Intermec EasyCoder 4100 User Manual

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User’s

Manual

4100 Bar Code Label Printer

P/N 057713-005

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4100 Bar Code Label Printer User's Manual

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.

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

Author Lori Austin

Mia Hayashida

Editor Craig Thompson

Technical Illustrators John Bickley

Karen Petruzzi

Technical Reviewers Scott Bale

Dzung Dang Jim Davison Terry Ho Jaye Jarchow Ed Millet Lisa Morin Mark Rasmussen

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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.

Version Date Description of Change

B 12/92 Added an addendum describing new features of ribbon save and the

cutter.

001 2/93 Incorporated addendum and added the cut option. Added a new label

that can be downloaded to the printer.

002 8/93 Chapter 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.

003 10/93 Firmware 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.

004 10/94 Manual 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

005 6/95 Page 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

Before You Begin xix

Warranty Information xix Safety Summary xix Warnings and Cautions xx About This Manual xxi Customer Advisory xxiii

Getting Started

Introduction to the 4100 Printer 1-3

Printing Capabilities 1-3 Printer Components 1-4 Printer Component Descriptions (Front View) 1-5 Printer Component Descriptions (Front Interior) 1-7 Printer Component Descriptions (Rear View) 1-9 Printer Component Descriptions (Mechanism Detail) 1-11 Printer Options 1-12

Ribbon Save 1-12 Cutter 1-12

Unpacking the 4100 1-13

Checking the Order for Completeness 1-13 Reporting Damage or Defects 1-13 Installing the Front Panel Cover 1-14

Preparing the Printer for Installation 1-14

Plugging in the Printer 1-14

Checking the DIP Switch Settings 1-15 Opening the Printer 1-15 Loading Media 1-15

4100 Bar Code Label Printer User's Manual

If You Have Difficulty Feeding the Media 1-17

Printing Configuration Test Labels 1-18

What the Configuration Test Labels Tell You 1-18

Installing the Printer

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About Printer Installation 2-3 Preparing for Installation 2-3

Situating the Printer 2-4

Connecting the Printer to the Host 2-4

Default (Point-to-Point) Installation 2-4 About Network Installations 2-5 Modem Installation Procedure 2-7

Configuring the Serial Port 2-8

Serial Port Settings 2-8

DIP Switch Settings 2-9

Connecting the Printer to a Network 2-10

Host Requirements 2-10 Communication Boundaries 2-10 Communication Protocols 2-10

Intermec “Standard” Protocol 2-11 Polling Mode D Protocol 2-12 Multi-Drop Protocol 2-12 XON/XOFF Protocol (Software and Hardware / Flow Control) 2-12 Ready/Busy Protocol 2-13 User-Defined Protocol 2-13

Communication Interfaces 2-14

RS-232C Serial Interface 2-15 RS-485 Serial Interface 2-16 RS-422 Serial Interface 2-17

Printer Serial Port 2-17

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Choosing the Correct Cable 2-17

Intermec Cables 2-18 Cable Schematics 2-18 RS-485 (Multi-Drop) Cables 2-20 Cabling Considerations in Noisy Electrical Environments 2-20

Operating the Printer

Contents

About Printer Operation 3-3 Opening and Closing the Printer 3-3

Opening the Printer 3-4 Closing the Printer 3-4

Using the Front Control Panel 3-4 Loading Media Into the Printer 3-5

Straight-Through Printing 3-6 Self-Strip Printing 3-8

Repositioning the Tear-Off Plate Before Printing 3-8

Loading the Media 3-8 Batch Take-Up Printing 3-10

Installing the Rewind Adapter Before Printing 3-10

Loading the Media 3-11 Fanfold Printing 3-12

Adjusting the Label Gap Sensor 3-13

Adjusting the Label Gap Sensor for Die Cut Media 3-14 Adjusting the Label Gap Sensor for Tag Stock 3-14

Setting Media Sensitivity 3-14

Setting the Approximate Sensitivity Rating for Your Media 3-15 Fine-Tuning the Sensitivity Rating 3-15

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4100 Bar Code Label Printer User's Manual

Loading the Thermal Transfer Ribbon 3-17 Image Band Setting 3-18

How the Image Bands Command works 3-18 Optimizing the Number of Image Bands 3-18 Modified Field Reimaging 3-19

Printing Labels 3-20

Routine Maintenance

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About Printer Maintenance 4-3

