Intermec 4820 Upgrade Instructions

Upgrade Instructions

P/N 962-018-012

Revision A

October 2000

4820 Printer Terminal Holder

P/N 962-018-012 Revision A

*962018012*

Instructions

This terminal holder connects the INTERMECR600 Series and 700 Series
Computers to the 4820 Printer. Perform these instructions, in the order given,to
ensure reliable operation of this equipment.

1. Test the printer and old terminal holder.

2. Remove the old terminal holder.

3. Connect the new terminal holder.

4. Orient and test the new terminal holder.

Terminal Holder Installation Kit

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Terminal Holder Assembly Various
Four screws, 8-32 x 1.25” (flathead) P/N: 801-115-000
I/O extension cable P/N: 226-329-001
13-conductor shielded flex cable P/N: 321-560-001 * See note
Ferrite bead P/N: 309-369-001 * See note
Double-sided tape for ferrite bead (1.25”) P/N: 906-011-002 * See note
Double-sided tape for printer frame (3–4”) P/N: 906-029-001
13x16 plastic bag P/N: 901-250-004
3x4 plastic bag P/N: 901-250-003
Terminal holder upgrade instructions P/N: 962-018-012

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NOTE: These items are required for regulatory compliance to prevent EMI interference.

Tools Required

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#1 Phillips screwdriver with a 9.5” (24 cm) shaft

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Needle-nosed pliers

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Wire cutter

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LoctiteR425 (orderable as a separate line item — P/N: 901-386-002)

Customer Support Center

Should you need assistance, the Intermec Customer Support Center (technical
support) telephone number is 800-755-5505 (U.S.A. or Canada) or 425-356-1799.
The facsimile number is 425-356-1688. Email is [e-mail].

If you email or fax a problem or question include the following information in
your message: your name, your company name and address, phone number and
email to respond to, and problem description or question (the more specific, the
better). If the equipment was purchased through a Value-Added Reseller please
include that information.

2 4820 Printer Terminal Holder Upgrade Instructions

Test Printer and Old Terminal Holder

Before you dismantle the 4820 Printer, insert an Intermec 62XX Computer in
the old terminal holder, then perform a print test to ensure that both the printer
and the terminal holder are in working order. Troubleshoot a ny problems before
continuing with this upgrade. Contact the Intermec Customer Support Center if
you have any questions.

Remove the Pivot Frame

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NOTE: Disable power to the 4820 Printer before dismantling the printer.

1. Remove the lid from the printer, unlatch the pivot frame, and remove any
paper from the paper tray.

2. Detach the two flex cables from the back of the control panel, then pull the
pivot frame up and out of its hinges.

3. Detach the 13-conductor flex cable from the pivot frame and discard it. Put
the pivot frame and remaining 14-conductor flex cable aside for later.

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If you are upgrading a 4820 Fixed-Mount Printer, go to page 4.

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If you are upgrading a 4820 Portable Printer, go to page 9.

4820 Portable Printer

1

2

1. 13-conductor flex cable (dispose)

2. 14-conductor flex cable (keep)

3. Pivot frame

4. Hinges

5. Control panel

Figure 1

Removing Pivot Frame

4820 Fixed Mount Printer

1

2

3

5

4

4820 Printer Terminal Holder Upgrade Instructions 3

Upgrade the Fixed-Mount Printer

1. Use the Phillips screwdriver to remove the blank cover plate. Save the
cover plate, its four screws, and their white spacers for future use.

2. Remove the old terminal holder, pull the slide retainer back to reveal the
two concealed screws. Discard all four screws.

3

1. Slide retainer

2. Terminal holder

3. Blank cover plate

Figure 2

Detaching Cover Plate and Terminal Holder

1

2

Install I/O Extension Cable

1. Detach the old terminal holder ground cable from the printer ground cable.

2. Detach the old terminal holder ribbon cable from the printer control panel.
Dislodge the ribbon cable from the printer frame, and pull the ribbon cable
out through the slot. Replace the 3–4” double-sided tape on the printer
frame, if needed.

