4630-4830 Field Training Manual

4630/4830
Section Seven
Version - 2.1 14-Oct-98

4x30 PRINTER
TABLE OF CONTENTS
Chapter 1 Introduction Page No.

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Page - ii Table of Contents

4630/4830 Introduction
The 4630 is a thermal/thermal transfer printer with a print width of 2 to 6.4 inches (16.26cm),
300dpi resolution (11.8 dots/mm), and a print speed of 2 to 8 ips. The 4630s mechanical and
electrical design is derived from the Datamax DMX 600.
The 4830 is a thermal/thermal transfer printer with a print width of 3 to 8.5 inches (21.6cm),
300dpi resolution (11.8 dots/mm), and a print speed of 2 to 5 ips. The 4830s mechanical and
electrical design is derived from the Datamax DMX 800.
Both printers communicate using IPL (Intermec Programming Language), with the same
command set as other Intermec printers. 4x30 printers are also compatible with Intermec
controllers like the 9154 and 9161 using multi-drop and polling mode D.
128K of battery backed RAM is standard for storage of formats, graphics and fonts. One Meg of
DRAM is used for label imaging and can be upgraded with a 4 Meg SIMM for imaging longer
labels.
Resident fonts include 3 outline and 21 bitmapped fonts, along with the Code Page 850 character
set.
The 4x30 can print PDF417, Code 1, and Maxicode 2D barcodes as well as standard one
dimension barcodes.
Both printers use a autoranging, switching power supply that accomodates 115/230 VAC at 50 or
60 Hz. Circuit protection is provided by 2, 8amp 250V fast-blo fuses, located in the power
supply.
4x30 - Introduction 4x30 Page 1 - 1

4830/4630 Features
• 300 Dpi Print Resolution
This print density offers the better print quality for graphics and fonts than 200dpi printers.
Bar code printing at 300 dpi gives an X dimension of 6.6 mils (0.0066 in).
• 6.4 inch (4630) and 8.5 inch (4830) Maximum Print Width
The 4630 has a print width from 2.0 to 6.4 inches (5.1 to 16.26 cm). The maximum media
width the printer will accept is 6.7 inches or 17.02 cm.
The 4830 has a print width from 3.0 to 8.5 inches (7.62 to 21.6 cm). The maximum media
width the printer accepts is 9.0 inches or 22.86 cm.
• Maximum Print Speeds of 2-8 ips (4630) or 2-5 ips (4830)
A user-selectable print speed offers the ability to adjust printer throughput to meet varied
printing requirements and media types. Factory default is 3.5 ips.
• IPL (Intermec Programming Language)
Both printers use the same command set as other Intermec printers like the 4400, 3240 and
3400. Both printers work with Intermec controllers so they can be attached to Pol D and
multi-drop configurations.
• LCD Control Panel
The control panel is similar to the 4400 control panel in physical layout and menu structure.
With a 16 character by 2 line LCD display, a Online/Offline button and LED, a Feed/Reload
and Canel button, an Alert LED for media lowstock indications and hardware faults and a
Power LED. An access door hides the Control Panel menu selection buttons.
The control panel makes it easy to configure the printer, enable or disable options, and test
the printer without it being connected to an external source.
• 2 Serial, Bi-Directional Parallel and General Purpose I/O
Both printers come standard with two serial ports, a Centronics type parallel port and a GPI
port. This provides a great deal of flexibility for connecting the printer to various or multiple
host systems. Both serial ports are DB-25 pin, with RS-232, RS-422 and RS-485
connections.
• 128K Storage RAM, 1Meg Image DRAM
The printers come with 128K of battery backed storage RAM for formats, graphics and fonts.
Image RAM is 1Meg that provides for a maximum label size of 10 inches for the 4630 and 8
inches for the 4830. Image DRAM can be upgraded with a 4 Meg SIMM for longer labels.
• Optional - 2Meg NVRAM Memory Card
The 2 meg memory card has the same footprint of a PC Card (PCMCIA) but is not PC Card
compatible. The card can be used to increase the amount of non-volatile storage for formats,
graphics and downloaded fonts. There are 2 separate memory card slots, located above the
label supply holder, for a 4 megaB total. See page A-6 for location.
• Optional - 4Meg Image DRAM Expansion
The 4 MB DRAM SIMM expansion is used to improve imaging performance when
customers need to print formats with a large number of graphics or variable fields. The 4
MB is added to the 1 MegB standard image DRAM and increases the maximum print length
to 64 inches.
This option is a factory or field service installed accessory.
4x30 Page 1 - 2 4x30 - Introduction