Safety Precautions 4-3

Inspecting the Printer 4-4 Components You Should Maintain 4-5

Lubrication 4-6

Cleaning the Printer 4-6

Cleaning the Drive Roller 4-6 Cleaning the Media Path 4-7 Cleaning the Printer Case 4-7 Cleaning the Printhead 4-8 Cleaning the Cutter Blades 4-9

Adjusting the Printhead Support 4-10 Adjusting the Printhead Alignment 4-11 Replacing the Cutter Blade 4-13 Replacing the Fuse 4-17

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Troubleshooting

Contents

About Troubleshooting 5-3 Troubleshooting Checklist 5-3 Printer Operation Problems 5-4 Print Quality Problems 5-5 Communication Problems 5-6 Error Handling 5-6

Syntax Errors 5-6 Parameter Errors 5-6 Image Overrun Errors 5-7 Invalid Numeric Character Errors 5-7 Insufficient Storage RAM Errors 5-7

Error Codes 5-8 Using Test and Service Mode 5-10

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

4100 Bar Code Label Printer User's Manual

Designing Labels and Using Commands

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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

Editing Labels and Working With Fields 6-22

Editing Labels 6-22 Deleting Fields 6-23 Scaling Fields 6-23

Positioning Fields 6-24

Magnifying Fonts and Character Fields 6-23 Magnifying Bar Code Fields 6-24

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Rotating Fields 6-26 Storing Label Formats 6-27 Designing Pages 6-27

Format Examples 6-28

Example 1 6-28 Example 2 6-31

Graphic for Example 2 6-31

Printer Commands

Contents

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

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

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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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

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Configuration Parameters Upload A-12 4100 Printer Options A-13

Present Sensor/Self-Strip A-13 Memory Expansion A-13 Cutter and Tray A-13 Ribbon Save A-14

Glossary

Index

Contents

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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 Media Chapter 1, "Getting Started." Provides information

Installing the Printer Chapter 2, "Installing the Printer." Describes printer

Printer Operation Chapter 3, "Operating the Printer." Gives

Maintenance Chapter 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.

Troubleshooting Chapter 5, "Troubleshooting." Provides instructions

for clearing error messages, troubleshoo ting programming and configuration problem s, and performing DIP switch settable procedu res.

Designing Labels Chapter 6, "Designing Labels and Using

Commands." Describes how to use the printer command set to design your labels.

Printer Commands Chapter 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.

Manual Intermec Part No.

Data Communications Manual 044737 Bar Code Book by Roger C. Palmer 051241

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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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

MODEL 4100

Prog 057733 Version 2.2

Code 39

3.0 / 1

Code 39

Intermec

Intermec Corporation Everett, WA 98203

*SUPPLIER*

*PICKET,FIELD*

*PICKET FIELD*

*PICKET,FIELD*

*PICKET FIELD*

4100-01

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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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PAUSE

FEED

CANCEL

DARKER

STOP/

PAPER/ RIBBON

POWER

TRANSFER ON

PAUSE

Intermec

PAP

A Litton Company

FEED

RIB

STOP/ CANCEL

DARKER

4100

TRANS

1-4

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Getting Started

Printer Component Descriptions (Front View)

The following table contains descriptions of the printer components as shown in the previous illustration.

No. Name Description

1 Right side cover Provides access to the media path, printhead, and thermal

transfer ribbon.

2 Front panel cover Provides access to the thermal/thermal transfer switch, and

darkness control adjustment knob

3 Label dispense opening Guides printed labels out of the printer mechanism for

removal.

4 Power on indicator Illuminates when the power switch on the rear panel is

turned on.

5 Stop/Cancel button Cancels the current print job. The printer continues to

process subsequent downloaded commands. 6 Feed button Advances the media. 7 Pause button Temporarily stops printing and holds all data in memory

until the button is pressed a second time to resume printing.

Pauses communication with the host. 8 Pause indicator Illuminates when the [PAUSE] button is pressed. Blinks

during communication with the host. 9 Paper/Ribbon indicator Illuminates when no media or ribbon are detected by the

printer sensors.

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4100 Bar Code Label Printer User's Manual

Front View of the 4100 Printer With the Front Cover Open

PAUSE

PAPER/

FEED

RIBBON

POWER

STOP/

CANCEL

DARKER

TRANSFER ON

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1-6

4100-02

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Getting Started

Printer Component Descriptions (Front Interior)

The following table contains descriptions of the printer components as shown in the previous illustration.

