Intermec® Corporation
6001 36th Avenue West
P.O. Box 4280
Everett, WA 98203-9280
U.S. technical and service support: 1-800-755-5505
U.S. media supplies ordering information: 1-800-227-9947
Canadian technical and service support: 1-800-688-7043
Canadian media supplies ordering information: 1-800-268-6936
Outside U.S. and Canada: Contact your local Intermec service supplier.
The information contained herein is proprietary and is provided solely for the purpose of allowing
customers to operate and/or service Intermec manufactured equipment and is not to be released,
reproduced, or used for any other purpose without written permission of Intermec.
All Rights Reserved
The word Intermec, the Intermec logo, Duratran, and CrossBar are trademarks of Intermec Corporation.
The name Centronics is wholy owned by GENICOM Corporation.
IBM is a registered trademark of International Business Machines Corporation.
TM
Throughout this manual, trademarked names may be used. Rather than put a trademark (
every occurrence of a trademarked name, we state that we are using the names only in an editorial
fashion, and to the benefit of the trademark owner, with no intention of infringement.
) symbol in
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Contributors
AuthorLori Austin
Mia Hayashida
EditorCraig Thompson
Technical IllustratorsJohn Bickley
Karen Petruzzi
Technical ReviewersScott Bale
Dzung Dang
Jim Davison
Terry Ho
Jaye Jarchow
Ed Millet
Lisa Morin
Mark Rasmussen
iii
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4100 Bar Code Label Printer User's Manual
Manual Change Record
This page records the changes to this manual. The manual was originally released as version 001.
VersionDateDescription of Change
B12/92Added an addendum describing new features of ribbon save and the
cutter.
0012/93Incorporated addendum and added the cut option. Added a new label
that can be downloaded to the printer.
0028/93Chapter 7 was reformatted to make it easier to use. Chapter 8 was made
to be a universal printer reference guide. Commands that are not
compatible with the 4100 printer are noted. Small changes were made to
the appendix.
00310/93Firmware version 2.3 addendum added to the manual. The changes were
made to the communications protocols and the configuration commands
such as end-of-print skip distance and the label rest point.
00410/94Manual updated to reflect the current style guide. A new file called
4100u-fr.pm4 was added. It contains all of the front matter that was
previously included in Chapter 1. What used to be Chapter 2 is now
Chapter 1, and so forth. There is no longer a Chapter 8. Firmware
version 2.4 information added to the manual. The new information
includes:
Image before print command
HIBC Code 128
New Code 128 selection to ignore brackets and spaces
Label rest location range expanded to +/-30
Top of form adjust range expanded to -10 to 4000
Reimage only changed fields
Test and Service DIP switch settable functions
Different sensitivity number for DT and TTR
0056/95Page numbers added to the printer command tables in Chapter 7 and
several command descriptions corrected. New cable diagrams added to
Chapter 2.
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Contents
Contents
Before You Begin xix
Warranty Information xix
Safety Summary xix
Warnings and Cautions xx
About This Manual xxi
Customer Advisory xxiii
Printing Test Labels 5-12
Using Data Line Print 5-12
Performing Cloning 5-13
Performing Selective Transfer 5-14
Using Memory Reset 5-15
Changing Configuration Commands in Test and Service Mode 5-16
Using Test and Service Mode Commands 5-24
Setting the Number of Dot Increments 5-17
Adjusting the Label Rest Point 5-18
Using 86XX Emulation Mode 5-19
Forms Adjust 5-21
Setting the X Forms Adjust 5-22
Setting the Y Forms Adjust 5-23
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4100 Bar Code Label Printer User's Manual
Designing Labels and Using Commands
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6
Introduction to Label Design 6-3
Using Label Formats 6-3
Communicating With the Printer 6-6
Using Intermec Label Design Software 6-6
Using the Printer Command Set 6-6
Downloading Printer Commands Using DOS 6-6
Using a Text Editor or Word Processor to Create Your Label 6-7
Downloading Printer Commands Using PC Communications
Programs or Host Terminals 6-8
Switching Between Print Mode and Program Mode 6-9
Creating Label Design Components 6-9
Different Kinds of Fields 6-10
About Bar Code Symbologies 6-10
Character Fields and Fonts 6-14
User-Defined Fonts 6-15
Downloading Fonts 6-16
Lines and Boxes 6-17
Graphics 6-18
One Bit Per Byte 6-18
Downloading One Bit Per Byte Graphics 6-19
Diamond Graphic 6-20
Six Bits Per Byte 6-20
Introduction 7-3
Command Set Summary 7-3
Using Printer Commands According to Function 7-10
Program Mode 7-10
Programming 7-10
Editing a Page 7-10
Editing a Format 7-10
Editing a Bar Code Field 7-11
Editing a Human-Readable Field 7-11
Editing an Interpretive Field 7-11
Editing a Line Field 7-11
Editing a UDC Field 7-12
Editing a Box Field 7-12
Editing a UDC 7-12
Editing a Bitmap User-Defined Field 7-12
Immediate Commands 7-12
System Commands 7-12
Print Mode 7-13
Print Commands 7-13
Configuration Commands 7-13
Transmit Commands 7-14
Protocol Modification Commands 7-14
Test and Service Commands 7-14
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4100 Bar Code Label Printer User's Manual
Immediate Commands 7-15
Abort Print Job 7-15
Error Code, Request 7-15
Label and Gap Length, Transmit 7-15
Remaining Quantity and Batch Count, Transmit 7-16
Reset 7-16
Status Dump 7-16
Status Enquiry 7-17
Print Mode Commands 7-18
86XX Emulation Mode, Select 7-19
Advanced Mode, Select 7-19
Alphanumeric Field Separator 7-19
Batch Count, Set 7-20
Clear All Data 7-20
Clear Data From Current Field 7-21
Command Terminator 1 7-21
Command Terminator 2 7-21
Configuration Parameters, Transmit 7-21
Cut 7-21
Data Shift – International Characters 7-22
Field, Select 7-22
Field Decrement, Set 7-22
Field Increment, Set 7-23
First Data Entry Field, Select 7-23
Font, Transmit 7-23
Form Feed 7-24
Format, Select 7-24
Format, Transmit 7-25
Increment and Decrement, Disable 7-25
Next Data Entry Field, Select 7-25
Numeric Field Separator 7-26
Options Selected, Transmit 7-26
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Page, Select 7-26
Page, Transmit 7-27
Print 7-27
Printhead Parameters, Transmit 7-27
Program Mode, Enter 7-27
Program Number, Transmit 7-28
Quantity Count, Set 7-28
Start and Stop Codes (Code 39), Print 7-28
Storage Area Usage, Transmit 7-29
Test and Service Mode, Enter 7-29
User-Defined Characters, Transmit 7-29
User-Defined Tables, Transmit 7-30
Warm Boot 7-30
Configuration Commands 7-31
86XX or Advanced Mode on Power Up 7-31
Amount of Storage, Define 7-32
Audible Alarm, Enable or Disable 7-32
Auto-Transmit 1, Enable 7-32
Auto-Transmit 2, Enable 7-33
Auto-Transmit 3, Enable 7-33
Auto-Transmit 1, 2, and 3, Disable 7-33
Control Panel Access Permission, Set 7-34
Cutter, Enable or Disable 7-34
Dark Adjust, Set 7-34
End-of-Print Skip Distance, Set 7-34
IBM Language Translation, Enable or Disable 7-35
Intercharacter Delay, Set 7-35
Interlabel Ribbon Save, Enable or Disable 7-35
Label Rest Point, Adjust 7-36
Label Retract, Enable or Disable 7-36
Label Retract Distance, Set 7-36
Label Stock Type, Select 7-37
Label Width, Set 7-37
Contents
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4100 Bar Code Label Printer User's Manual
Maximum Label Length, Set 7-37
Media Sensitivity, Select 7-37
Message Delay, Set 7-38
Number of Image Bands, Set 7-38
Online or Offline on Power Up 7-38
Postamble, Set 7-39
Preamble, Set 7-39
Print Speed, Set 7-39
Printer Language, Select 7-40
Printhead Pressure, Set 7-40
Printhead Test Parameters, Set 7-40
Ribbon Save Zones, Set 7-40
Self-Strip, Enable or Disable 7-41
Top of Form, Set 7-41
Program Mode Commands 7-42
Bar Code, Select Type 7-43
Bar Code Field, Create or Edit 7-48
Bitmap Cell Height for Graphic or UDF, Define 7-49
Bitmap Cell Width for Graphic or UDF, Define 7-49
Bitmap User-Defined Font, Clear or Define 7-50
Border Around Human-Readable Text, Define 7-50
Box Field, Create or Edit 7-50
Character Bitmap Origin Offset, Define 7-51
Character Rotation or Bar Code Ratio, Define 7-51
Code 39 Prefix Character, Define 7-52
Command Tables, Load 7-52
Current Edit Session, Save 7-53
Data Source for Format in a Page, Define 7-53
Field, Delete 7-54
Field Data, Define Source 7-54
Field Direction, Define 7-55
Field Origin, Define 7-55
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Font Character Width, Define 7-56
Font Type, Select 7-56
Format, Create or Edit 7-57
Format, Erase 7-57
Format Direction in a Page, Define 7-57
Format Offset Within a Page, Define 7-58
Format Position From Page, Delete 7-58
Format Position in a Page, Assign 7-58
Graphic Type, Select 7-58
Graphic or UDC, Define 7-59
Height Magnification of Bar, Box, or UDC, Define 7-59
Human-Readable Field, Create or Edit 7-60
Intercharacter Space for UDF, Define 7-60
Interpretive Field, Edit 7-61
Interpretive Field, Enable or Disable 7-61
Length of Line or Box Field, Define 7-61
Line Field, Create or Edit 7-62
Outline Font, Clear or Create 7-62
Outline Font, Download 7-62
Page, Create or Edit 7-63
Page, Delete 7-63
Pitch Size, Set 7-63
Point Size, Set 7-63
Print Line Dot Count Limit, Set 7-64
Program Mode, Exit 7-64
User-Defined Character, Clear or Create 7-64
User-Defined Character Field, Create or Edit 7-64
User-Defined Font Character, Create 7-65
Width of Line, Box, Bar, or Character, Define 7-65
Contents
Test and Service Mode Commands 7-66
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4100 Bar Code Label Printer User's Manual
User-Defined Interface Tables 7-67
Print Commands (t=0) 7-68
Escape Print Commands (t=1) 7-69
Shift Print Commands (t=2) 7-70
Status Responses and Auto-Transmit Commands (t=3) 7-71
Protocol Commands (t=4) 7-72
Communication Protocol Characters 7-73
Printer Functional Boundaries 7-74
Appendix
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A
4100 Printer Specifications A-3
Dimensions (no options installed) A-3
Electrical Requirements A-3
Printing Method A-3
Printing Speed A-3
Printhead A-3
Media Specifications A-4
Ribbon Specifications A-4
Cutter Specifications A-4
Environment A-4
Communications A-5
Fonts and Graphics A-5
Character Sets A-5
Bar Code Symbologies A-5
Factory Defaults A-6
Extended Character Sets A-7
International Character Sets A-9
ASCII Translation Table A-11
Present Sensor/Self-Strip A-13
Memory Expansion A-13
Cutter and Tray A-13
Ribbon Save A-14
Glossary
G
Index
Contents
I
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xviii
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Before You Begin
This section introduces you to standard warranty provisions, safety
precautions, warnings and cautions, document formatting conventions, and
sources of additional product information.
Warranty Information
To receive a copy of the standard warranty provision for this product, contact
your local Intermec sales organization. In the U.S. call (800) 755-5505, and in
Canada call (800) 688-7043. Otherwise, refer to the Worldwide Sales & Service
list shipped with this manual for the address and telephone number of your
Intermec sales organization.