• Autoranging Switching Power Supply
Both printers use a autoranging, switching power supply that accomodates 115/230 VAC at
50 or 60 Hz. Circuit protection is provided by 2, 8amp 250V fast-blo fuses, located in the
power supply.
• 18,000 inch (452meter) Ribbon Supply
Ribbon to label supply ratio is 3 to 1. Ribbon replacement only needs to occur after every 3
rolls of label stock, reducing down time.
• Metal Construction and Enclosed Media
The 4x30 is specifically engineered to withstand heavy-duty industrial applications and harsh
environments. The media enclosure protects label stock from contamination that can
negatively affect print quality.
• Optional - Full Roll Internal Rewinder
For rewinding large batches of labels or for taking up label backing when using the Self-Strip
adapter option. This option is can be installed only at the factory.
• Programmable, Non-Volatile Printer Configuration
The printer configuration can be changed via the control panel or with online commands.
Some commands change printer configuration only while the printer is powered on while
other commands change the power up configuration. All power-up configuration changes are
saved in battery backed SRAM.
• 2D Symbology Support ( PDF 417, Code One and Maxicode)
The 4x30 can print PDF417, Code 1, and Maxicode 2D barcodes as well as the standard one
dimension barcodes.
• Outline/Vector Font Support
There are 3 outline fonts resident; c25 is a monospace 821 standard, c26 is a monospaced
821 bold, and c27 is a proportional Dutch Roman 801. They give smooth, rounded characters
at any point size.
• Bitmapped Font Capabilities
21 point sizes offer customers greater imaging speed and format flexibility with a range of 6
points to 36 points.
• User Selectable Gap Feature For Fonts
A fonts intercharacter gap is adjustable. This can help to maximize the usability of a text
fields label area.
• Printable Control Characters
Beside the normal way of sending commands and data to the printer using control characters,
you can now use printable control characters and the printer will interpret them.
Control characters represent the first 32 characters of the ASCII chart and are normally
unprintable. Control characters are entered from the keyboard using the Ctrl key + a printable
character, like Ctrl + G is a <BEL> character. This method of using control characters can be
confusing, complicated and unworkable with most text editors.
To simplify the sending of commands and data to the printer, printable control characters
were implemented. You can now send the printable characters <+B+E+L+> instead of
having to enter control characters like Ctrl + G. This makes it possible to use any text editor
to create a file of commands and data for the printer.

• Third Party label design software
Loftware (LLM) and Seagull Scientific (Bar Tender) have drivers for the 4x30 printer in
their label design software packages.
• Optional - Internal Twinax/Coax Interface
The Intermec 4630/4830 IBM Coax-Twinax Interface Adapter allows customers to connect
the 4630 and 4830 printers to an IBM coax or twinax cable system.
The twinax capability enables the printer to operate with an IBM system 34/36/38 or AS/400
host computer as specified in the IBM 5250 Twinax Interface Programming Application
Interface. The adapter supports a half-duplex, two wire, twisted pair twinaxial cable
interface. Connected to the this twinax port, the printer emulates IBM 4234-002 / 5225-
1/2/3/4 printers. This enables programming staff to easily develop software to print to the
4630 and 4830 and provides seamless integration into an IBM midrange system. Host-to-
printer commands are sent from the host computer to the Twinax adapter. The Twinax
adapter converts EBCDIC/IBM commands into ASCII/Intermec printer commands.
The coax capability is designed for connecting Intermec 4630 and 4830 bar code printers to
IBM 3270 Type A cable computer systems operating in the VTAM (CICS/TSO)
environment. This interfaces supports the IBM 3174/3274 coax electrical standard as
specified in the IBM 3174/3274 Coax Programming Application Interface. Connected to the
coax port, the 4630 or 4830 printer emulates IBM 3287/4234 type printers. A customer’s
programming staff can then develop software to print to the 4630 and 4830.
• Optional - Self-Strip with Present Sensor
For on-demand label applications using adhesive back labels, this option automatically
removes the backing paper and presents the label ready for use. With the media present
sensor, the printer waits until the last printed label is taken, then prints the next label. The
Self-Strip Adapter must be used in conjunction with the Full Roll Internal Rewind option.
Option Restrictions: In lieu of Cutter Accessories
• Optional Connectivity Features
Local Area Network Connectivity
Customers can connect the 4630 or 4830 to an Ethernet TCP/IP or Novell Netware
network using the Extended Systems Print Server which can be acquired through
Intermec’s Buy-On-Order process. The Print server attaches to the standard parallel
interface and is powered by an external power supply adapter.
This option is a customer installed accessory.
RF Connectivity
Customers can connect the 4630 or 4830 to an Intermec 902 MHz RF network by using the
Intermec 9189-C02 RF Gateway.
This option is a customer installed accessory.

