LINE key to step the counter to the desired setting. The display will increment one step for each time the LINE key is pressed. If the LINE key is held pressed for more than two seconds, it will automatically go into the fast scroll mode. The reading will advance to a setting of 3.3 (the maximum voltage) after which it will automatically wrap and start at 0.0 again. If a value of 0.0 is set, the printer will automatically set the level each time the printer is powered on with labels loaded or the head is closed. 5. Once the setting is correct, pressing the FEED key will accept the setting and advance to the Online Feed display. ONLINE FEED YES NO This selection specifies whether or not the printer will automatically feed a blank label when it is placed in the Online mode. 1. Use the LINE key to step the cursor to desired setting. If Yes is selected, the printer will feed a blank label anytime it enters the Online mode. If No is selected, the display will advance to the mode display. FEED ON ERROR YES NO This selection specifies whether or not the printer will feed a blank label automatically when an error condition is cleared. 1. Use the LINE key to step the cursor to desired setting. If Yes is selected, the printer will feed a blank label anytime an error condition is cleared. If No is selected, the display will advance to the mode display.

EYE INPUT

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This selection specifies whether or not the printer will print the last printed label stored in memory when the FEED key is pressed in the Normal Online mode. 1. Use the LINE key to step the cursor to desired setting. If Yes is selected, the printer will reprint the last label when the FEED key is pressed when the printer is Online. If the printer is Offline, pressing the FEED key will feed a blank label. If No is selected, the display will advance to the mode display. FORWARD/BACKFEED DISTANCE DEFAULT This dsiplay will only appear when Backfeed is enabled (DSW3-4 = OFF). The maximum backfeed distance is 255 mm. 1. Use the LINE key to select either the Default or the Distance selection. If Default is selected, the display steps to the Web acceleration selection. FORWARD/BACKFEED DISTANCE XXXmm 2. If Manual setting is selected, use the LINE key to advance the distance to the desired setting. Each time the LINE key is pressed, the Distance will advance 1 mm. The maximum distance is 255 mm. 3. Once the desired distance is set, press the FEED key to accept the setting and step to the next display. EURO CODE D5 This selection allows the user to specify the dexadecimal code for the character which is replaced with the Euro Character. The default is D5H. 1. The cursor should be positioned over the first digit selection. Use the LINE key to step to the desired setting. 2. Press the FEED key to advance the cursor to the second digit of the desired hexacecimal code. 3. Press the LINE key to step to the desired setting. 4. When the setting is correct, press the FEED key to accept the setting and step to the next display. SELECT LANGUAGE ENGLISH This selection allows the user to select the character set used by the printer. The selections are English, French, German, Spanish, Italian and Portuguese. 1. Press the LINE key to advance to the desired languarge setting. 2. When the setting is correct, press the FEED key to accept the setting and step to the next display. PRIORITY SETTING LCD COMMAND This selection allows the user to assign a priority for Print Darkenss, Print Speed and Print Offset. 1. Use the LINE key to step to the desired priority. If LCD is selected, the setting established via the LCD display/menu system will be used for an incoming label job, regardless of any different command settings. If Command is selected, any commands in the label job will take precedence and be used for printing the job and the LCD Display will reflect the new setting. 2. Once the desired setting is selected, press the FEED key to accept the setting and step to the next display.

Mounting Screws

Signal Connector Print Head

Power Connector

Page 4-4
7. Disconnect the signal and power cables from the print head connectors and set the Print Head aside. 8. Carefully attach the new print head to the connectors, using caution to make sure the connector keys are correctly positioned. NOTE: Be careful not to scratch the printing surface of the print head while installing it. Scratching the surface will cause permanent and irreparable damage and is not covered by the warranty! 9. Locate the two mounting screws in the top plate assembly and align them with the tapped holes in the new print head. 10. Re-secure the print head by tightening the screws.

CLEANING THE SENSORS

There are two sensors that are used to control the positioning of the label. One is a transmissive see-thru sensor that detects the edge of the label by looking through the backing paper which is translucent and detecting the presence of the opaque label. The other is a reflective sensor that detects the light reflected from the bottom of the label liner. When a printed black Eye-Mark passes through the beam, the light is no longer reflected back to the sensor detector, indicating to the printer that it should use this position as the start of a new label. When dust, dirt or other foreign matter interferes with the light path of either of these sensors, the results is erratic label positioning. These sensors should be cleaned regularly, at least every two rolls of labels. Supplies Needed: 1. Turn the printer off and remove the power cable. 2. Open the Label Access Door. 3. Open the Label Hold-Down by disengaging the latch. The Label Hold-Down is spring loaded and will stay in the up position. Two rectangular holes will be visible underneath the Label Hold-Down when it is raised. These are located approximately 1 and 2 inches in from the printer side plate. 4. Apply SATO Thermal Print Head Cleaner to one of the cotton swabs.
SATO CL Series e Printers 9001074 Rev. B Page 4-5 Label Hold-Down Assembly
Sensors located beneath Label Hold-Down