Safety Summary
Your safety is extremely important. Read and follow all warnings and cautions
in this book before handling and operating Intermec equipment. You can be
seriously injured, and equipment and data can be damaged if you do not
follow the safety warnings and cautions.
Before You Begin
Do Not Repair or Adjust Alone Do not repair or adjust energized equipment
alone under any circumstances. Someone capable of providing first aid must
always be present for your safety.
First Aid Always obtain first aid or medical attention immediately after an
injury. Never neglect an injury, no matter how slight it seems.
Resuscitation Begin resuscitation immediately if someone is injured and stops
breathing. Any delay could result in death. To work on or near high voltage,
you should be familiar with approved industrial first aid methods.
Energized Equipment Never work on energized equipment unless authorized
by a responsible authority. Energized electrical equipment is dangerous.
Electrical shock from energized eqiupment can cause death. If you must
perform authorized emergency work on energized equipment, be sure that you
comply strictly with approved safety regulations.
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4100 Bar Code Label Printer User's Manual
Warnings and Cautions
The warnings and cautions in this manual use the following format.
Warning
A warning warns you of an operating procedure, practice, condition, or
WARNING
CAUTION
statement that must be strictly observed to avoid death or serious injury to the
persons working on the equipment.
Avertissement
Un avertissement vous alerte d'une procédure de fonctionnement, d'une
méthode, d'un état ou d'apport qui doit être strictement respecté pour éviter
l'occurrence de mort ou de blissures graves aux personnes manupulant
l'équipement.
Caution
A caution alerts you to an operating procedure, practice, condition, or
statement that must be strictly observed to prevent equipment damage or
destruction, or corruption or loss of data.
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Conseil
Une précaution vous avertit d'une procédure de fonctionnement, d'une méthode,
d'un état ou d'un rapport qui doit être strictement respecté pour empêcher
l'endommagement ou la destruction de l'équipement, ou l'altération ou la perte
de données.
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About This Manual
This manual contains all of the information necessary to install, operate,
configure, design labels, troubleshoot, and maintain the 3400 printer. Below is a
table listing the information contained in each chapter of this manual.
For information on:Refer to:
Loading MediaChapter 1, "Getting Started." Provides information
Installing the PrinterChapter 2, "Installing the Printer." Describes printer
Printer OperationChapter 3, "Operating the Printer." Gives
MaintenanceChapter 4, "Routine Maintenance." Describes how
Before You Begin
on plugging in the printer, loading media,
configuring the printer, and printing a
configuration test label.
installation for a variety of data collection systems.
step-by-step procedures fo r normal printer
operations and for everyday maintenance such as
reloading media and ribbon.
to keep your 4100 printer running efficiently so it
continues to produce top quality labels.
for clearing error messages, troubleshoo ting
programming and configuration problem s, and
performing DIP switch settable procedu res.
Designing LabelsChapter 6, "Designing Labels and Using
Commands." Describes how to use the printer
command set to design your labels.
Printer CommandsChapter 7, "Printer Commands." Provides a
complete guide to the p r in ter command set.
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4100 Bar Code Label Printer User's Manual
Related Intermec Manuals
The following manuals provide additional information about printing labels
with your 4100 bar code printer.
ManualIntermec Part No.
Data Communications Manual044737
Bar Code Book by Roger C. Palmer051241
Terms and Conventions
Listed below are special terms and conventions used throughout the manual.
For a complete list of terms, refer to the glossary.
Terms
“Printer” refers to the 4100-series bar code printer.
A “symbol” or “bar code symbol” consists of alphanumeric characters
encoded in a bar code format.
“Media” is the label stock on which the printer prints labels.
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“Reader” refers to a data collection device that decodes bar code symbols into
alphanumeric characters.
“Input device” refers to a device used for scanning bar codes, such as a wand
or laser scanner.
Conventions
The following conventions are used throughout this manual for operating
procedures and descriptions of the printer.
• Names of buttons on the printer front panel are uppercase, bold, and
enclosed in square brackets. For example, [FEED] refers to the button
labeled FEED.
• Downloaded commands appear in the order you enter them into the
printer:
Mnemonic representations of ASCII control characters
are enclosed in angle brackets <>. For example, <ETX>
represents the ASCII “End of Text” control character.
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Variable data are enclosed in braces {}. For example: {n}
signifies a variable for which you could designate a
constant value.
All characters not enclosed in brackets are taken literally.
For example, E3;F3; means: [E][3][;][F][3][;] with E and F in
uppercase.
Customer Advisory
To reduce the risk of printer errors, the buyer should frequently check the
accuracy of printer bar code and alphanumeric information. In those situations
where accuracy is imperative, the buyer must confirm the accuracy of all
printed labels with the information originally intended to be encoded on the
label. Persons operating the printer should maintain it according to the
procedures in this manual to keep it in good working condition.
Before You Begin
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4100 Bar Code Label Printer User's Manual
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xxiv
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Getting Started
1
1
Getting Started
1-1
4100 Bar Code Label Printer User's Manual
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1-2
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Introduction to the 4100 Printer
The Intermec 4100 printer is a thermal and thermal transfer bar code printer
designed to print high-quality labels in an industrial environment. These labels
can contain data in both text and bar code form as well as graphics, lines, and
boxes in a variety of sizes and orientations. The 4100 is an economical printer
that can emulate the Intermec 4400 and Intermec 86XX series bar code label
printers.
Printing Capabilities
You can use the 4100 printer for all your label needs since it prints many
different bar codes, lines, and graphics in user-defined fields. Below is an
example of a label printed with a 4100 printer.
Sample Label Printed With a 4100 Printer
*DRAG,FIELD*
*INTERMEC*
CODE 39 3.0 / 1
Code 39
2.5 / 1
*PICKET,FIELD*
*PICKET FIELD*
Getting Started
1
MODEL
4100
Prog 057733
Version 2.2
Code 39
3.0 / 1
Code 39
Intermec
Intermec Corporation
Everett, WA 98203
*SUPPLIER*
*SUPPLIER*
*PICKET,FIELD*
*PICKET FIELD*
*PICKET,FIELD*
*PICKET FIELD*
4100-01
1-3
4100 Bar Code Label Printer User's Manual
Printer Components
The following figures and tables will help familiarize you with the 4100 bar
code printer. Be sure you understand the purpose of these components before
you use the printer.
Front View of the 4100 Printer
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8
9
7
PAUSE
6
FEED
5
CANCEL
DARKER
STOP/
PAPER/
RIBBON
POWER
TRANSFER ON
4
PAUSE
Intermec
PAP
A Litton Company
FEED
RIB
PO
STOP/
CANCEL
DARKER
4100
TRANS
1
3
2
1-4
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Getting Started
1
Printer Component Descriptions (Front View)
The following table contains descriptions of the printer components as shown in
the previous illustration.
No.NameDescription
1Right side coverProvides access to the media path, printhead, and thermal
transfer ribbon.
2Front panel coverProvides access to the thermal/thermal transfer switch, and
darkness control adjustment knob
3Label dispense openingGuides printed labels out of the printer mechanism for
removal.
4Power on indicatorIlluminates when the power switch on the rear panel is
turned on.
5Stop/Cancel buttonCancels the current print job. The printer continues to
process subsequent downloaded commands.
6Feed buttonAdvances the media.
7Pause buttonTemporarily stops printing and holds all data in memory
until the button is pressed a second time to resume printing.
Pauses communication with the host.
8Pause indicatorIlluminates when the [PAUSE] button is pressed. Blinks
during communication with the host.
9Paper/Ribbon indicatorIlluminates when no media or ribbon are detected by the
printer sensors.
1-5
4100 Bar Code Label Printer User's Manual
Front View of the 4100 Printer With the Front Cover Open
5
4
PAUSE
PAPER/
FEED
RIBBON
POWER
STOP/
CANCEL
DARKER
TRANSFER ON
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1-6
3
1
4100-02
2
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Getting Started
1
Printer Component Descriptions (Front Interior)
The following table contains descriptions of the printer components as shown in
the previous illustration.
No.NameDescription
1Drive rollerAdvances media through the printer.
2Rewind assist rollerGuides media to the rewinder hub during batch take-up and
self-strip printing.
3Transfer on switchToggles between direct thermal printing (OFF) and thermal
transfer printing (ON). Direct thermal printing is the factory
default.
4Darkness control adjustmentAdjusts a new printhead to produce the same level of
darkness as the previous printhead. Does not adjust the
darkness quality of individual print jobs.
5Quick remove hingeAllows the front cover to be easily removed or installed.
1-7
4100 Bar Code Label Printer User's Manual
Rear View of the 4100 Printer
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I
O
S1
J2
1
S2
250V, 1.5A S-B
OFF ON
AC POWER
5
4
2
3
4100-03
1-8
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Getting Started
1
Printer Component Descriptions (Rear View)
The following table contains descriptions of the printer components as shown
in the previous illustration.
No.NameDescription
1DIP switchesControl various printer modes and configuration settings.
The top bank of DIP switches is above the serial port and the
bottom bank is beneath the serial port.
2Fuse holderContains a 1.5A Slo-Blo fuse for 115 VAC operation or a
double pole circuit breaker at 1.2A for 230 VAC operation.
3Power switchTurn the printer on by moving the switch to the ON position
and off by moving it to the OFF position.
4AC power cord receptacleThe AC power cord plugs into this receptacle.
5Serial communications portConnects the printer to a host computer with a 25-pin
D-style subminiature receptacle.
1-9
4100 Bar Code Label Printer User's Manual
View of the 4100 Printer Mechanism
17
PAUSE
16
DARKER
FEED
STOP/
CANCEL
PAPER/
RIBBON
POWER
TRANSFER ON
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1
2
3
4
1-10
15
14
13
12
11
10
5
6
7
8
4100-04
9
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Getting Started
1
Printer Component Descriptions (Mechanism Detail)
The following table contains descriptions of the printer components as shown
in the previous illustration.
No.NameDescription
1Supply roll back stopPrevents the roll of unused media from rubbing against the
interior of the printer.
2Supply roll retainerSecures the roll of unused media to the supply roll hanger.
3Supply roll hangerHolds the roll of unused media.
4Rewind adapterGuides printed media onto the rewinder hub during batch
take-up printing. (Shown in its storage position when not in
use).
5Rewinder claspSecures printed media or used media backing to the
rewinder hub.
6Rewinder hubCollects printed media in batch take-up mode or media
bacing in self-strip mode.
7Label adjust guideGuides media from the supply roll to the drive roller.
8Head lift leverDisengages the printhead for loading media or ribbon and
for adjusting printhead alignment.
9Label gap sensor adjustmentAdjusts the label gap sensor, which scans the media for label
gaps or edges so the printer can determine where to start a
new label. Adjustable from 0.25" to 2.3".
10PrintheadPrints label formats as they are transmitted from the host
computer. The printhead resolution is 203 dots per inch
(DPI).
11Printhead support adjust screwMoves the printhead support plate up or down to
accomodate narrow media.
12Tear off plateUsed for tearing off labels in straight-through printing mode.
13Printhead support plateSupports the outer end of the printhead when narrow media
is used.
14Ribbon rewind hubCollects used thermal transfer ribbon.
15Ribbon claspSecures used thermal transfer ribbon to the ribbon rewind
hub.
16Ribbon supply hubHolds the supply of unused thermal transfer ribbon.
17Ribbon supply back stopPrevents the roll of thermal transfer ribbon from rubbing
against the interior of the printer.
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4100 Bar Code Label Printer User's Manual
Printer Options
Listed below are the factory installabel options available for the 4100 printer.
