Sato Thermal Barcode Printer Errors

Ribbon End

How it works: The ribbon sensor reads the speed of the un-wind (supply), and the front re-wind spindle is belt driven so the back spindle simple follows the front. The ribbon sensor is an intelligent motion sensor. If for any reason the timing fails the Ribbon Error will display even if you have plenty of ribbon available. This error is the most difficult to diagnose all with Sato printers. This is because it just so happens to be the first one to trigger when something mechanically goes wrong. You will need to ask yourself a few questions in order to find out how to fix this error.

• If the printer will print but the Ribbon End error stops the printer before the roll is completed or when it gets really low, most of the time it is because of the washers under to end cap on the far right of the spindles that controls the ribbon tension. This is done with a spring. There are two washers underneath the cap, one has an align hole that needs to be seated to the ribbon boss (The plastic piece the ribbon slides onto) and this ribbon boss has a notch. If the align hole on the washer jumps off of the notch on ribbon boss it will create slippage and trigger a false ribbon end error. If you dis-assemble the end of the spindle and inspect the washers you know this is it, because if it is, the align hole will be clogged with buildup and you will need to remove the buildup and re-seat it back on the notch and make sure you feel and hear it snap on. The other washer goes on next this has an inside diameter like a half moon type shape in order to fit the shaft. Then the spring is seated and the cap (Collar) is placed over the spring. The shaft is double threaded so when the adjust nut is replaced turn it until it is flush to the collar than give it two full turns and most of the time this will set the tension on the spring well enough. Last lock in the adjust nut with the lock screw. If you still get ribbon error remove the lock screw and turn the adjust nut a half turn until the tension is satisfied.

• If the front supply spindle don't turn at all, remove the side cover to see if the belt is on the ribbon shaft pulley it on correctly.

• If the Ribbon End error displays before it can even move, trick the printer by changing it to direct thermal mode but leave the ribbon on the printer. How to change to the Direct Thermal Mode will be in the Operators manual. This will disable the ribbon sensor long enough to see if it will move because you can't troubleshoot it until you get it to move. If it feeds or will print this means the sensor may need to be cleaned or replaced. If it don't move and you now receive a sensor error disable the sensor and this can also be found in the operators manual. Now you will be able to determine what is going on. Take the printer offline and press the feed key. Watch and listen carefully. If it hums you may have a bad logic board that drivers the stepper motor or the stepper motor itself is bad. If it don't make any sounds the belt may have broken, stripped or slipped. It could be the motor pulley is spinning on the motor shaft or the pulley is cracked. If all these things seem good last but not least try a EPROM Clear. Always remember to place the printer back to Transfer Thermal Mode.

Sensor Error

Paper End

M5900, M5900RV, CL408, CL412, CL408e, CL412e, GT408e, GT412e, GT424e, GL408e, GL412e, CT400, CT410, D500, M10e, MB200, MB400

How it works: The I-Mark and/or Eye sensor sits underneath and it sends a slight beam upward then expects a reflection to return. Sometimes called the Reflective sensor in some materials.

The models listed above all use the I-Mark sensor to detect the labels. This sensor serves as a dual-purpose sensor. You will not find this information in the Operator or Service manuals for these printer models at this time.

Keep in mind clear labels will not work. There are other models with micro switches that will run clear labels but to the printers listed above clear labels and no labels all provide the same condition to the main logic broad.

• The first thing to check is how the labels are loaded and to make sure they are tracking under the sensor assembly. This happens to the best of us.

• Second, check how far left is the sensor assembly, if it is too far to left the edge of the label stock will let light in and will generate a false paper end because the light interferes with the voltage reading so it may need to be moved to the right just a little

• If you still get a Paper End check the voltage setting for the I-Mark sensitively. The industrial printers will have a display to review the readings and how to review these readings can be found in Operators Manual listed in the menu section.

The smaller compacts without displays should be done by a trained technician and not listed in the Operators Manual, only in the Service Manuals.

• If you have an Industrial Printer with a display; look up in the Operators manual on how to bring the I-Mark reading onto the display. There are too many printer menus to list but most always will be in the Service Mode.

• The best trick is to change the tolerance (Input, Threshole) to 0.0V then enter that selection and power the printer off and when the printer is powered on and fed one label the printer will automatically calculate to proper value for you

• From the sensor to the print elements will always be a fixed distance and the printer logic uses math in order to make decisions and sometimes if the printer runs for a long time out of calibration it will become mathematically bogged down and unable to calculate at all. If the above suggestions still do not clear the error you may need to do a EPROM clear to unlock all of the old logic and it will be able to calculate again The EPROM clear should also be listed in the manual.

• Not all models but for most of them there is a VR (Variable Resistor) adjustment and there again go to the menus to see the I-Mark reading on the display and set the low reading to 0.2V when the label is loaded under the sensor. The set the tolerance (Input) to 0.0V again power the printer off then when fed one label it will auto calculate.

• If you get no voltage change at all with the label loaded or unloaded check to see if there may be a piece of old label stuck and blocking the sensor or last but not least the sensor may be bad and in need of a replacement.

Pause

• When Pause displays this is due to the status and will need to be changed from Status 4 to Status 5. If you have a Sato "e' (Enhance) model printer there is a setting in the Service Mode called IGNORE CAN/DLE and will be set to No by default. If you go to the Service Mode and change it to Yes the Pause will no longer stop the print job.

EPROM Error

• One reason can be the Date/Time clock. If your printer has the time clock installed and it is over five years old there is a chance the time clock chip needs replacement. They contain a small battery in the time chip that keeps the date and time when no power is supplied and can become weak or die out.

• Although this error can be caused by the EPROM; the Firmware and main logic board can also cause a EPROM error if they fail. However most of the time the EPROM is bad.

• Anytime the main logic board, firmware or EPROM is changed don't skip the EPROM Clear procedure or it can cause an array of intermittent errors.

Knocks Offline

• Most of the time this is caused by the Head open or Cover open micro-switches. They can intermittently open and close again so fast the main PCBA never has time to show Head Open or Cover Open on the display. For safety reasons any time the cover or print head is opened the printer goes to the Offline condition therefore it goes straight to the Offline condition without displaying why. Placing a jumper on the connector temporally to one at a time can prove which micro-switch is causing the problem. This can verify the correct part for replacement.

Aging Mode