3 Short

Media Error

3 Short None None

Media Error Ribbon Near End Buffer Near Full

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APPENDIX A. OPTIONAL ACCESSORIES
This section contains instructions for using the following CL Series eoptional features: Label Rewinder Label Cutter Label Dispenser PCMCIA Memory Expansion Internal Flash ROM Memory Expansion Calendar Interface Cards

LABEL REWINDER

The rewinder is an external unit that allows for labels and tags to be rewound in rolls up to 8.5 inches in diameter. It derives its power directly from the printers EXT connector using a built-in cable. The rewinder provides the ability to rewind tags/labels from the printer and subsequently be unwound for later use with applicators. Installation 1. Position the Rewinder at the front of the printer and align it with the label slot. (The Rewind Wheel/Spindle should be positioned away from the printer.) 2. Connect the built-in cable from the Rewinder to the EXT connector at the rear of the printer. 3. On the Rewinder, remove the metal clamp from the Rewind Spindle. 4. Feed the lead end of the label stock under the first spindle and onto the Rewind Spindle. Feed the stock around the spindle once, then replace the metal clamp over the label stock. Wind another revolution to ensure the labels are secure on the spindle. 5. Select the REWIND option on the rewinder, then set the power switch to ON. (The printer must be powered ON for the rewinder to function.) Removing and Unwinding the Roll As labels are printed, tension from the rewinder should keep the label stock taut as it wraps itself on the spindle.

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Appendix A: Optional Features
To remove the roll from the spindle, first set the power switch to OFF. Remove the metal clamp, then remove the rewound roll of labels. To unwind for using with an applicator, first set the power switch OFF. Attach the lead edge of the labels from the rewind spindle to the applicator entry point. Select the WIND option on the rewinder, and when ready to begin, set the power switch to ON.

LABEL CUTTER

The label cutter consists of an internal mechanism that will cut labels or tags as they exit from the printer. The cutter can be used to print labels of various lengths using continuous form label/tag stock or to easily separate labels when there is no perforation at the label gap. Operator Setup The following steps should be taken to set up the label cutter. 1. Install the label cutter, following the instructions provided with the unit. The installation time is approximately 20 minutes. 2. Power the printer ON. 3. The printer must be configured to use the Label Cutter option. Switches DSW3-1 and DSW3-2 on the front panel are used to configure the printer. To enable the cutter, DSW3-1 should be in the ON position and DSW3-2 should be in the OFF position. 4. Open the Print Head Assembly and feed the edge of the labels/tags into the cutter assembly and out between the label cutters. NOTE: Although the cutting blade is fairly well protected, be careful as you feed labels into the cutter area. You may want to have the printer powered OFF at this point. 5. Close the Print Head Assembly and place the printer on-line. 6. The Label Cutter is ready for use. 7. Adjust the cut position using the backfeed adjustment procedures outlined in Section 3: Configuration. General Operation The data stream to be sent to the printer may need to be altered to add the Cutter Command. If this command is not used, the cutter will default to cut after every label assuming it has been enabled in the printer configuration. For more details, see the e and PRO Printer Programming Reference. As the labels are printed, they will be cut based on the the data supplied using the cutter command.

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Appendix A: Optional Features LABEL DISPENSE OPTION CL608e and CL612e
The CL608e and CL612e Label Dispense Option is an external mechanism that provides the ability to print labels in the demand mode. It is attached to rear of the printer with two screws and is connected to the internal drive mechanism of the printer. When the label dispenser is installed and configured for operation, the printer dispenses one label at a time, peeling the backing from the label, which allows for immediate application to the product by the operator. Operator Setup The following steps should be taken to set up the Label Dispense Option. 1. Install the option using the instructions provided with the unit. The installation time is approximately 30 minutes. 2. Power the printer ON. 3. The printer must be configured to used the label dispenser option. Switches DSW3-1 and DSW3-2 on the front panel are used to configure the printer. To enable the dispenser, both DSW3-1 and DSW3-2 should be in the ON position. 4. Remove enough labels from the backing paper to provide 24 to 30 inches of backing free from labels. 5. Open the Print Head assembly and feed the backing paper through the print area in the normal manner. 6. At the label exit area, feed the backing paper down and behind the Knurled Roller, then back down and around the Backing Roller. 7. Feed the backing paper out the slot in the bottom rear of the printer and attach to the Backing Rewind Spindle.