Ribbon Save
Ribbon save is a factory-installed option that lifts the printhead either between
labels (interlabel ribbon save) and/or within the label (intralabel ribbon save) so
that the ribbon will not advance with the media.
When you use interlabel ribbon save, the printhead lifts when it detects the end
of one label and lowers when it detects the front of the next label.
When using intralabel ribbon save, you must set the start and stop zones (lift
and lower the printhead) within each label. For example, you may want to use
ribbon save when printing a single bar code on a preprinted label. You would
then program the 4100 printer to lift the printhead during the preprinted
section and lower it when the label has fed far enough to print the bar code.
Since the ribbon normally advances with the media when the printhead is
down, if the printhead is up the ribbon will not advance with the media and
ribbon will be conserved. You can set up to 10 zones per label. The minimum
width of these zones depends on your printing speed.
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1-12
Cutter
The cutter is a factory-installed option. The cutter mechanism can easily be
removed at any time to return the printer to its normal tear off, self-strip, or
batch rewind print modes. For your safety, the cutter comes with two interlock
switches that prevent the cutting mechanism from operating if the front cover
is not closed securely.
Operating Specifications
• media width: 0.75 inch (19mm) minimum; 4.25 inch (108mm) maximum
• media length: 0.50 inch (13mm) minimum; no limit on maximum
• media thickness: 0.005 inch (0.127mm) minimum; 0.10 inch (2.54mm)
maximum
• tray size: Adjustable from 3.5 to 6.25 inches
• blade life: Approximately 1 million cuts (500,000 per cutting edge
depending on media type)
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Unpacking the 4100
Unpack the printer and put it on a clean, stable surface for testing. Remove the
packing material from the printer mechanism that was used to prevent damage
during shipping. Store the shipping container and materials in case you need
to ship the printer for any reason.
The front panel cover of the printer is packed in a separate bag and must be
installed on the printer. Refer to the instructions later in this section.
Checking the Order for Completeness
As you unpack the printer, verify the contents of the shipping container against
this list.
• 4100 printer
• Front panel cover
• AC power cord
Getting Started
1
• 4100 Printer User’s Manual
• Media envelope (contains sample thermal media and information on
Intermec media products).
If any parts are missing, please contact your local Intermec representative.
Reporting Damage or Defects
Your 4100 printer was thoroughly tested and inspected before it was shipped
from the factory. If any items are damaged, you can take the following steps to
correct the problem.
• Take photographs if necessary.
• Contact the transport carrier.
Note: The customer is responsible for all damage claims against the carrier. See the
“Intermec Terms of Sale” printed on your sales invoice.
1-13
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Installing the Front Panel Cover
Before you can operate the printer, you must install the front panel cover.
To install the cover
1. Remove the front panel cover from its shipping bag.
2. Locate the two hinge pins on the front left of the printer. The top pin is
positioned approximately 0.5 inch from the top of the printer, and the
bottom pin is 1 inch from the bottom.
3. Align the two hinge pins with the hinges on the front panel cover and lower
the cover panel into place on the printer.
Preparing the Printer for Installation
Before you install your 4100 printer and connect it to your data collection
system, you need to start your printer and print a configuration test label. This
test prints labels that provide information about the printer’s configuration. For
more detailed testing procedures, see Chapter 5, “Troubleshooting.”
1-14
Use the instructions on the following pages to prepare your printer for
installation. These procedures provide the most efficient method of starting
your 4100 printer so you can operate it immediately and take advantage of all its
features.
Plugging in the Printer
1. Check that the printer power switch is in the OFF position.
2. Plug the AC power cord into the receptacle on the back of the printer.
3. Plug the other end into a grounded wall outlet or surge protector.
4. Set the power switch (located on the back panel of the printer) to the ON
position. When the printer is fully powered, the Power indicator light is lit.
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Checking the DIP Switch Settings
Make sure the DIP switches on the rear panel are set to their factory default
positions. For the top bank, Switch 1 is set to position 1 (ON) and Switches 2
through 8 are set to position 0 (OFF). For the bottom bank, Switches 1 through
8 are set to 0 (OFF). See “Configuring the Serial Port” in Chapter 2, “Installing
the Printer,” for details about the 4100 printer‘s factory default settings.
Opening the Printer
Whenever you load media, or perform most other maintenance procedures,
you must open the printer.
To open the printer
1. Facing the front of the printer, grasp the right side of the front panel cover
and pull it toward you to release the cover from its magnetic latches. The
cover will swing open to the left on its hinges.
2. Grasp the bottom center of the right cover and pull it upward. The hinged
right cover should come to rest on the top of the printer. No latches secure
this cover when it is in the closed position.
Getting Started
1
Loading Media
Once you have opened the two printer covers, you can load the media. Use the
direct thermal media supplied with the printer to print the subsequent
configuration test labels. When loading media, the power to the printer can
either be turned on or off. This procedure assumes the printer has been turned
on.
Note: This procedure covers how to load media for the straight-through printing mode
using direct thermal label stock on a roll. The printer‘s factory default is to print in
direct thermal mode. Other forms of printing including self-strip mode, batch take-up
mode, and thermal transfer printing are explained in Chapter 3, “Operating the
Printer.”
To load media
1. Disengage the printhead by rotating the head lift lever clockwise to the UP
position.
1-15
4100 Bar Code Label Printer User's Manual
Loading Media Into the Printer
1
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2
3
4
4100-05/16
8
7
5
Label Gap Sensor
6
1-16
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2. Slide the retainer to the outer end of the supply mount and flip the retainer
down.
3. Place the label roll on the supply mount.
4. Flip the retainer to the upright position and slide it back firmly against the
roll of media.
5. Rotate the media guide down.
6. Insert the label stock through the printer mechanism as shown. Make sure
the label passes between the two forks of the label gap sensor, and that the
front edge of the media passes over the tear off plate and through the label
dispense opening in the front cover.
7. Rotate the media guide up and slide it to the edge of the media.
8. Engage the printhead by rotating the head lift lever counterclockwise to the
DOWN position.
9. Close the right cover and front cover of the printer.
10. Press [FEED] to advance several inches of media through the printer and
out the label opening in the front cover. The printer is now ready for you to
print configuration test labels.
Getting Started
1
If Y ou Have Difficulty Feeding the Media
The 4100 printer uses a label gap sensor to detect whether media is feeding
through the printhead mechanism. If the printer is not sensing the media, try
adjusting the label gap sensor’s position by turning the adjusting knob for the
movable label gap sensor. The sensor gauge behind and below the printhead
can be viewed for making this adjustment. The sensor must be positioned over
the media for the printer to print correctly.
If a label is not detected within 12 inches of feeding, the printer will stop and
the PAPER/RIBBON indicator light will remain lit. In this case, check the
threading of the media through the paper path and through the upper and
lower media guides of the label gap sensor.
If the paper feeds forward only about 2.5 inches each time you press the feed
button and does not seem to be stopping on a label edge, the printer may be
configured for continuous stock instead of interlabel gap stock. Download the
correct label stock configuration command, found in Chapter 7, “Printer
Commands,” then press [FEED].
1-17
4100 Bar Code Label Printer User's Manual
Printing Configuration Test Labels
Once you have loaded the media into the printer you are ready to print
configuration test labels for your printer’s hardware and software
configurations. These configuration tests require you to temporarily change the
DIP switch settings on the back panel of the printer. When you have completed
printing the test labels, be sure to return the DIP switches to their default
settings described on page 1-15.
To print a self-test label
1. Turn the printer power switch OFF.
2. Enable Test and Service Mode by moving Switch 8 on the bottom bank of
DIP switches to the 1 (ON) position.
3. Turn on the power to the printer. The printer will form-feed a few inches of
media. The printer is now in Test and Service mode.
4. To print a hardware configuration label, set all of the switches on the top
bank of DIP switches to the 0 (OFF) position. The settings for a software
configuration label are the same except Switch 7 on the top bank must be set
to the 1 (ON) position.
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1-18
5. To print one configuration test label, set Switch 8 on the bottom bank of DIP
switches to the 0 (OFF) position. To print a batch of 100 configuration test
labels, set Switch 8 to the 1 (ON) position.
6. Press the [ FEED] button to print the configuration test label or labels.
7. To temporarily halt printing, press the [PAUSE] button. To terminate the
test, press the [STOP/CANCEL] button.
Note: Be sure to return all DIP switches to the original settings after you complete the
configuration tests. These switch settings will not take effect until you turn the printer
off and then on again.
What the Configuration Test Labels T ell You
The configuration test labels offer useful information about your 4100 printer’s
configuration. The hardware test label provides statistics on the printer’s
installed memory, the amount of media printed, and on the printhead
configuration. The three software test labels give detailed information on the
printer’s operational settings and capabilities.
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If you are experiencing poor print quality, you may need to adjust the
printhead support. Refer to Chapter 4, “Adjusting the Printhead Support,” if
any of the following items are true:
• The printer is exhibiting signs of ribbon wrinkling.
• The print darkness on the label is inconsistent from top to bottom.
• You are using media less than 3.5 inches wide.
Sample Hardware Configuration Test Label
Hardware Configuration
Memory Installed
Storage RAM
Image RAM
Mileage
Inches Processed
Inches Burned
Labels Cut
: 120 kilobytes
: 286 kilobytes
: 29676
: 20268
: 0
Getting Started
1
Printhead
Width
Dot Size
Burn Pot Setting
Firmware Checksum
ROM0 (U30)
ROM1 (U4)
: 832 dots
: 5.0 mil
: 133
: B535
: E63F
4100.07
1-19
4100 Bar Code Label Printer User's Manual
Sample Software Configuration Test Labels
Program Version : 1.02
Pages Defined : 0
Formats Defined : 0
Fonts Defined : 0, 1, 2, 20, 21, 22, 23, 24
Graphics Defined : none
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INTERMEC 4100 Printer
4100-08
1-20
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Getting Started
1
PRINT SPEED - 3.5 IPS
IMAGE BANDS - 3
MAX LABEL LENGTH - 5 inches
LABEL STOCK - Inter-label gap
MEDIA TYPE - Thermal Transfer
MEDIA LENGTH - 0 inches
CHARACTER SET - US ASCII
EMULATION - Disabled
LABEL RETRACT - Enabled
PARITY - Even
RIBBON SAVE - Disabled
SELF-STRIP - Disabled
CUTTER - Disabled
DARK ADJUST - 0
FORMS ADJUST - 0
SENSITIVITY - 420
BAUD RATE - 9600
DATA BITS - 7
MESSAGE LENGTH - 255
STOP BITS - 1
PROTOCOL - Standard
DEVICE ADDRESS - A
INTERNAL OPTIONS - none
EXTERNAL OPTIONS - none
4100-09
1-21
4100 Bar Code Label Printer User's Manual
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1-22
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Installing the Printer
2
2
Installing the Printer
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4100 Bar Code Label Printer User's Manual
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2-2
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About Printer Installation
The Intermec 4100 bar code printer operates in a wide range of environments
and can be configured to match most data collection systems. You can connect
your printer directly to a host computer or integrate it into a large data
collection network by connecting to the host through a port concentrator or
controller. The printer can run in a point-to-point or in a multi-drop network
configuration, or from a remote location through a dedicated modem.
This chapter shows how to connect the printer to a host through the printer’s
serial port. The serial port is wired as a data terminal equipment (DTE) device.
The printer’s default communications parameters are suitable for most serial
point-to-point installations, but can easily be changed if they are not the correct
parameters for your system. Instructions for changing these parameters are
included in this chapter.