No. Name Description

1 Drive roller Advances media through the printer. 2 Rewind assist roller Guides media to the rewinder hub during batch take-up and

self-strip printing. 3 Transfer on switch Toggles between direct thermal printing (OFF) and thermal

transfer printing (ON). Direct thermal printing is the factory

default. 4 Darkness control adjustment Adjusts a new printhead to produce the same level of

darkness as the previous printhead. Does not adjust the

darkness quality of individual print jobs. 5 Quick remove hinge Allows the front cover to be easily removed or installed.

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4100 Bar Code Label Printer User's Manual

Rear View of the 4100 Printer

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250V, 1.5A S-B

OFF ON

AC POWER

4100-03

1-8

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Getting Started

Printer Component Descriptions (Rear View)

The following table contains descriptions of the printer components as shown in the previous illustration.

No. Name Description

1 DIP switches Control 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. 2 Fuse holder Contains a 1.5A Slo-Blo fuse for 115 VAC operation or a

double pole circuit breaker at 1.2A for 230 VAC operation. 3 Power switch Turn the printer on by moving the switch to the ON position

and off by moving it to the OFF position. 4 AC power cord receptacle The AC power cord plugs into this receptacle. 5 Serial communications port Connects the printer to a host computer with a 25-pin

D-style subminiature receptacle.

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4100 Bar Code Label Printer User's Manual

View of the 4100 Printer Mechanism

PAUSE

DARKER

FEED

STOP/

CANCEL

PAPER/ RIBBON

POWER

TRANSFER ON

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1-10

4100-04

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Getting Started

Printer Component Descriptions (Mechanism Detail)

The following table contains descriptions of the printer components as shown in the previous illustration.

No. Name Description

1 Supply roll back stop Prevents the roll of unused media from rubbing against the

interior of the printer. 2 Supply roll retainer Secures the roll of unused media to the supply roll hanger. 3 Supply roll hanger Holds the roll of unused media. 4 Rewind adapter Guides printed media onto the rewinder hub during batch

take-up printing. (Shown in its storage position when not in

use). 5 Rewinder clasp Secures printed media or used media backing to the

rewinder hub. 6 Rewinder hub Collects printed media in batch take-up mode or media

bacing in self-strip mode. 7 Label adjust guide Guides media from the supply roll to the drive roller. 8 Head lift lever Disengages the printhead for loading media or ribbon and

for adjusting printhead alignment. 9 Label gap sensor adjustment Adjusts 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". 10 Printhead Prints label formats as they are transmitted from the host

computer. The printhead resolution is 203 dots per inch

(DPI). 11 Printhead support adjust screw Moves the printhead support plate up or down to

accomodate narrow media. 12 Tear off plate Used for tearing off labels in straight-through printing mode. 13 Printhead support plate Supports the outer end of the printhead when narrow media

is used. 14 Ribbon rewind hub Collects used thermal transfer ribbon. 15 Ribbon clasp Secures used thermal transfer ribbon to the ribbon rewind

hub. 16 Ribbon supply hub Holds the supply of unused thermal transfer ribbon. 17 Ribbon supply back stop Prevents 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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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

• 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.

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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.”

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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

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.

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4100 Bar Code Label Printer User's Manual

Loading Media Into the Printer

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4100-05/16

Label Gap Sensor

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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

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].

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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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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

Printhead

Width Dot Size

Burn Pot Setting Firmware Checksum

ROM0 (U30) ROM1 (U4)

: 832 dots : 5.0 mil : 133

: B535 : E63F

4100.07

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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

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Getting Started

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

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4100 Bar Code Label Printer User's Manual

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Installing the Printer

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4100 Bar Code Label Printer User's Manual

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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

• 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.”

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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.

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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 port Default setting

Baud rate 9600 Data bits 7 Parity Even Stop bits 1 Protocol Standard

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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

PAUSE

Intermec

PAP

A Litton Company

FEED

RIB

STOP/

4100

CANCEL

DARKER

TRANS

Printer

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.