Backing Rewind Spindle

Knurled Roller

Backing Roller

Label Dispenser Routing, CL608e/CL612e
SATO CL Series e Printers PN 9001074 Rev. B Page A-3
8. Close the Print Head and place the printer on-line. 9. The Label Dispense Option is ready for use.

LABEL DISPENSE OPTION

The CL408e and CL412e have an internally mounted Label Dispense Option which rewinds the label backing as the labels are stripped. When the Label Dispense Option is installed and configured for operation, the printer dispenses one label at a time, peeling the backing from the label, which allows for immediate application to the product by the operator. Operator Setup The following steps should be taken to set up the Label Dispense Option. 1. Install the Label Dispense Option using the instructions provided with the unit. The installation time is approximately 30 minutes. 2. Power the printer OFF. 3. The printer must be configured to used the Label Dispense Option. Switches DSW3-1 and DSW3-2 on the front panel are used to configure the printer. To enable the dispenser, both DSW3-1 and DSW3-2 should be in the ON position. 4. Remove enough labels from the backing paper to provide 24 to 30 inches of backing free of labels. 5. Open the Top Access Door and the Front Access Door. 6. The Backing Idle Roller is held closed by the green Front Access Door Latch ( the Front Access Door is held in the closed position by a magnetic latch when the Label Dispense Option is installed). Push down on the rear of the

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Appendix A: Optional Features PCMCIA MEMORY CARDS
Description The Memory Card Option provides the connectors and interface board for one PCMCIA memory card slot. The PCMCIA memory is selected for use via the <ESC>CC Memory Area Select command. It can be used to store fonts, graphic images and forms. Type Applicable Specifications Size Connector Pins Battery Write Protect Low Battery Detect Installation Instructions for installing the Memory Card Option are included with the installation kit. Error Handling Memory Card error conditions are indicated to the operator using a combination of the ERROR LED on the front panel, the LCD display and the audible indicator.
ERROR DESCRIPTION Low Battery - Low battery condition is detected when printer is powered on. INDICATION ERROR LED: Blinking Audible Beep: 1 long Display: Card Low Battery Depress LINE key to print Card Status. Card R/W Error 1. No card is inserted. 2. Card is write protected. 3. Invalid store/recall number. 4. Card has not been initialized. Warning 1. Duplicate number. 2. Data not in print area. 3. Data overflows card memory. ERROR LED: On Audible Beep: 1 long Display: Card R/W Error Printer must be powered off to reset. Audible Beep: 1 short Display: None Printer will ignore invalid commands. 1. Insert card into selected slot. 2. Remove write protect tab. 3. Correct program 4. Initialize card with BJF command 1. Correct program. 2. Correct program. 3. Use card with more capacity. REMEDY Replace Memory Card battery. Note that all data will be lost when the battery is removed.
SRAM or Flash PCMCIA Version 2.1 (JEIDA Version 4.1) Up to 4MB SRAM or 16MB Flash 68 Approximately two years (manufacturer dependent) Yes Yes

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Appendix A: Optional Features INTERNAL FLASH ROM MEMORY EXPANSION
Description A factory installed option allows the internal FLASH ROM to be expanded from 2MB to 6 MB by adding an additional 4MB. It can be used to store fonts, graphic images and form overlays. The Expanded Memory is selected using the <ESC>CC Memory Area Select command. This option requires the installation of an Expanded Memory pcb and is a factory-only installed option.

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Appendix A: Optional Features CALENDAR ALL MODELS
The Calendar Option allows the date and time to be maintained in the local printer rather than using the system clock. It consists of an integrated circuit module containing the clock components and battery and plugs into a socketon the main pcb assembly. A qualified technician should perform the upgrade as it requires modifications to the main PCB assembly. Please call SATO Technical Support if you need to add this option to an existing printer in the field.
PLUG-IN INTERFACE MODULES
The CL Series e printers have user changable Plug-In Interface Modules. The Interface Module is accessible from the Rear Panel and is retained by two screws. Use the following procedure to replace an interface molule. 1. Turn power off both the printer and the host and remove the power and interface cables. 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 and is not covered by warranty. 2. Remove the two Interface Module Retaining Screws. 3. Grasp the Interface Module and pull it out of the connector. 4. Place the new Interface Module in the slot and press inward firmly until it is properly seated. 5. Replace the two Interface Card Retaining Screws. 6. If the new Interface Module is for a serial interface, set DSW1 for the proper operation. 7. Connect the interface cable to the connector.