These installation procedures contain the following information:
• Setting up the printer
• Connecting the printer to the host
• Configuring the serial port
Installing the Printer
2
• Determining the appropriate configuration
• Selecting appropriate cables
Preparing for Installation
Before you connect the 4100 printer to your system, you need to follow the
steps below to set up your printer. Be sure to print a configuration test label by
following the instructions in Chapter 1, “Getting Started.”
2-3
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4100 Bar Code Label Printer User's Manual
Situating the Printer
The printer has these physical requirements:
• A location within 5 feet (1.5 m) of an electrical source
• A level, sturdy operating area
• Easy access to the power switch and the rear panel
• Make sure the printer is located away from potential hazards, such as water
or other liquids
Connecting the Printer to the Host
You are now ready to connect your printer to the host computer. The proper
way to connect the printer depends on the way your system is configured. This
section contains procedures for point-to-point and nonswitched modem
installations. References are provided for network installations.
2-4
Default (Point-to-Point) Installation
The printer’s serial port default settings, shown in the table below, are suitable
for connecting the serial port on the 4100 printer to most host computers. If
these settings are compatible with your system, use the procedure following the
table to connect the printer to the host computer.
Serial portDefault setting
Baud rate9600
Data bits7
ParityEven
Stop bits1
ProtocolStandard
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To use this procedure to install your system, you need a serial cable with an
RS-232C or RS-422/485 interface, a 25-pin D-style subminiature connector on
one end, and the appropriate host connector on the other end. If you are
unsure about which cable to use, see “Connecting the Printer to a Network”
later in this chapter.
To install the printer
1. Plug the 25-pin plug into the serial port on the rear panel of the 4100 printer.
2. Plug the other end of the cable into a serial port on the host computer. Your
printer is now installed.
3. If necessary, change the printer configuration to match the host. See
“Configuring the Serial Port” later in this chapter.
Typical Point-to-Point Installation
Installing the Printer
2
PAUSE
Intermec
PAP
A Litton Company
FEED
RIB
PO
STOP/
4100
CANCEL
DARKER
TRANS
Printer
PC
4100-06
About Network Installations
If you are installing your printer in a network environment, you may need to
change the serial port settings to match the requirements of your network.
You can determine the communications requirements for your network by
referring to the controlling device documentation. If the controlling device is
an Intermec product, refer to the following manuals for instructions and
information on the necessary cabling and connections.
2-5
4100 Bar Code Label Printer User's Manual
• 9154 Multi-Drop Line Controller System Manual (Intermec Part No. 048517)
• 9161B Installation Manual (Intermec Part No. 049572)
• 9180 Network Controller User’s Manual (Intermec Part No. 054292)
• RF System User’s Manual (Intermec Part No. 053574)
• Data Communications Reference Manual (Intermec Part No. 044737)
If you need to change the printer’s communications parameters, follow the
procedures in “Configuring the Serial Port” later in this chapter.
Typical Network Installation
PAUSE
Intermec
PAP
A Litton Company
FEED
RIB
PO
S
T
4100
O
C
P
DARKER
/
A
N
C
E
L
T
R
A
N
S
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PAUSE
Intermec
PAP
A Litton Company
FEED
RIB
PO
S
T
4100
O
C
P
DARKER
/
A
N
C
E
L
T
R
A
N
S
2-6
Host Computer
PAUSE
IntermecIntermec
PAP
A Litton Company
FEED
RIB
PO
S
TO
4100
C
P
DARKER
/
A
N
C
E
L
TR
A
N
PAUSE
Intermec
PAP
A Litton Company
FEED
RIB
PO
S
T
4100
O
C
P
DARKER
/
A
N
C
E
L
T
R
A
N
S
S
Controller
PAUSE
IntermecIntermec
PAP
A Litton Company
FEED
RIB
PO
S
T
4100
O
C
P
DARKER
/
A
N
C
E
L
T
R
A
N
PAUSE
Intermec
PAP
A Litton Company
FEED
RIB
PO
S
T
4100
O
C
P
DARKER
/
A
N
C
E
L
T
R
A
N
S
Printers (End Devices)
Printers (End Devices)
S
4100-07
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Modem Installation Procedure
Modems allow the printer to communicate with the host computer from a
remote location not accessible with remote cabling. You must use an
asynchronous, dedicated (nonswitched or manually switched), full duplex
modem. Communications requirements should be described in the modem
documentation.
To connect the printer to a host with a modem
1. Connect the printer serial port to a modem using a 25-pin to 25-pin RS-232
modem cable assembly (Intermec Part No. 043237S).
2. Connect a second modem to the host computer using an appropriate cable
assembly for the host and modem.
3. Connect the two modems together using an acoustic coupler or a direct
connection to telephone communication lines.
4. If necessary, change the printer’s serial port configuration by following the
instructions in “Configuring the Serial Port” later in this chapter.
Typical Modem Installation
Installing the Printer
2
Host Computer
ModemModem
P
A
U
S
E
IntermecIntermec
P
A Litton Company
A
P
FE
R
IB
ED
PO
STOP/
4100
CANCEL
DARKER
TRANS
Printer
4100-08
2-7
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4100 Bar Code Label Printer User's Manual
Configuring the Serial Port
The 4100 printer’s serial port settings should match those of your host
computer or network controlling device. If you need to change the default
settings, refer to the following tables. Use a small screwdriver or other
suitable tool to move the DIP switches to the desired settings. The switches
should click securely into the 1 (ON) or 0 (OFF) positions. The printer must
then be turned off and on for the new switch settings to take effect.
Serial Port Settings
The following table summarizes your choices for the printer serial port
settings.
ParameterSettingsDescription
Baud Rate110, 300, 600 , 1200, 2400, 4800,
9600, 19200
Data Bits7 or 8The number of bits that represent the ASCII characters.
ParityOdd, Even, NoneChecks each transmitted character for errors.
Stop Bits1 or 2B its that follow each character to sy nchronize chara cter
ProtocolStandard, XON/XOFF,
Multi-Drop, Polling Mode D
Device AddressA to Z, 0 to 5Unique address for each device connecte d with
Test and ServiceEnabled or DisabledProvides printer diagnostics to the host and prints test
Self-StripEnabled or DisabledPeels the media backing away from labels one at a time
The rate, in bits per second, at which the host exchanges
data with the printer.
transmission.
The type of network used to connect the printer, the host,
and the rest of the data collection system.
Multi-Drop protocol.
labels.
for on-demand printing.
2-8
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O = OFF
1 = ON
Baud Rate Selection
19,200
9,600
4,800
2,400
1,200
600
300
110
Parity Selection
Even
Odd
None
None
Stop Bits
Data Bits
Self-Strip
Disabled
Enabled
Installing the Printer
DIP Switch Settings
The following table lists all possible settings for the top bank of DIP switches.
Note: DIP switch position 1 = ON, and DIP switch position 0 = OFF.
Top Bank Switch Number
OFF
ON
1 2 3 4 5 6 7 8
O
O
O
1
O
O
O
1
O
1
1
O
O
O
1
1
O
1
O
1
1
1
1
1
O
O
1
O
O
1
1
1
1
2
7
8
O
1
O
1
O = OFF
1 = ON
Communication Protocol
Multi-Drop Address Selection
O
1
Test and Service Modes
Standard
XON/XOFF
Polling Mode D
Multi-Drop
Disabled
Enabled
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
0
1
2
3
4
5
Bottom Bank Switch Number
OFF
ON
1 2 3 4 5 6 7 8
O
1
O
1
I
2
O
O
1
1
O
O
O
1
O
O
1
1
1
O
O
1
O
O
1
1
1
O
O
1
O
O
1
1
1
O
O
1
O
O
1
1
1
O
O
1
O
O
1
1
1
O
O
1
O
O
1
1
1
O
O
1
O
O
1
1
1
O
O
1
O
O
1
1
1
O
O
O
O
O
O
O
O
O
O
O
O
O
1
O
O
1
O
O
1
O
O
1
1
O
O
1
O
O
1
O
O
1
O
O
1
O
1
1
O
1
1
O
1
1
O
1
O
1
O
O
1
O
O
1
O
O
1
O
O
1
1
O
1
1
O
1
1
O
1
1
1
1
O
1
1
O
1
1
O
1
1
O
1
1
1
1
1
1
1
1
1
1
1
1
O
1
4100-45
2-9
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4100 Bar Code Label Printer User's Manual
Connecting the Printer to a Network
Refer to the following information on interfaces and protocols if you are
integrating your 4100 printer into a data collection network.
Host Requirements
Hardware and software requirements for operating the 4100 printer as follows:
• The host computer must use the American Standard Code for Information
Exchange (ASCII) for data communications.
• A serial port must be available on the host if you are connecting directly to
the printer.
• The host must support at least one of the following data communication
interfaces: RS-232C, RS-422, or RS-485.
For information about configuring the host computer, port concentrator, or
network controller, see the reference manual for the controlling device.
2-10
Communication Boundaries
The information below applies to all the printer’s supported protocols.
ParameterMaximum capacity
Message delay9999 milliseconds
Character delay9999 milliseconds
Message block size255 characters (including STX and ETX
characters)
Device address number (Multi-Drop)A to Z, 0 to 5
Communication Protocols
The 4100 printer supports the flow control and block transfer protocols
described below. All of these protocols are point-to-point except Multi-Drop.
Application programs and/or ROM BIOS determine which protocols your
computer can support. For more detailed information refer to the Intermec
Data Communications Reference Manual, Part No. 044737.
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Installing the Printer
2
Intermec “Standard” Protocol
Intermec “Standard” protocol is a proprietary block transfer/status response
protocol. With the exception of single character status commands such as
<ENQ> and <VT>, data is transmitted in message blocks beginning with the
start of text (<STX>) character and ending with the end of text (<ETX>)
character. Message blocks can be up to 255 characters, including the start of text
and the end of text characters.
The printer returns its highest priority status when it receives a valid block
(<STX>data<ETX>) or when it receives the status request command <ENQ>.
When the printer receives the status dump command (<VT>), the printer
returns all active status. The printer status response time ranges from 30 to
100 ms, depending on the complexity of the received message block. In the case
of a transmission error, the printer responds with a <NAK> and discards the
entire message block. Printer status conditions in descending order of priority,
status response characters, and pin 11/20 states are shown in this table:
Printer statusCharacterPin 11/20
Buffer already fullGSBusy
Ribbon faultUSBusy
No label stockEMBusy
Buffer now fullDC3Busy
Printhead hotSIBusy
Offline (paused)DC3Busy
Label at strip pinFSReady
Label skippingDC1Ready
PrintingDC1Ready
Ready/OnlineDC1Ready
When the printer returns Buffer now full (<DC3>) status, the currently received
message block is accepted. At this time, the printer can accept short messages
to allow parsing of immediate commands such as Reset (<DLE>) or Cancel
batch printing (<EM>). However, if the printer responds with a <GS> to any
message block, it means that the buffer is already full and the entire message
block has been discarded.
2-11
4100 Bar Code Label Printer User's Manual
Polling Mode D Protocol
Polling Mode D is a proprietary Intermec block transfer protocol that transmits
data in blocks of up to 255 characters, including protocol overhead. The blocks
are framed with LRC characters for additional data integrity. Use Polling
Mode D for point-to-point networks that connect the 4100 to an Intermec port
concentrator (RS-232C or RS-422).
Multi-Drop Protocol
Multi-Drop is a network protocol that allows you to connect up to 32 devices to
an Intermec controller on a four-wire RS-485 (two twisted pair) interface. This
protocol is similar to Polling Mode D except each device has a unique address
(POL and SEL characters). You must use RS-485, which is automatically
enabled when you enable Multi-Drop. Be sure to specify a unique address for
the printer and verify that the baud rate is between 2,400 and 19,200.