3. Align the I/O extension cable along the same path as the old ribbon cable.
Insert the I/O extension cable into the control panel. Press the I/O exten­sioncableontothetapeinsidetheprinterframe.

Ribbon cable

Slot in printer frame

4 4820 Printer Terminal Holder Upgrade Instructions

Figure 3

Following Ribbon Cable Path

Press Cables to Bottom of Terminal Holder

Dothefollowingtokeepthegroundcableandribboncableoutofthepaperpath.

1. Strip the protective paper off the tape on the bottom of the new terminal
holder.

2. Press the terminal holder ground cable across the middle of t he tape.

3. Do the same with the terminal holder ribbon cable, over the ground cable.
Make sure the ribbon cable is firmly in place.

3

1

2

1. Tape

2. Ground cable

3. Ribbon cable

Figure 4

Pressing Cables to New Terminal Holder

Install Terminal Holder and Ferrite Bead

1. Position the new terminal holder on the printer, with the connector end
closest to the control panel. Pull the two terminal holder cables through
the slot in the printer frame.

2. Clamp the ferrite bead around the three green, red, and black power cables.
Strip the protective paper from one side of the 1.25” double-sided tape and
press the tape to the ferrite bead. Do not put the tape on the clasp. Strip
the protective paper from the other side of the tape, then press the bead to
the wall of the printer frame.

1

4

3

Open Ferrite Bead

1. Connector end

2. Slot in printer frame

3. Ferrite bead on power cables

4. Clasp

2

Figure 5

Ferrite Bead Clamped on Power Cables

4820 Printer Terminal Holder Upgrade Instructions 5

Connect Cables

1. Insert the male ground connector (terminal holder ground cable) into the
female ground connector (printer ground cable). Use needle-nosed pliers, if
necessary.

2. Connect the terminal holder ribbon cable with the I/O extension cable.
Close the clasps on the I/O extension connector to secure the two cables.

Ground Connectors

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3

1

1. Female ground connector (printer cable)

2. Male ground connector (terminal holder cable)

3. Joined connectors

4. Clasp

Ribbon Connectors

4

Figure 6

Connecting and Securing Cables

Store Excess Cables

Insert all excess ground and ribbon cabling in the channel between the printer
frame and the paper tray.

6 4820 Printer Terminal Holder Upgrade Instructions

1

2

3

1. Paper tray

2. Channel

3. Printer frame

Figure 7

Moving Excess Cabling out of Paper Path

Install Flex Cables and Pivot Frame

1. Install the new 13-conductor shielded flex cable to the back of the pivot
frame and align the pivot frame back onto its hinges.

2. Attach the two flex cables to the printer control panel and lower the pivot
frameintoplace.

2

1

1. Pivot frame

2. 14-conductor flex cable

3. 13-conductor shielded flex cable

4. Control panel

Attaching Pivot Frame

3

Figure 8

4

Reinstall the Blank Cover Plate and Printer Lid

1. Position white spacers over the printer screw holes where the blank cover
plateistobeattached,thenplacethecoverplateonthespacers.

2. Squeeze a small drop of Loctite 425 onto the tip of each screw, enough to
cover 3–4 threads, then insert each screw into a hole and tighten into place.

3. Put the lid back onto its hinges and close into place.

2 of 4 screw holes for blank cover plate

Figure 9

Attaching Blank Cover Plate

4820 Printer Terminal Holder Upgrade Instructions 7

Secure New Terminal Holder

Four 8-32 x 1.25” flathead screws are included in this kit. Loctite 425 is required
to secure these screws.

1. Squeeze a small drop of Loctite 425 onto the tip of each screw, enough to
cover 3–4 threads, then insert each screw into a hole and tighten into place.

2. Use a soft cloth to wipe away excess threadlocker.

3. Go to page 12 to orient and test the new terminal holder.

2

1

Aligning Screws with New Terminal Holder

1. New terminal holder

2. Screws

Figure 10

8 4820 Printer Terminal Holder Upgrade Instructions

Upgrade the Portable Printer

1. Use the Phillips screwdriver to remove the old terminal holder from the
printer. Pull the slide retainer back to reveal the two concealed screws.
Discard all four screws.