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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

S T

4100

DARKER

/ A N

C E

T R

A N

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PAUSE

Intermec

PAP

A Litton Company

FEED

RIB

S T

4100

DARKER

/ A N

C E

R A

N S

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Host Computer

PAUSE

IntermecIntermec

PAP

A Litton Company

FEED

RIB

S TO

4100

DARKER

N C

A N

PAUSE

Intermec

PAP

A Litton Company

FEED

RIB

S T

4100

DARKER

N C

E L

T R

A N

Controller

PAUSE

IntermecIntermec

PAP

A Litton Company

FEED

RIB

S T

4100

DARKER

/ A N

R A

PAUSE

Intermec

PAP

A Litton Company

FEED

RIB

4100

DARKER

N C

E L

T R

A N

Printers (End Devices)

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

Host Computer

Modem Modem

P A

U S

IntermecIntermec

A Litton Company

R IB

STOP/

4100

CANCEL

DARKER

TRANS

Printer

4100-08

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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.

Parameter Settings Description

Baud Rate 110, 300, 600 , 1200, 2400, 4800,

9600, 19200 Data Bits 7 or 8 The number of bits that represent the ASCII characters. Parity Odd, Even, None Checks each transmitted character for errors. Stop Bits 1 or 2 B its that follow each character to sy nchronize chara cter

Protocol Standard, XON/XOFF,

Multi-Drop, Polling Mode D Device Address A to Z, 0 to 5 Unique address for each device connecte d with

Test and Service Enabled or Disabled Provides printer diagnostics to the host and prints test

Self-Strip Enabled or Disabled Peels 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.

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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

1 2 3 4 5 6 7 8

1 2

7 8

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

X Y

Bottom Bank Switch Number

OFF

1 2 3 4 5 6 7 8

O O

1 1

4100-45

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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.

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Communication Boundaries

The information below applies to all the printer’s supported protocols.

Parameter Maximum capacity

Message delay 9999 milliseconds Character delay 9999 milliseconds Message block size 255 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

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 status Character Pin 11/20

Buffer already full GS Busy Ribbon fault US Busy No label stock EM Busy Buffer now full DC3 Busy Printhead hot SI Busy Offline (paused) DC3 Busy Label at strip pin FS Ready Label skipping DC1 Ready Printing DC1 Ready Ready/Online DC1 Ready

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.

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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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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 Received Online/Offline Pin 11/20 Transmit

Do not care Offline Busy <DC3> 768 Offline Busy 768 + each 15 thereafter Online Busy <DC3> Buffer empty Online Ready <DC1> (if DC3 was

sent)

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.

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4100 Bar Code Label Printer User's Manual

Communication Interfaces

Character Protocol Affected

SELECT IN Polling Mode D Multi-Drop POLL IN Polling Mode D Multi-Drop RES IN Polling Mode D Multi-Drop REQ IN Polling Mode D Multi-Drop SOM IN Standard Polling Mode D Multi-Drop XON/X OFF EOM IN Standard Polling Mode D Multi-Drop XON /XO FF AFF IN Polling Mode D Multi-Drop NEG IN Polling Mode D M ulti-Drop DLE IN Standard Polling Mode D Multi-Drop XON/X OFF XON IN XON/XOFF

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XOFF IN XON/XOFF SELECT OUT Multi-Drop POLL OUT Multi-Drop RES OUT Polling Mode D Multi-Drop REQ OUT Polling Mode D Multi-Drop SO M OU T Polli ng M ode D Mult i- Dro p EOM OUT Polling Mode D Multi-Drop AFF OUT Polling Mode D Multi-Drop NEG OUT Standard Polling Mode D Multi-Drop DLE OUT Standard Polling Mode D Multi-Drop XON/XOFF XON OUT XON/XOFF XOFF OUT Polling Mode D Multi-Drop XON/XOFF PROTO- CM D 1 Standar d XON /X OFF PROTO- CM D 2 Standar d XON /X OFF TIMEOUT ON EOM Polling Mode D Multi-Drop

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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.

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.

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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 ace Pi n No. Na m e Oper ati on

RS-232/422/485 1 Chassis Ground

(GND)

RS-232 2 Transmit Data (TD) Output: Connect to receive data pin of connected

RS-232 3 R eceiv e Data (RD ) Input: Connect to transmit data pin of connected

RS-232/422/485 4 Request to Send

(RTS)

RS-232/422/485 5 Clear to Send (CTS) Input: When a modem is used, connect to modem

RS-232/422/485 7 Signal Ground To enable communications, connect to signal ground

RS-232/422/485 1 1 Printer Status (PS) Output: When not using software flow control

RS-422/485 13 Input B Input: 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-422/485 1 4 Output A Output: Serial differential d ata fr om t he pri n ter . RS-422/485 16 Input A Input: Serial differential data to the pr int er. RS-422/485 1 9 Output B Output: Serial differential d ata fro m t he pri nt er . RS-232/422/485 2 0 Data Terminal R eady

(DTR)

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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

2 1

SG CTS

RTS RD

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

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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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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

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GROUND

SHIELD

1 2 3 4 5 6 7

NOTE: The metal backshell is connected directly to the shield to achieve electrostatic discharge (ESD) immunity.