XON/XOFF Protocol (Software and Hardware / Flow Control)
XON/XOFF protocol stops the host from sending data when the printer buffer
fills up and starts the host again when the buffer empties. When you select the
XON/XOFF protocol, you concurrently enable software and hardware flow
control. Software flow control uses the ASCII characters <DC1> (XON) and
<DC3> (XOFF) to start and stop the flow of data from the host to the printer.
Hardware flow control uses pin 11 or pin 20 (internally connected together) on
the printers serial port to indicate “Ready” or “Busy” for data flow control.
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2-12
Note: Do not confuse the <DC1> and <DC3> with the Standard protocol ready
<DC1> and buffer full <DC3> status characters.
The message length for the XON/XOFF protocol is unrestricted. The printer
processes information as it is downloaded and stops when there is no more
information. Use and <STX> and an <ETX> when you want to add comment
lines to your command file. The printer ignores comments between an <ETX>
and an <STX>. This comment feature is similar to using comment lines when
programming in computer languages. Use it to document commands sent to
the printer.
Pin 11/20 reports “Ready” and a <DC1> (XON) is transmitted when the printer
finishes reloading at power up. Pin 11/20 reports “Busy” when the printers
input buffer fills with 768 bytes of data. If the host ignores pin 11/20 and
continues to transmit data, the printer transmits a <DC3> (XOFF) after
receiving 15 additional characters. The printer continues to transmit a <DC3>
after every 15 characters received if the host continues to transmit data. Data
integrity is not guaranteed if this happens.
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Installing the Printer
Pin 11/20 becomes “Ready” when the printer finishes transferring all the data
from the input buffer. If a <DC3> is sent, the printer transmits a <DC1> (XON)
and the host resumes transmission. When you switch the printer to Offline, pin
11/20 becomes “Busy” and a <DC3> is transmitted. When you switch the
printer to Online and the input buffer is empty, pin 11/20 becomes “Ready” and
a <DC1> is transmitted. The following table describes the states of printer
XON/XOFF operation:
Note: If the printer is already in an XOFF condition, switching to Offline or Online has
no effect.
# of Bytes ReceivedOnline/OfflinePin 11/20Transmit
Do not careOfflineBusy<DC3>
768OfflineBusy
768 + each 15 thereafterOnlineBusy<DC3>
Buffer emptyOnlineReady<DC1> (if DC3 was
sent)
2
Ready/Busy Protocol
Ready/Busy protocol uses hardware flow control on pin 11 or pin 20 to indicate
the printer mechanical status and the printer input buffer input buffer status. To
control data flow, pin 20 is the industry standard, however pin 11 is included in
Intermec products for backward compatibility. The printer reports “Busy” on
pin 11 and pin 20 when you switch to Offline, and “Ready” when you switch
Online assuming the buffer is not full. Pressing the [PAUSE] button on the 4100
printer toggles the printer Online (LED off) and Offline (LED on).
Enable this option by setting the communication protocol to Ready/Busy.
Hardware flow control does not work with multi-drop or modem connections.
User-Defined Protocol
The 4100 printer allows you to change protocol characters. However, unlike the
Intermec 86XX series printer, the 4100 does not allow you to define your own
protocol. Instead, you may substitute new characters to be used as protocol
characters, but the rules for the protocol chosen do not change. There is one
table of user-definable protocol characters that, when changed, is used by all
protocols. Refer to the following table for the user-definable characters and the
protocols they affect.
Note: Any status response character that is replaced by the NUL character will not be
sent back to the host.
2-13
4100 Bar Code Label Printer User's Manual
Communication Interfaces
CharacterProtocol Affected
SELECT INPolling Mode DMulti-Drop
POLL INPolling Mode DMulti-Drop
RES INPolling Mode DMulti-Drop
REQ INPolling Mode DMulti-Drop
SOM INStandardPolling Mode DMulti-DropXON/X OFF
EOM INStandardPolling Mode DMulti-DropXON /XO FF
AFF INPolling Mode DMulti-Drop
NEG INPolling Mode DM ulti-Drop
DLE INStandardPolling Mode DMulti-DropXON/X OFF
XON INXON/XOFF
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Code 39 18 pt
XOFF INXON/XOFF
SELECT OUTMulti-Drop
POLL OUTMulti-Drop
RES OUTPolling Mode DMulti-Drop
REQ OUTPolling Mode DMulti-Drop
SO M OU TPolli ng M ode DMult i- Dro p
EOM OUTPolling Mode DMulti-Drop
AFF OUTPolling Mode DMulti-Drop
NEG OUTStandardPolling Mode DMulti-Drop
DLE OUTStandardPolling Mode DMulti-DropXON/XOFF
XON OUTXON/XOFF
XOFF OUTPolling Mode DMulti-DropXON/XOFF
PROTO- CM D 1Standar dXON /X OFF
PROTO- CM D 2Standar dXON /X OFF
TIMEOUT ON EOMPolling Mode DMulti-Drop
2-14
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Installing the Printer
The 4100 printer supports serial communications with the following Electronics
Industries Association (EIA) interfaces:
• RS-232C
• RS-422
• RS-485
These interfaces are described below. You may also find more detailed
information in the Data Communications Reference Manual (Intermec Part No.
044737). The table that follows these interface descriptions lists the appropriate
pin assignments for each interface.
2
RS-232C Serial Interface
The RS-232C serial interface is used in all asynchronous point-to-point full or
half-duplex direct data communications or modem control. The cable
connected to the printer must have the pin assignments listed in the table to
operate properly under RS-232C.
Pin 20
Pin 20 of the RS-232C interface is the primary pin used by the 4100 printer to
indicate its status when standard protocol is selected. Pin 20 is high when the
printer status is ready. Pin 20 is low when the printer is in one of these
conditions:
• Buffer full
• Ribbon fault
• No label stock
• Label at strip pin
• Offline
In XON/XOFF or hardware flow control, pin 20 and pin 11 indicate the printer
mechanical status and the status of the printer input buffer. They are high
when there is room in the buffer and low if the buffer is full or the printer is
offline.
Pin 11
Pin 11 of the RS-232C interface is used by the 4100 printer to indicate its status.
In Intermec Standard protocol, pin 11 still used for backward compatibility to
the 86XX product line. It is high when the printer status is ready. Pin 11 is low
during the same conditions as when pin 20 is low.
2-15
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4100 Bar Code Label Printer User's Manual
RS-485 Serial Interface
The RS-485 serial interface is used for multi-drop installations only. The cable
connected to the printer must have the pin assignments listed in the table to
operate properly under RS-485.
Interf acePi n No.Na m eOper ati on
RS-232/422/4851Chassis Ground
(GND)
RS-2322Transmit Data (TD)Output: Connect to receive data pin of connected
RS-2323R eceiv e Data (RD )Input: Connect to transmit data pin of connected
RS-232/422/4854Request to Send
(RTS)
RS-232/422/4855Clear to Send (CTS)Input: When a modem is used, connect to modem
RS-232/422/4857Signal GroundTo enable communications, connect to signal ground
RS-232/422/4851 1Printer Status (PS)Output: When not using software flow control
RS-422/48513Input BInput: Serial differential dat a to t he prin ter .
Connect to pin 1, chassis ground, of connected device.
device.
device.
Output: When a modem is u sed, co nnected t o
modem RT S pin. RT S is s et t o tr ue befor e
transmission. The printer sets RTS to false after
transmission.
CTS p in. Mo d em m u st s et C TS true before t he p rinter
transmits data. If not connected, CTS sets itself true.
of connected device. Completes circuit for all RS-232
signals.
(XON/XOFF), connect t o input of connected devi ce
(CTS) . I ndi c at es pr in t er m ec h anical st at u s an d s t at us
of pri nt er in put b uffe r.
RS-422/4851 4Output AOutput: Serial differential d ata fr om t he pri n ter .
RS-422/48516Input AInput: Serial differential data to the pr int er.
RS-422/4851 9Output BOutput: Serial differential d ata fro m t he pri nt er .
RS-232/422/4852 0Data Terminal R eady
(DTR)
2-16
Output: When a modem is u sed, co nnect to modem
DSR pin. Indicates the printer is switched on. When
using XON/XOFF or hardware flow co ntrol, this pin
indicates the printer mechanical status and the status
of pri nt er in put b uffe r.
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RS-422 Serial Interface
The RS-422 interface is used in long line point-to-point direct connect
installations. The cable connected to the printer must have the pin assignments
listed in the table to operate properly under RS-422.
Printer Serial Port
The serial port connection is on the printer rear panel. It is a 25-pin
D-style subminiature receptacle. The port is wired as a data terminal
equipment (DTE) device. Refer to the following illustration for the serial port
pin assignments.
Printer RS-232/422/485 Serial Port
DTR
Installing the Printer
25
13
24
12
23
11
22
10
21
9
20
8
19
7
18
6
17
5
16
4
15
3
14
2
1
PS
SG
CTS
RTS
RD
TD
2
GND
Choosing the Correct Cable
Your 4100 printer has many different cabling options available. Your choice of
cabling depends on the network configuration, hardware interface, protocol
used, cabling distance, and the electrical and environmental operating
conditions of your printer. For typical installations, Intermec recommends the
following:
• Shielded cable, minimum 24 gauge
• 25-pin D-style subminiature connector with metal backshell
• Cable shield connected to metal backshell
• EIA RS-232, RS-422, or RS-485 electrical interface
4100-09
2-17
4100 Bar Code Label Printer User's Manual
Intermec Cables
Intermec offers a full line of interface cables. These cables are not included with
the printer and must be ordered separately. Contact your Intermec
representative for ordering assistance.
For connecting the 4100 printer to an IBM PC AT or compatible, use this
Intermec cable: Intermec Part No. 048693.
For connecting the 4100 to an IBM PC XT or compatible, use this Intermec
cable: Intermec Part No. 048668.
Cable Schematics
If you are making your own cables, the following diagrams show cable
schematics for some of the more commonly used cables.
RS-232 Null Modem Cable for PC
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Code 39 18 pt
25-PIN (SOCKET) D-SUB
METAL BACKSHELL
CHASSIS GROUND
TRANSMITTED DATA
RECEIVED DATA
REQUEST TO SEND
CLEAR TO SEND
DATA SET READY
DATA TERMINAL READY
CARRIER DETECT
2-18
GROUND
SHIELD
1
2
3
4
5
6
7
20
8
PC
NOTE: The metal backshell is connected directly
to the shield to achieve electrostatic discharge
(ESD) immunity.
1
3
2
8
20
7
6
4
5
PRINTER
25-PIN (PLUG) D-SUB
METAL BACKSHELL
CHASSIS GROUND
RECEIVED DATA
TRANSMITTED DATA
CARRIER DETECT
DATA TERMINAL READY
GROUND
DATA SET READY
CLEAR TO SEND
4100-12
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Code 39 18 pt
RS-232 Null Modem Cable for AT
9-PIN (SOCKET) D-SUB
METAL BACKSHELL
RECEIVED DATA
TRANSMITTED DATA
CLEAR TO SEND
REQUEST TO SEND
DATA TERMINAL READY
DATA SET READY
CARRIER DETECT
GROUND
2
3
8
7
4
6
1
5
AT
NOTE: The metal backshell is connected directly
to the shield to achieve electrostatic discharge
(ESD) immunity.
SHIELD
Installing the Printer
25-PIN (PLUG) D-SUB
METAL BACKSHELL
CHASSIS GROUND
1
TRANSMITTED DATA
2
RECEIVED DATA
3
CARRIER DETECT
8
DATA SET READY
6
DATA TERMINAL READY
20
CLEAR TO SEND
5
REQUEST TO SEND
4
GROUND
7
PRINTER
2
4100-11
RS-422 Software Flow Control Null Modem Cable for AT
SHIELD
25-PIN (PLUG) D-SUB
METAL BACKSHELL
CHASSIS GROUND
RECEIVED DATA
TRANSMITTED DATA
1
+
13
-
16
+
14
-
19
PRINTERHOST
NOTE: The metal backshell is connected directly
to the shield to achieve electrostatic discharge
(ESD) immunity.
➤
➤
➤
➤
25-PIN (PLUG) D-SUB
METAL BACKSHELL
1
CHASSIS GROUND
+
13
-
+
-
TRANSMITTED DATA
16
14
RECEIVED DATA
19
4100-14
2-19
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Code 39 18 pt
4100 Bar Code Label Printer User's Manual
Straight Through DTE to DCE Cable for Use With a Modem
SHIELD
Input RxDB
Input RxDA
Output TxDA
Output TxDB
RS-485 (Multi-Drop) Cables
Refer to the following manuals for information on multi-drop cabling and
connections.
• 9154 Multi-Drop Line Controller System Manual Part No. 048517
• 9161B Installation Manual Part No. 049572
1
+
13
-
16
-
14
+
19
PRINTERHOST
➤
➤
➤
➤
1
19
14
16
13
NOTE: Connect pin 1 to shield
at one end only.
4100-15
Cabling Considerations in Noisy Electrical
Environments
The items listed below create noisy electrical environments that can disrupt
data communications between your host computer and the 4100 printer:
• Large power transformers
• Large electrical motors
• Arc welders
• Motor controllers
• Switch gears
2-20
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Code 39 18 pt
Installing the Printer
If any of these items are near the printer, you can reduce the effects of their
electrical noise by following these directions:
• Always use shielded cable. Connect the cable and shield to the metal
backshells on the cable connectors and fasten the connectors to the serial
ports using screws.
• Install ferrite cable clamps.
• Connect the printer chassis ground to the building ground. The chassis
ground is on the ground pin of the printer power cord.
Some experimentation may be required to eliminate the problems. If you need
help, ask your Intermec representative for assistance.
2
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4100 Bar Code Label Printer User's Manual
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Code 39 18 pt
2-22
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Code 39 18 pt
Operating the Printer
3
3
Operating the Printer
3-1
4100 Bar Code Label Printer User's Manual
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3-2
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Code 39 18 pt
About Printer Operation
Your 4100 printer comes with a variety of features and many choices for
configuring and programming it. However, normal operation is quite
straightforward.
This chapter describes the procedures that you use in the normal operation of
your printer:
• Opening and closing the printer
• Loading various types of media
• Changing the thermal transfer ribbon
• Using the front control panel
• Adjusting the label gap sensor
• Printing the printer’s buffer contents to clear the memory
Note: If you are not familiar with the components that make up the printer, refer to the
illustrations and descriptions in Chapter 1, “Getting Started.”
Operating the Printer
3
Opening and Closing the Printer
To replace media, clear paper jams, or maintain the printer, you must open the
front and side covers of the printer. The front cover is held shut by two
magnets. The side cover is held closed by its own weight, and has a clear
plastic window that allows you to see how much media is loaded and how the
printer is operating.
3-3
4100 Bar Code Label Printer User's Manual
Opening the Printer
You need to open the printer when you load media or perform most other
maintenance procedures.
To open the printer
1. Facing the front of the printer, grasp the right side of the front cover and
pull it toward you to release the cover from its magnetic latches.
2. Grasp the bottom center of the right side cover and pull it upward. The
hinged right cover should come to rest on the top of the printer.
Closing the Printer
To close the printer after loading media or performing printer maintenance
1. Grasp the topmost part of the side cover and gently rotate it down until it
rests against the printer.
Helvitica condensed 9 pt italic
Code 39 18 pt
2. Swing the front cover to the closed position until the magnetic latches
securely hold the cover.
Using the Front Control Panel
The front control panel of the 4100
printer, illustrated at right, contains
three buttons and three indicator
lights that you use in the normal
operation of the printer. The table on
the next page describes the control
panel components.
PAUSE
FEED
STOP/
CANCEL
DARKER
PAPER/
RIBBON
POWER
TRANSFER ON
4100-01b
3-4
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Code 39 18 pt
ComponentDescription
Power On IndicatorIlluminates when the power switch on the rear panel is turned on.
Feed ButtonAdvances the media to the first position on the next label or to the tear-off plate.
Holding this button down continuously advances the media.
Stop/Cancel ButtonCancels the current print job. The printer continues to process subsequent
downloaded commands.
Pause ButtonTemporarily stops printing and host communications. Holds all data in memory
until the button is pressed a second time to resume printing.
Pause IndicatorIlluminates when the pause button is pressed. Flashes when data is
downloading to the printer.
Paper/Ribbon IndicatorIlluminates when the printer is out of paper or ribbon.
Darkness Control
Adjustment
(Potentiometer)
Transfer On SwitchSwitch to off for direct thermal printing, or to on for thermal transfer printing.
Adjusts the resistance in a new printhead to print the same level of darkness as
the previous printhead. Do not use this to adjust the darkness of individual
labels or or print jobs. Instead, use the downloaded darkness command
described in Chapter 7.
Operating the Printer
3
Loading Media Into the Printer
The procedures on the next few pages explain how to load media (label stock)
into the printer. The 4100 printer is capable of four different types of printing,
and each type requires a different method of loading media. The four types of
printing are:
• Straight-through printing
• Batch take-up printing
• Self-strip printing
• Fanfold printing
When you load media, you can turn the power to the printer either on or off.
The following procedures for loading media assume the printer is turned on.
Note: If you are using media that is 3.5 inches or less in width, you will need to adjust
the printhead support to ensure optimum print quality. Refer to Chapter 4, “Routine
Maintenance,” for instructions.
3-5
4100 Bar Code Label Printer User's Manual
Note: The 4100 printer is adjusted at the factory using 4 mil thick label stock. When
using heavier tag stock, the printhead may need to be adjusted. Refer to Chapter 4,
”Routine Maintenance,“ for these procedures.
Tools required: Phillips screwdriver
Straight-Through Printing
In straight-through printing, a roll of media is loaded on the supply roll and is
fed straight through the printer mechanism and out the label dispense opening
in the front panel. As individual labels are printed, you can remove them from
the roll by pulling them down across the tear-off plate. If you are using the
optional media cutter and tray, this device automatically cuts the printed labels
off the roll and stacks them in the tray.
To load media for straight-through printing
1. Disengage the printhead by rotating the head lift lever clockwise to the UP
position.
Helvitica condensed 9 pt italic
Code 39 18 pt
2. Slide the retainer to the outer end of the supply mount and flip it down.
3. Remove the old label roll and place the new label roll on the supply mount.
4. Flip the retainer to the upright position and slide the retainer firmly back
against the roll of media.
5. Rotate the media guide down.
6. Insert the label stock through the printer mechanism as shown. Make sure
the label passes between the two forks of the label gap sensor, and that the
front edge of the label passes over the tear-off plate and through the label
dispense opening in the front cover.
7. Rotate the media guide up and slide it to the edge of the media.
8. Engage the printhead by rotating the head lift lever counterclockwise to the
down position and close the printer covers.
9. Press [FEED] to advance several inches of media through the printer and
out the label opening in the front cover. The printer is now ready for
printing.
3-6
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Code 39 18 pt
Loading Media Into the Printer for Straight-Through Printing
1
8
7
5
Operating the Printer
2
3
4
3
4100-05/16
Label Gap Sensor
6
3-7
4100 Bar Code Label Printer User's Manual
Self-Strip Printing
In self-strip printing, the printer presents each label after it is printed with the
backing removed so it may be applied immediately. The backing is collected
on the rewinder hub after passing over the bottom assist roller. The rewinder
hub can hold the backing for an entire roll of media.
Follow the procedures below to prepare the printer for self-strip printing.
Tools required: Phillips screwdriver.
Note: You must have the Present Sensor option installed to print in Self-Strip mode.
The Present Sensor detects when a label has been removed and automatically advances
the next one through the label dispense opening.
Repositioning the Tear-Off Plate Before Printing
Helvitica condensed 9 pt italic
Code 39 18 pt
1. Remove the tear-off plate by
unfastening the two screws that
secure the plate to the printer.
3-8
2. Flip the tear-off plate upside
down so that its serrated edge is
on the bottom with the teeth
facing the printer. Reattach the
tear-off plate to the printer using
the two screws.
4100-17a
Loading the Media
With the tear-off plate reinstalled, you are ready to load the media for self-strip
printing.
The first six steps of this procedure are shown in the illustration for straightthrough printing earlier in this section. Steps 7 through 9 are shown in the
illustration that accompanies this procedure.
1. Disengage the printhead by rotating the head lift lever clockwise to the UP
position.
Helvitica condensed 9 pt italic
Code 39 18 pt
Loading Media Into the Printer for Self-Strip Printing
Operating the Printer
2. Slide the retainer to the outer end
of the supply mount and flip it
down.
3. Place the label roll on the supply
mount.
4. Flip the retainer to the upright
position and slide the retainer
firmly back against the roll of
media.
5. Rotate the media guide down.
6. Insert the label stock through the
printer mechanism as shown in
the illustration. Make sure the
front edge of the media passes
through the label gap sensor
(illustrated on page 3-7) and over
the top of the drive roller.
3
7. Pull the leading edge of the media
down over the tear-off plate and
beneath the bottom assist roller.
8. Remove the clasp from the media
rewinder hub.
8/9
7
4100-17b
9. Wind a few inches of media
counterclockwise onto the media
rewinder hub, and then secure the
media to the rewinder with the
clasp.
10. Rotate the media guide up and
slide it to the edge of the media.
11. Engage the printhead by rotating
the head lift lever
counterclockwise to the down
position and close the printer
covers.
12. Set Switch 8 on the top bank of
DIP switches to position 1 or on.
3-9
4100 Bar Code Label Printer User's Manual
13. Press [FEED] to advance a label through the printer.
14. Grasp the leading edge of the label where it has separated from the backing
and pull it away from the printer.
Batch Take-Up Printing
Batch take-up printing (also known as label rewinding) allows you to print a
batch of labels without having to remove individual labels from the front of the
printer. As labels are printed, they are routed back inside the printer and
collected on the media rewinder hub. Later, you can remove the roll of printed
labels from the rewinder hub.
The printed labels are collected on the media rewinder hub after passing over
the rewind adapter mounted on the front of the printer beneath the driver
roller. The printer rewinder hub has a maximum capacity of 2,100 inches of
rewound media; it cannot rewind an entire roll of media.
The procedure for loading media for batch take-up printing includes setting up
the rewind adapter. Follow the steps below to prepare the printer for batch
take-up printing.
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Code 39 18 pt
3-10
Tools required: Phillips screwdriver.
Installing the Rewind Adapter Before Printing
Before you can load the media for batch take-up printing, you must install the
rewind adapter that guides the printed labels out of the printer mechanism and
onto the media rewinder hub.
To install the rewind adapter
1. Open the front panel cover of the printer and remove the metal plate below
the label dispense opening in the cover. The metal plate snaps in and out
using two small clamps on the left and right of the plate.
2. If the tear-off plate is installed, unscrew the two screws that fasten it to the
printer and remove the tear-off plate from the printer.
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PAUSE
PAPER/
FEED
RIBBON
POWER
STOP/
CANCEL
DARKER
TRANSFER ON
1
3
4
Operating the Printer
3
3. Open the right side cover and
unscrew the knob that holds the
rewind adapter in place. Remove
the adapter from the printer.
When not in use, store the rewind
adapter below the media supply
hub at the back of the printer
interior.
4. With the front panel cover open,
2
place the rewind adapter where
the tear-off plate was attached.
5. Fasten the adapter to the printer
by turning the center knob
clockwise until the rewind
5
adapter fastens securely to the
printer. Make sure the top edge
of the rewind adapter is parallel
to the drive roller and the head
4100-18a
adjust plate.
Loading the Media
With the rewind adapter in place, you are ready to load the media for batch
take-up printing. The first six steps of this procedure are shown in the
illustration for straight-through printing earlier in this section. Steps 7 to 9 are
shown in the illustration that accompanies this procedure.
1. Disengage the printhead by rotating the head lift lever clockwise to the UP
position.
2. Slide the retainer to the out of end of the supply mount and flip it down.
3. Place the label roll on the supply mount.
4. Flip the retainer to the upright position and slide the retainer firmly back
against the roll of media.
5. Rotate the media guide down.
6. Insert the label stock through the printer mechanism as shown in the
illustration. Make sure the front edge of the media passes through the label
gap sensor and over the top of the drive roller.
3-11
4100 Bar Code Label Printer User's Manual
7
8/9
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Code 39 18 pt
7. Pull the leading edge of the
media down over the rewind
adapter and beneath the bottom
assist roller.
8. Remove the clasp from the media
rewinder hub.
9. Wind a few inches of media
counterclockwise onto the media
rewinder hub, and then secure
the media to the rewinder with
the clasp.
10. Rotate the media guide up and
slide it to the edge of the media.
11. Engage the printhead by rotating
the head lift lever
counterclockwise to the DOWN
position and close the printer
covers.
12. Press [FEED] to advance several
inches of media through the
printer and onto the media
rewinder hub.
3-12
4100-18b
Fanfold Printing
In fanfold printing, a stack of fanfold media is placed outside the back of the
printer and fed into the printer though a gap in the back of the side cover. The
media is fed into the printer mechanism using the same method as for straightthrough printing.
To load fanfold media
1. Disengage the printhead by rotating the head lift lever clockwise to the UP
position.
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Code 39 18 pt
2. Rotate the media guide down.
3. Insert the label stock through the back of the printer into the printer
mechanism, making sure the front edge of the media passes over the tear-off
plate and through the label dispense opening in the front cover.
4. Rotate the media guide up and slide it to the edge of the media.
5. Engage the printhead by rotating the head lift lever counterclockwise to the
DOWN position.
6. Close the printer covers. Make sure the fanfold media can move freely
through the gap in the back of the side cover.
7. Press [FEED] to advance several inches of media through the printer and
out the label opening in the front cover. The printer is now ready for
printing.
Adjusting the Label Gap Sensor
If you are using die cut or tag stock media, you may need to adjust the label
gap sensor. The label gap sensor detects the gap between individual labels of
die cut media, and detects the notch separating tag stock labels. The printer
uses this information to index the labels.
Operating the Printer
3
If the printer is not sensing the media, try adjusting the sensor position by
turning the adjusting knob for the movable label gap sensor. The sensor is
near the end of the two prongs that guide the media through the label gap
sensor. Turning the knob clockwise moves the sensor away from the inside
wall of the printer; turning the knob counterclockwise moves the sensor toward
the inside wall of the printer.
If the media feeds forward only about 2.5 inches each time you press the
[FEED] button, and does not seem to be stopping on a label edge, the printer
may be configured for continuous stock instead of interlabel gap stock.
Download the correct label stock configuration command, found in Chapter 7,
“Printer Commands,” and then press [FEED].
3-13
4100 Bar Code Label Printer User's Manual
Adjusting the Label Gap Sensor for Die Cut Media
For die cut media, the sensor can be positioned anywhere over the label so that
it can detect the label gap. If you are using narrow media, you will need to
adjust the sensor inward, in the direction of the supply roll back stop. To do
this, turn the adjusting knob counterclockwise until the sensor is positioned
over the media.
Adjusting the Label Gap Sensor for Tag Stock
If you are using tag stock, you must use a different procedure for adjusting the
label gap sensor. The printer indexes tag stock using the notches along the
edge of the media that indicate the spaces between the tags.
When you load tag stock, a notched edge of the media roll should face the
supply roll back stop, toward the interior of the printer. For the label gap
sensor to detect the notches, you must position the sensor over the notches on
the inside edge of the media. To do this, turn the label gap adjusting knob
counterclockwise until the sensor is over the notches. Use the notch in the
sensor mechanism to line up the sensor with the notch on the edge of the
media.
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Setting Media Sensitivity
When you load media into the printer, you should check to see that the
sensitivity rating for the media matches the rating set in the printer. The
sensitivity rating consists of three digits, and is printed on each media roll or
box. When you set the sensitivity in the printer to match the rating for your
media, the amount of energy the printhead uses adjusts to a value that is
suitable for your media. This setting improves the print quality and sets the
darkness to an appropriate level.
To check your media sensitivity rating, print out a software configuration label.
The sensitivity setting is one of the configuration settings displayed on the
software configuration label. Refer to Chapter 1, “Getting Started,” for
directions on printing the label.
The default setting of media sensitivity for direct thermal media on the 4100
printer is 420. The default setting for thermal transfer media is 563.
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Setting the Approximate Sensitivity Rating for Your
Media
You only need to enter the first digit to set the approximate rating for your
media. The first digit (in the hundreds place) designates the range of sensitivity
for your media. The second and third digits are used to fine-tune the printhead
energy to improve print quality and label darkness. The approximate
sensitivity ratings are the first numbers listed for each group in the media
sensitivity setting table.
Fine-Tuning the Sensitivity Rating
The sensitivity rating on each roll of thermal transfer media or ribbon has an
asterisk (*) in one of the digits. On thermal transfer media, the rating contains
the first and second digits, with an asterisk in place of the third digit because
this digit is reserved for ribbon. The rating on the ribbon has numbers in either
the first and third digits, with an asterisk in place of the second digit because
this digit is reserved for media.
For example, you may see 56* on the media and 5*3 on the ribbon. In this case,
fine-tuning of the printhead requires that you set the sensitivity rating to 563.
Operating the Printer
3
Set media sensitivity with the configuration command <SI>g. For example,
enter the following command to set the sensitivity number 563:
<SI>g1, 563
Where:
<SI>g1 sets the printer to thermal transfer media.
,563 sets the sensitivity number to 563.
See Chapters 6, “Designing Labels and Using Commands,” and Chapter 7,
“Printer Commands,” for more information on how to use this command.
To set the sensitivity rating for direct thermal media, use the three digit
sensitivity rating located on the roll of media or listed in the following table.
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4100 Bar Code Label Printer User's Manual
The following table provides you with both approximate sensitivity settings
and settings that can be used for fine-tuning:
Duratherm II-2130
Duratherm II Tag160
Duratherm Buff Tag190
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Loading the Thermal Transfer Ribbon
If you are printing in thermal transfer mode, you must install a thermal transfer
ribbon on the ribbon supply hub and collect the used ribbon on the ribbon
rewinder.
To load thermal transfer ribbon
1. Disengage the printhead by
2. Remove the ribbon clasp from the
3. Slide the roll of ribbon onto the
3
6
2
5
4
4. Route the ribbon through the
5. Wind a few inches of ribbon onto
Operating the Printer
rotating the head lift lever
clockwise to the UP position.
ribbon rewinder.
ribbon supply hub so that you can
pull leading edge of the ribbon
counterclockwise off the top of
the roll.
print mechanism as illustrated.
Make sure the ribbon runs
between the two edges of the
black ribbon guide located behind
the printhead. The shiny side of
the ribbon must come in contact
with the printhead. Do not thread
the ribbon between the two forks of
the label gap sensor.
the ribbon rewinder in a
counterclockwise direction.
3
4100-19
6. Slide the ribbon clasp over the
ribbon and onto the rewinder.
7. Engage the printhead by rotating
the head lift lever
counterclockwise to the DOWN
position.
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4100 Bar Code Label Printer User's Manual
Image Band Setting
To print labels as quickly as possible, you must adjust the print speed in
conjunction with the number of image bands, which controls the speed of the
imaging/printing process.
The 4100 printer starts imaging a label as soon as it receives the command that
selects a format. If the Image Band command is too low, the imaging process is
unable to keep up with the print speed, and the printer stops printing and then
starts again at the lowest printing speed. If the Image Band command is set too
high, the printer spends too much time imaging before printing which slows
down label production. Since the 4100 printer begins imaging so early in the
printing process, there is a reduced chance of imaging and print speed
incompatibility. The image before print feature also improves label
throughput.
How the Image Bands Command Works
The Image Band command controls the amount of memory allotted to the
imaging process. When you increase the image band adjustment to a higher
number, you are adding more buffers to the imaging memory, thus giving the
printer more memory (and time) to image the label before it starts printing.
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3-18
The minimum number of required image bands depends on the print speed
and the complexity of the label. More elements in a label require more image
bands. Generally, the presence of the following factors require higher Image
Band settings:
• Different sizes of outline fonts
• Formats with numerous fields
• Formats with numerous graphics
Optimizing the Number of Image Bands
To optimize the number of image bands, set the Image Bands at the lowest
number (2) and then print a label. If the label prints at the set print speed, then
the Image Band setting is correctly optimized.
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If the printer aborts the label before it is through printing and attempts to
reprint at the slowest (2.5 ips) speed, then the image band setting is too low.
Return to the original print speed and increase the original number of image
bands (the printer will have set the number of image bands maximum, which is
ten). Continue to increase the number of image bands until the printer prints a
label correctly at the optimal print speed.
If the printer aborts and reprints at the highest Image Band setting, the image
band is too high. Lower the print speed and then try printing a label with the
minimum number of image bands (2). Gradually increase the number of image
bands until the label prints at the set print speed.
Modified Field Reimaging
If you are updating data in just a few fields, it might be faster to use the
modified field reimaging command. When used correctly, this command can
greatly increase the processing ability of your printer because only the fields
that change or receive new data are reimaged. However, you need to take into
account the number of fields you are thinking of reimaging. If the fields you
choose to reimage take longer to erase and reimage than an entire label format,
you will not increase throughput because erasing a field requires reimaging it
with white space and erasing a label just requires clearing the RAM. The
increase in processing can only be determined by printing a label both with and
without modified feild reimaging enabled, and comparing the results.
Operating the Printer
3
When using the modified field reimaging command, make sure that you select
enough image bands to allow the printer to retain the entire label image. One
image band is equal to one inch. For example, if the printed image stops four
inches from the beginning of the label, you must select four image bands to
prevent reimaging.
To select the fields to reimage, use the following command:
<ESC>E {n}{,m}
where the default for n,m=0,0
If the current page is 0, n is a numeric format ID ranging from 0 to 19.
If a page other than 0 is selected, n is an alphabetic format position within the
page that can be any letter from a to z. An error code is generated if an invalid
format is entered.
If m=0, modified field reimaging is disabled. When m is a non-zero number,
only the fields that receive new data are reimaged.
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4100 Bar Code Label Printer User's Manual
Note: After the format is selected, the field pointer points to the lowest numbered data
entry field. All host entered/variable data is cleared from this format.
Printing Labels
Once you have loaded the media, the 4100 is ready to print labels. Before you
print labels make sure you have:
• Loaded the correct size and type of media into the printer.
• Loaded ribbon into the printer if you will be printing in thermal transfer
mode.
• Lowered the printhead securely into place.
• Switched the Thermal/Thermal Transfer switch to the appropriate setting
for the type of printing you will be doing.
• Set the DIP switches to the appropriate printing configuration.
• Turned on the power to the printer.
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• Connected the printer to the host or to the data collection network.
You are now ready to print labels by downloading data from the host to the
4100 printer. Refer to Chapter 6, “Designing Labels and Using Commands,”
and Chapter 7, “Printer Commands.”
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Routine Maintenance
4
4
Routine Maintenance
4-1
4100 Bar Code Label Printer User's Manual
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4-2
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About Printer Maintenance
For best performance, clean your 4100 printer on a regular basis, especially if
it is exposed to debris. This chapter explains how to maintain the printer and
covers the following topics:
• Inspecting the printer work environment and system connections
• Cleaning each printer component
• Adjusting the printhead support
• Replacing the cutter blade
• Replacing the printer’s fuse
For information on replenishing media or ribbon, clearing jams, and other
online maintenance procedures, see Chapter 3, “Operating the Printer.”
Safety Precautions
Read the following precautions carefully before cleaning or repairing the
printer.
Routine Maintenance
4
WARNING
WARNING
Always turn the power off before doing any maintenance work.
AVERTISSEMENT
Fermez toujours le courant avant de procéder à toute maintenance.
4-3
4100 Bar Code Label Printer User's Manual
Do Not Repair or Adjust Alone
Do not, under any circumstances, repair or adjust energized equipment alone.
The immediate presence of someone capable of rendering aid is essential for
operator safety.
Do Not Repair or Clean With the Power On
Always turn off and unplug any device before cleaning or repairing it.
Accidentally turning on any piece of equipment while cleaning can cause a
serious injury.
First Aid
An injury, no matter how slight, should never be neglected. Always obtain first
aid or medical attention immediately after incurring an injury.
Resuscitation
Persons working on or near high voltage equipment should be familiar with
approved industrial first aid procedures. If someone is injured and stops
breathing, begin resuscitation immediately.
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Energized Equipment
Electrical equipment is dangerous. Never work on energized equipment unless
authorized. Authorized emergency work on energized equipment must be
performed in strict compliance with current safety regulations.
Inspecting the Printer
Inspect the printer and the rest of your data collection system equipment on a
regular basis. Your inspections should include the following steps:
• Make sure the printer is properly grounded.
• Inspect the work environment. Large electric motors, welders, and
switching equipment can affect printer performance. See Chapter 2,
“Installing the Printer,” for guidelines on appropriate environments.
• Keep the printer away from liquids.
• Check the data collection network regularly for loose wires or poorly
installed connections. Be sure to replace corroded wires.
4-4
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Components You Should Maintain
Clean your printer regularly to maintain the quality of your labels and extend
the life of your printer. Refer to the illustration of parts to be maintained to
locate the parts you should clean on the printer. The optional cutter has not
been included in the illustration, however it does need to be cleaned if your
printer has one. Use the following items to clean the printer effectively and
safely:
• Isopropyl alcohol
• Cleaning brush
• Cotton swabs
• Clean lint-free cloth
Parts to Be Maintained
Routine Maintenance
4
Case
PAUSE
PAPER/
FEED
RIBBON
POWER
STOP/
CANCEL
DARKER
TRANSFER ON
Tear-Off Plate
(the drive roller is
located directly behind
the tear-off plate.)
Media Path
Printhead
4100-20
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4100 Bar Code Label Printer User's Manual
Printer ComponentMaintenance Period
Driver roller and tear-off plateClean whenever contaminated by debris.
Media pathClean whenever contaminated by debris.
CaseClean as necessary.
PrintheadClean every 50,000 linear inches of media
CutterClean after every 5,000 to 10,000 labels cut.
Lubrication
All bearings in the 4100 printer are either permanently lubricated or made of
low friction plastic and do not require maintenance lubrication. The three slip
clutches in the printer are prelubricated and should not require further
lubrication. However, if the printer mechanism creates a squeaking or
humming noise, contact your Intermec representative for assistance.
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(approximately eight 6,000-inch rolls) for direct
thermal printing. Clean every 250,000 linear
inches (approximately 41 6,000-inch rolls) for
thermal transfer printing.
Replace after 500,000 cuts per side (total 1
million cuts).
Cleaning the Printer
The following procedures tell you how to access printer components and clean
them without causing any damage.
Note: Before cleaning any components, turn off and unplug the printer.
Cleaning the Drive Roller
If the drive roller becomes contaminated with grit, label adhesive, or ink, your
print quality may deteriorate. Clean the drive roller whenever these conditions
occur.
Do not scrape the rubber drive roller. Scraping will gouge the roller and void
CAUTION
any applicable warranty. Gouged rollers must be replaced to maintain high
quality label printing.
CONSEIL
Ne grattez pas le rouleau caoutchouté. Gratter le rouleau gougera le
caoutchouc et annulera toute garantie applicable. Vous devez remplacer les
rouleaux gougés pour maintenir une haute qualité d’imprimante d’étiquettes.
To clean the drive roller
1. Remove the tear-off plate from the front of the printer.
2. Rotate the printhead lift lever clockwise to the UP position.
3. Wipe any accumulated debris off the roller using a clean cloth or cotton
swabs and alcohol. Rotate the roller to clean all areas.
4. Wipe any debris from the tear-off plate before reinstalling it.
Routine Maintenance
4
Cleaning the Media Path
During normal operation of the 4100 printer, media debris may accumulate
around the printer mechanism and along the media path. This debris should
be cleaned away regularly using a soft bristle brush or vacuum cleaner.
Remove all traces of dust, paper, and adhesive. Clean the flat services of the
media path with a lint-free cloth and isopropyl alcohol.
Cleaning the Printer Case
The 4100 printer case may be cleaned with a general purpose cleaner. Do not
use abrasive cleansers or solvents. Be sure to clean the transparent panel on the
right side of the printer so that the media supply inside is visible when the
cover is closed.
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4100 Bar Code Label Printer User's Manual
Cleaning the Printhead
Cleaning media debris from the printhead maintains close contact between the
media and printhead, which provides good print quality. When using direct
thermal media, you should clean the printhead after every 50,000 linear inches
(approximately eight 6,000-inch rolls). When using thermal transfer media, the
printhead should be cleaned after every 250,000 linear inches (approximately 41
6,000-inch rolls).
CAUTION
Do not use sharp objects such as knives or screwdrivers to scrape the printhead
CAUTION
clean. Cleaning with sharp objects will damage the printhead. Clean with
only a cotton swab, or a clean, lint-free cloth or tissue damp with isopropyl
alcohol.
CONSEIL
N’utilisez pas d’objets pointus tels que couteaux ou tournevis pour nettoyer la
tête d’imprimante. Nettoyer avec des objets pointus endommagera la tête
d’imprimante. Nettoyez-la seulement avec de la ouate ou avec un linge propre
et libre de peluches, humecté avec de l’alcool d’isopropyl.
1. Open the front panel cover and the right side cover.
2. Rotate the printhead lift lever clockwise to the UP position.
3. Remove the printhead support plate and ribbon shield from the front of the
printer mechanism. They are fastened to the printhead mount by two
screws located above the drive roller. This step exposes the front edge of
the printhead and the print surface on the bottom of the printhead.
4. Use a cotton swab and alcohol to remove any dirt, adhesive, or debris from
the print surface on the bottom of the printhead.
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Cleaning the Printhead
3
5
4
4100-21
Routine Maintenance
5. Reinstall the printhead support
plate and ribbon shield. Make
sure the tab on the right side of
the ribbon shield fits into the slot
on the printhead mount, and that
the ribbon shield is parallel to the
drive roller. Also make sure the
slotted plastic spacer attached to
the head support adjustment
screw fits into the notch in the
printhead mount.
6. Rotate the printhead lift lever
counterclockwise to the down
position until the lever is locked
securely in place.
Note: For details about the printhead
support plate, refer to the illustration in
the next section.
4
CAUTION
Cleaning the Cutter Blades
The cutter requires a minimal amount of maintenance.
Tools Required: WD-40® or a similar petroleum-based lubricant, silicone-
based lubricant, clean cloth or cotton swab.
CAUTION
Do not use any petroleum-based lubricants on the plastic parts of the cutter
mechanism as they can damage the plastic. You must use silicone-based
lubricants on the plastic areas of the cutter.
CONSEIL
Ne pas utiliser de lubrifiant à base d'essence sur les parties en plastique du
mécanisme du massicot, sous peine de risquer de les endommager. Utiliser
seulement des lubrifiants à base de silicone.
4-9
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4100 Bar Code Label Printer User's Manual
After every 5,000 to 10,000 labels cut, check the front and back sides of the
cutter blades. If there is adhesive buildup on the blades, clean them with a
cloth or cotton swab sprayed with WD-40 or a similar product. Rub the
surfaces until the blades are completely clean.
You should also clean parts of the cutter where the media enters and exits the
cutter assembly. Watch for signs of adhesive buildup such as slower cutter
operation or increased effort to cut media.
You may also want to lubricate the plastic part of the cutter blade assembly that
moves up and down with the blade. Be sure that you use a silicon-basedlubricant on the plastic.
The cutter produces dust and paper particles as it operates. Make sure this
debris does not build up inside the printer or the cutter mechanism. A small
vacuum cleaner or compressed air is effective in removing a buildup of these
particles.
Adjusting the Printhead Support
If you are using media that is 3.5 inches or less in width, you must adjust the
printhead support to ensure optimal print quality and to avoid excessive wear
on the drive roller and printhead. You may also need to adjust the printhead
support if your printer exhibits signs of ribbon wrinkling or the print darkness
on the label is inconsistent from top to bottom.
The printhead support plate supports the outer end of the printhead when you
are using narrow media. Without this support, the printhead would bear
down excessively on the drive roller.
1. Loosen the two screws that fasten the printhead support plate to the
printhead mount, leaving the screw on the left slightly snug.
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Printhead Support Adjustment
1-4
Routine Maintenance
2. Load the media you will be
printing on and engage the
printhead by rotating the head lift
lever to the DOWN position.
3. Turn the printhead support
adjustment screw clockwise until
the printhead support plate
3
4100-26
moves down and contacts the
bearing plate underneath.
4. Tighten the two screws to secure
the printhead support plate to the
printhead mount.
Note: The screws that secure the
printhead support plate to the printhead
mount also secure the ribbon shield.
When you loosen these screws, both the
plate and the ribbon shield may move.
Make sure the ribbon shield is parallel to
the drive roller when you have completed
this adjustment procedure.
4
Adjusting the Printhead Alignment
The 4100 printer is adjusted at the factory using 4 mil thick label stock. When
using heavier tag stock, you may need to adjust the printhead forward.
Adjust the horizontal position of the printhead by turning the right and left
printhead adjust screws that correspond to the right and left sides of the
printhead. Turning the screws 1/2 turn counterclockwise will move the
printhead .012 inch forward. Conversely, turning the screws 1/2 turn
clockwise moves the printhead backward by the same amount.
Tools Required: Phillips screwdriver, 1/16 inch hex key, and 4100 alignment
plate.
4-11
4100 Bar Code Label Printer User's Manual
To adjust the printhead alignment for a coarse adjustment
1. Loosen the screws that secure the bearing block mounting bracket.
2. Place the alignment plate over the bearing block mounting bracket and
insert the upper and lower drive roller bearings into the corresponding
holes in the alignment plate. The narrow tab on the top of the alignment
plate should be centered in the printhead alignment slot. If the tab does not
center, use the hex key to turn the left printhead adjust screw until the tab is
centered.
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Printhead Adjustment Screws (2)
4-12
CAUTION
4100-22
CAUTION
Do not turn the printhead adjust screws more than two turns in either
direction. Damage to the printhead assembly could result if the adjustment
screws are turned too far.
CONSEIL
Ne tournez pas les vis d'ajustement de la tête d'impression de plus de deux
tours dans chaque direction. Vous risquez d'endommager l'assemblage de la
tête d'impression si les vis d'ajustement sont serrées à fond.
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