2. Detach the old terminal holder cables from the printer control panel, then
discard the old terminal holder.

2

1

1. Slide retainer

2. Terminal holder

3. Control panel

Figure 11

Removing Old Terminal Holder

3

Position New Terminal Holder

Pull the new terminal holder cables through the printer frame, then position the
terminal holder on the printer screw holes.

1

2

1. Cables through printer frame

2. Terminal holder in position

Figure 12

Positioning New Terminal Holder

4820 Printer Terminal Holder Upgrade Instructions 9

Install Ferrite Bead

If the portable printer has an ac foot and one gray power cable,
Position the ferrite bead onto the floor of the printer frame, betw een the paper
tray and the battery compartment, as in Figure 13 below.

If the portable printer is dc-powered and has three power c ables,

Position the ferrite bead onto the wall of the printer frame, between the paper
tray and the printer frame (see Figure 5 on page 5 for location).

1. Clamp the ferrite bead around the power cable.

2. Strip the protective paper from one side of the 1.25” double-sided tape and
press the tape to the ferrite bead. Do not put the tape on the clasp.

3. Strip the paper off the other side of the tape, then press the bead into place.

Clasp

Open Ferrite Bead

Figure 13

Ferrite Bead Clamped on Gray Power Cable

Connect Cables

1. Use wire cutters to clip a squa re out of the red insulating boot on the print­er ground connector to fit within the new terminal holder insulating boot.

2. Slide the male ground connector (printer cable) into the female ground con­nector (terminal holder cable). Use needle-nosed pliers, if necessary.

3. Connect the terminal holder ribbon cable to the the control panel.

4. Route the excess cabling between the paper tray and the printer frame un­der the control panel.

4

1

2

1. Wire cutters

2. Cut piece off insulating boot

3. Female ground connector (printer cable)

4. Male ground connector (terminal holder cable)

5. Joined connectors

3

5

Connecting Ground Cables — Portable Printer Only

10 4820 Printer Terminal Holder Upgrade Instructions

Figure 14

Install Flex Cables and Pivot Frame

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NOTE: See Figure 8 on page 7 for guidelines.

1. Install the new 13-conductor shielded flex cable to the back of the pivot
frame and align the pivot frame, with its 14-conductor flex cable, back onto
its hinges.

2. Attach the two flex cables to the printer control panel and lower the pivot
frameintoplace.

3. Install the lid back onto its hinges and close into place.

Secure New Terminal Holder

Four 8-32 x 1.25” flathead screws are included in this kit. Loctite 425 is required
to secure these screws.

1. Squeeze a small drop of Loctite 425 onto the tip of each screw, enough to
cover 3–4 threads.

2. Insert each screw into a hole and tighten into place. Use a soft cloth to
wipe away excess threadlocker.

3. Go to page 12 to orient and test the new terminal holder.

Screws

Figure 15

Aligning Screws for New Terminal Holder

4820 Printer Terminal Holder Upgrade Instructions 11

Orient and Test the New Terminal Hold er

Use a 600 Series or 700 Series Computer to test the terminal holder installation.

Insert the Computer

1. Insert the top of the computer into the terminal slide retainer and use the
computer to push the slide retainer all the way in the direction shown
(Figure 16, part a).

2. Lower the bottom of the computer into the terminal holder, then slide the
computer to fully seat it in the docking connector (Figure 16, part b).

1

2

(a) (b)

1. Top (display) of computer

2. Docking connectors

Figure 16

Installing Computer

Perform a Print Test

Apply power to the 4820 Printer, then load paper into the unit. Perform a print
test to ensure that both the printer and the new terminal holder are in working
order. Contact the Customer Support Center if you have any questions.

12 4820 Printer Terminal Holder Upgrade Instructions

Intermec Technologies Corporation

550 Second Street SE

Cedar Rapids, IA 52401