1 3 2

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

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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

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

TRANSMITTED DATA

RECEIVED DATA

CARRIER DETECT

DATA SET READY

DATA TERMINAL READY

CLEAR TO SEND

REQUEST TO SEND

GROUND

PRINTER

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

PRINTER HOST

NOTE: The metal backshell is connected directly to the shield to achieve electrostatic discharge (ESD) immunity.

➤ ➤

25-PIN (PLUG) D-SUB METAL BACKSHELL

CHASSIS GROUND

TRANSMITTED DATA

RECEIVED DATA

4100-14

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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

PRINTER HOST

➤ ➤

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

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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.

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4100 Bar Code Label Printer User's Manual

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Operating the Printer

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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

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.

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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.

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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

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Component Description

Power On Indicator Illuminates when the power switch on the rear panel is turned on. Feed Button Advances 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 Button Cancels the current print job. The printer continues to process subsequent

downloaded commands.

Pause Button Temporarily stops printing and host communications. Holds all data in memory

until the button is pressed a second time to resume printing.

Pause Indicator Illuminates when the pause button is pressed. Flashes when data is

downloading to the printer. Paper/Ribbon Indicator Illuminates when the printer is out of paper or ribbon. Darkness Control

Adjustment (Potentiometer)

Transfer On Switch Switch 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

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.

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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.

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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.

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Loading Media Into the Printer for Straight-Through Printing

Operating the Printer

4100-05/16

Label Gap Sensor

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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

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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.

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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.

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.

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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.

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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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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

Operating the Printer

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,

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

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.

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4100 Bar Code Label Printer User's Manual

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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.

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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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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

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].

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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

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:

Media Type Sensitivity Setting

700 Series High Sensitivity Direct Thermal

Duratherm Lightning Plus 720

600 Series Thermal Transfer

Duratran Kimdura/Standard ribbon 622 Duratran Kimdura/Premium ribbon 628 Duratran Syntran/Premium ribbon 678 Duratran Polyester/Premium ribbon 688

500 Series Thermal Transfer

Duratran II Tag-5 mil/Premium ribbon 518 Duratran II Tag-8 mil/Premium ribbon 528 Duratran II-2/Premium ribbon 548 Duratran II-1/Standard ribbon 562 Duratran II-1/Red ribbon 564 Duratran II-1/Green ribbon 565 Duratran II-1/Premium ribbon 568

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400 Series Direct Thermal Media

Duratherm Lightning-1 420 Duratherm Lightning IR 450 Duratherm Lightning-2 470

300 Series Thermal Transfer Media

Super Premium Polyester/Super Premium ribbon 371

100 Series Low Sensitivity Direct Thermal

Duratherm II-2 130 Duratherm II Tag 160 Duratherm Buff Tag 190

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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

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.

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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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

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

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4100 Bar Code Label Printer User's Manual

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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

WARNING

Always turn the power off before doing any maintenance work.

AVERTISSEMENT

Fermez toujours le courant avant de procéder à toute maintenance.

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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.

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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

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

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4100 Bar Code Label Printer User's Manual

Printer Component Maintenance Period

Driver roller and tear-off plate Clean whenever contaminated by debris. Media path Clean whenever contaminated by debris. Case Clean as necessary. Printhead Clean every 50,000 linear inches of media

Cutter Clean 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.

Tools Required: Phillips screwdriver, cotton swabs or clean cloth, 70% isopropyl alcohol.

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CAUTION

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

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.

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Tools Required: Phillips screwdriver, cotton swabs or clean cloth, isopropyl alcohol.

To clean the printhead

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

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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.

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.

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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-based lubricant 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.

Tools Required: Phillips screwdriver, cotton swabs or clean cloth, isopropyl alcohol.

To adjust printhead support

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

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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

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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.

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.

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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)

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CAUTION

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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.

Intermec EasyCoder 4100 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual