Warning: This is an ESD sensitive process. A grounding strap MUST be worn for this process, due to the handling of circuitry. For more information, click here.


The Gap Sensor is a sensor that detects the gap between each label on a roll as the label roll feeds through the print head. The sensor is housed in a black plastic piece that the labels are routed through as they enter the back of the Sato printer. The sensor location is designated by two green indicator strips, refered to as "eyes".

Adjusting the Gap Sensor

1. Open the printer cover.

2. Use the light purple knob on the end of the black bar to adjust the location of the "eyes" in relation to the label roll. Align the "eyes" with the middle of the label roll.

Note: If the "eyes" are set at the edge of the label roll, they may have trouble telling the difference between the edge of the label and the gap between the labels.

 2. Peel a label off the backing right behind the gap sensor.

3. Release the print head and feed the label roll into the gap sensor, until only the bare backing is within the gap sensor bar.

4. Lock the label roll in place by latching the print head. Close the lid of the printer.

4. The printer should be in “Offline” mode because the lid was open. It is not, press the “Line” button until the screen reads "Offline".

5. With it printer offline, press the “Enter” button to open the menu.

6. Navigate to “Service Mode” using the arrows.  It is the bottom right icon and is represented by a single hammer. (this picture is wrong)

7. Press “Enter” until the screen displays the I-Mark value and its “Level Offset”. The Level Offset should be set to 15. If it isn’t, use the up and or down arrows to change it.
8. Press "Enter" until the screen displays the Gap value and its “Level Offset”.  The “Level Offset” should be set to 45. If it isn’t, use the up and down arrows to change it.

Note: The “Gap” value represents how many volts it is using to look through the paper. Without a label, it should read “0.2”. If it doesn’t, there is a potentiometer (pot) located internally on the control board that can be accessed through a small panel on the back side of the SATO printer.
Note: It may be easier to do this step with the applicator slid forward, closest to the front of the machine.

9. The access panel is held in place with a Phillips head screw, and a small tab. Unscrew the screw, and then remove the panel.

Note: There are three potentiometers, and the Gap Sensor is the middle potentiometer of the three. It is important not to disturb the two on the outsides.

10. Use a small precision flat screwdriver to adjust the potentiometer. Twisting it clockwise will increase voltage and counter-clockwise will decrease voltage. Adjust the potentiometer until the Gap value is 0.2 volts.

CAUTION: The Potentiometer has internal stops! The potentiometer can only turn so far before encountering one of the stops. If a stop is overpowered, the main control board in the printer will have to be replaced.

11. After the Gap value is 0.2 without a label, advance or reverse the label role until the sensor is looking at a label. The Gap value should now register between 1.7 and 2.0.

If the gap value isn’t between 1.7 and 2.0, confirm that the Gap value is still 0.2 when looking at the backing without a label.

If the value without a label is still 0.2, but with a label is still outside of the correct range, please contact EII Customer Support.
12. After the Gap is correctly set, press "Enter" to advance to the "Slice Level" setting. This needs to be set at the middle value of the readings of with and without a label.
13. Set the "Slice Level" to “1.0v” by using the arrow keys.
14. Press "Enter" until to the home menu screen is displayed.
15. Navigate to the Online Mode (top left icon) using the up arrow and press "Enter".
16. Press the “Line” button to bring the printer back online.

17. Feed three labels through the printer by hitting the "Feed" button three times.  This insures that the setting take effect.