• Optional - Cutter and Tray
There is a Standard Cutter for the 4630, recomended for cutting liner between labels or for
cutting paper and tag stock less than 7.5 mils (1.91mm) in thickness. This high grade tool
steel blade cutter is easily attached to the front exterior of the printer with two thumb-screws.
The cutter gets its power directly from the printer through an RJ-11 telephone style
connector, so no additional power supply is required. Its self-sharpening rotary blade is rated
for 500,000 cuts and can be replaced when it becomes dull.
This option is a customer installed accessory only.
Option Restrictions: In lieu of the Self-Strip Adapter or Heavy Stock Cutter.
A Heavy Stock Cutter is offered on both the 4630 and 4830 printers for when the customer
needs to cut thick paper stock greater than 6 mils thick, through the paper/adhesive stock in
continuous rolls, or fibrous stocks such as Kimdura or synthetic materials.
As with the Standard Cutter, it is a rotary style cutter which mounts and connects to the
printer in the same fashion. It is self sharpening and is capable of cutting over 500,000 cuts.
Its blades can be flipped when they become dull, doubling the number of cuts the blade is
capable of cutting to 1 million cuts total. On the average the blades should be cleaned every
20,000 cuts.
This option is a customer installed accessory only.
Option Restrictions: In lieu of Self-Strip Adapter or Standard Cutter.
• User’s Manual (Optional)
A getting started manual is provided with the 4x30. Customers interested in programming the
printer or having a complete reference source can purchase the User’s Manual.
• Intermec Warranty (North America Only)
Intermec stands behind its products and customers by featuring the longest product warranty
in the industry. The 4x30 comes standard with a 12-month warranty that will repair or
replace standard products or subassemblies which fail due to faulty manufacture or design. In
addition, Intermec’s Thermal Print Head Replacement Policy is unmatched in the
thermal/thermal transfer printer industry. It states that if a print head fails within 5 years
from the date of purchase, Intermec will provide a replacement print head free of charge if
the customer is using Intermec Media Products exclusively.
• Intermec Industry-Leading Sales and Support
Intermec offers the largest team of factory trained Service Representatives in the industry
Since automated data collection is their sole expertise, customers receive more
knowledgeable product support and higher quality service before, during and after
installation.
• Maintenance Manual (Optional)
The maintenance manual is used for Intermec service and support. The part number is
064674.

Specifications Summary
4630 4830
Print Features
Print Mode DT / TTR DT / TTR
Print Width, Max 6.4” 8.5”
(162.6 mm) (215.9 mm)
Print Length, Max 10” 8”
(254 mm) (203.2 mm)
Print Length, Optional 64” 64”
(1625 mm) (1625 mm)
Resolution 300 dpi 300 dpi
(11.8 dots/mm) (11.8 dots/mm)
Print Speed 2 - 8 ips 2 - 5 ips
(50.8 - 203 mm/s) (50.8 - 127 mm/s)
Media Features
Label Width, Max 6.7” 9.0”
(170.2 mm) (228.6 mm)
Label Width, Min 2.0” 3.0”
(50.8 mm) (76.2 mm)
Media Supply Internal Internal
Ribbon Length, Linear 18,000” 18,000”
(457m) (457m)
Other Features
Memory, Std 1 MB 1 MB
Language IPL IPL
Emulation’s None None
Processor 32-bit RISC 32-bit RISC
Interfaces, Std 2-Serial, Bi-dir 2-Serial, Bi-dir
Parallel & GP I/O Parallel & GP I/O
Optional Features
Rewind Internal full roll Internal full roll
Self-Strip with Present Yes Yes
Sensor
Cutter Standard stock or Heavy stock
heavy stock
Memory 4 MB On-board 4 MB On-board
DRAM or 2-2 MB DRAM or 2-2 MB
SRAM Modules SRAM Modules
IBM Coax / Twinax Yes Yes
Interface
Physicals
Weight 55 lb. 65 lb.
(24.8 kg) (29.5 kg)
Size (h” x w” x d”) 14”x13”x18” 15”x15”x18”
(34x32x46 mm) (38x38x46 mm)

Compatibility Chart
Differences In Intermec’s High Performance Printer Family

Feature 4400 4630 4830
Maximum Print Speed 10 ips 8 ips 5 ips
254 mm/s 203 mm/s 127 mm/s
Print Resolution 203 dpi 300 dpi 300 dpi

8 dots/mm 11.8 dots/mm 11.8 dots/mm
Maximum Label Width 5.12 inches 6.7 inches 9.0 inches
130 mm 170 mm 228 mm
Maximum Print Width 4.4 inches 6.4 inches 8.5 inches
111.8 mm 162.6 mm 215.9 mm
Print Length, Unlimited 10 / 64 inches 8 / 64 inches
Standard / Optional 254 / 1625 mm 203 / 1625 mm
Media Sensitivity Supported Not Supported Not Supported
Numbers
Image Bands Supported Not Supported Not Supported
Printhead Resistance Supported Not Supported Not Supported
Test
Tests and Service Supported Not Supported Not Supported
Functions to Test
Printhead, Ribbon
Supply and Take-up
Motors
Set Printhead Pressure Supported Not Supported Not Supported
86XX Emulation Supported Not Supported Not Supported

Media Specifications
Note: The reflective sensor mark must be carbon based. The sensor is infrared and will not
reflect off a plain black mark.
Dim Description 4630 4830

Min Max Min Max
(inch/mm) (inch/mm) (inch/mm) (inch/mm)
A Label width 2.00 / 50.80 6.70 / 170.18 3.00 / 76.2 9.00 / 228.6
B Backing width 2.00 / 50.80 6.70 / 170.18 3.00 / 76.2 9.00 / 228.6
C Gap between labels 0.10 / 2.54 99.99 / 645 0.10 / 2.54 99.99 / 645
D Label length 0.50 / 12.70 99.99 / 645 0.50 / 12.70 99.99 / 645
E Backing thickness 0.0023 / 0.058 0.005 / 0.127 0.0023 / 0.058 0.005 / 0.127
F Label thickness 0.0023 / 0.058 0.005 / 0.127 0.0023 / 0.058 0.005 / 0.127
G Width of sensor opening 0.20 / 5.08 0.50 / 12.70 0.20 / 5.08 0.50 / 12.70
H Distance from edge of media to 0.20 / 5.08 3.25 / 82.55 0.20 / 5.08 3.25 / 82.55
edge of sensor opening
I Reflective sensor mark width 1.00 / 25.40 4.00 / 101.60 1.00 / 25.40 4.00 / 101.60
J Distance between reflective 0.25 / 6.35 99.99 / 645 0.25 / 6.35 99.99 / 645
mark
K Reflective sensor mark length 0.10 / 2.54 99.99 / 645 0.10 / 2.54 99.99 / 645

Printer Setup
Contents of the Shipping Container
4630 or 4830 Printer
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Front View of Printer
4x30 - Printer Basics 4x30 Page 2 - 1

Back View of Printer
Internal Components
4x30 Page 2 - 2 4x30 - Printer Basics

Media Loading
The printer accepts a wide range of media. It can be loaded with roll fed, fan folded, or die cut
continuous media of either Thermal Transfer or Direct Thermal type.
Media width can range from:
4630 2 in. (25.4 mm) to 6.7 in. (170 mm)
4830 3 in. (76 mm) to 9 in. (229 mm)
Media thickness can range from 0.0025 in. (0.0535 mm) to 0.01 in. (0.254 mm) for both printers.
Loading Roll Labels
1. Open the stock door

2. Slide a roll of the chosen medium onto the media hub assembly.
3. Raise the printhead latch wing and rotate it counterclockwise one half turn to unlock the
printhead. Swing the printhead to the raised position.
4. Route the media under the bouncer assembly and in between the upper and lower media
guides. Feed the media until it exits the printhead assembly.
5. Lower the printhead and engage the printhead latch. Rotate the latch wing one half turn
clockwise and snap the latch wing down to lock the printhead into position.
Note:


Media Width Adjustment
The printer can use a variety of media widths and thicknesses. To ensure even print quality
across the media regardless of changes in media dimensions, the print head has a leveling cam
adjustment. The cam raises and lowers the right side of the print head to keep the printhead level
across the media.
Your printer is setup at the factory for the following media:
4630 Standard 4 mil thick, 6.5 inch wide print media.
4830 Standard 4 mil thick, 9.0 inch wide print media.
The cam adjustment is designed to compensate for the use of narrower width stock. When the
cam is out of adjustment, print along one side of the label will be missing as the print drops off
suddenly, rather than gradually fading out.
The adjustment knob is designed with detents that allow it to turn a specific distance, one click at
a time. The knob has numbers for you to use as reference points when adjusting media width;
however, the numbers do not relate to specific media sizes. Turn the knob one click at a time
until the desired print quality is achieved.
When changing media of a different thickness, it may also be necessary to reset the cam
adjustment bracket.
To reset the cam adjustment bracket
1. Turn the adjustment knob counterclockwise until it stops.
2. Loosen the two screws securing the bracket.
3. Load the new media.
4. Slide the bracket up or down to contact the cam adjustment.
5. Tighten the two screws to secure the bracket.
6. Print a test label. You may need to turn the cam adjustment knob to fine tune the print
quality.

Loading Thermal Transfer Ribbon
If you plan to print in thermal transfer mode, you must install a thermal transfer ribbon on the
ribbon supply hub after you install the thermal transfer media.
To load thermal transfer ribbon

1. Open the stock door.
2. Raise the printhead latch wing and rotate counterclockwise one half turn to unlock the
printhead. Swing the printhead to the raised position.
3. Slide the ribbon roll onto the hub, making sure the ribbon roll is up against the hub
flange.
4. Pull the free end of the ribbon under the printhead carriage.
5. Remove the J-hook from the ribbon rewind hub.
6. Pull the ribbon over the ribbon idler rollers, wrap the free end of the ribbon around the
ribbon take-up hub and slide the J-hook ribbon clasp into place. Rotate the hub until all
slack is removed from the ribbon (do not use the J-hook to rotate the hub).
7. Lower the printhead, engage the printhead latch, rotate the latch wing one half turn
clockwise and lower the latch wing.
8. Close the stock door.
Removing Thermal Transfer Ribbon

Generally, ribbons are used to completion and then replaced. To remove the old ribbon, pull it
straight off the take-up hub and discarding it. However, there may be times when you need to use
direct thermal media before the thermal transfer ribbon has been completely used.

To remove the thermal transfer ribbon
1. Cut the ribbon between the idler rollers.
2. Turn the ribbon supply hub clockwise to draw the unused portion of the ribbon back
until it is clear of the printhead. You do not have to unlatch the printhead or remove the
unused portion of the ribbon.
3. Turn the ribbon take-up hub counterclockwise to roll up the used portion of the ribbon,
and slide the used ribbon off the hub.
The unused portion of the ribbon may be left in place until the next thermal transfer print
job, at which time it may be installed following the ribbon installation procedure.
Using the Tear Bar

The tear bar is already fastened to the printer. To utilize the tear bar, remove the rewind bracket
and replace the thumbscrews.
Using the Control Panel

You can operate many features of the printer directly from the control panel instead of through a
host computer. The control panel provides the means for all direct communications with the
printer such as advancing media or canceling the current print job.
Reading the Display

Messages that indicate printer settings and alert conditions appear on the control panel display.
Operating Messages

ONLINE
READY
Menu Messages

!

DARK ADJUST
5*
The asterisk (*) appears next to the current setting.
Error Messages "

RIBBON FAULT

Front Panel Buttons
The three control panel keys perform the following functions:
On line/Off line Toggles the printer between

online and offline. When online, the printer prints any
data it receives. When offline, the printer stops
printing and cannot accept data (but can accept
protocol commands) from the host computer.
For most menu panel operations, the printer must be
offline.
Feed/Reload When the printer is offline, you can
use this key to reload media or advance the media. On line/Off line Online
Pressing this key once advances media to the next
print point. Pressing it twice feeds an entire blank
label through the printer.
Feed/Reload Alert
Cancel Press this key to delete the current print job
after the current label has finished printing. The
printer starts the next print job immediately.
Cancel Power
Status LEDs
The control panel has three lights that indicate the current operating status of the printer. All
three are lit briefly when the printer is turned on.
On line When lit, this light indicates the printer is online (it can receive data from the host
computer). While the printer is online, the only commands you can access from the control
panel are the commands in the Operator menu.
Alert This light flashes when a condition arises that requires your attention, such as an
open paper path. A message describing the alert condition appears on the control panel
display.
Power This light remains on as long as the printer is turned on and is receiving power.

Using the Menu Buttons
The six keys on the menu panel allow you to change

printer parameters and setup security levels. As you
read about the menu panel keys, refer to the Printer
Menu Circle as this will help you understand how to
access the features shown on the circle.
Select Selects menus and features, and returns to
the last adjustment screen after you have left the
menus. This key also selects a digit to be changed
when changing parameters.
Enter Activates a selected option. This key also
starts a selected Test or Service function.
Menu Returns to a menu list so you can change
menus.
Cont Exits the menus.
↑ and ↓ Scrolls through menus and choices of
selections within menus.
4630-13B
Menu Structure
The printer has four menus that divide its features into categories described by the title of each
menu. Use the following table to locate the menu you will use the most, based on the tasks you
are performing with the printer.
Menu Description User

Operator Used for making fine adjustments to the darkness, Operators who use the printer
print alignment, and cutoff point of your labels. daily.
This menu can be accessed when the printer is
online or offline.
Install Select communication parameters and security Programmers, systems

levels and install printer options. The printer must analysts, or other personnel
be offline to access this menu. who install and set up the
printer
Service Set and adjust operating features, calibrate printer Technicians or other personnel
sensors, and test current settings. The printer must qualified to do repair and
be offline to access this menu. service.
Configuration Change the operating parameters and activate or Programmers, systems

disable optional features. The printer must be analysts, or supervisors who
offline to access this menu. program and set up the
commands for the printer and
label formats.

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Wheel-6x
Accessing Printer Menus

The selections for changing the printer settings are divided into four menus that cover four
different categories for maintaining and customizing your printer.
To access the printer menus
# $ %&" '"()* +Menu,
OFFLINE
OPERATOR MENU
- . +↓,
OFFLINE
INSTALL MENU
/ 0 +↑, +↓,


Using the Menu Circle
The circle lets you review all of the printer features at once. When you are familiar with using
the circle to access the menus and features you need, you will find it quite useful whenever you
need to quickly locate and change a feature.
The circle shows the menu structure with the ONLINE READY or OFFLINE READY screen in
the middle. As you move outwards, you see the menu levels. The final level, at the edge, contains
the settings.
To use the circle:
# $ %&" '"()* 1 $

$&%&" '"()*2
- . +Menu, 3
/ . +↑, +↓,

4 . +Select,

5 ' / 4

6 . +Enter,

7 . +Cont, '
The table below shows how the keys on the menu panel move to the menus and selections as they
are shown on the circle. Use these keys as listed below to move around the circle to reach the
selection you need.
Press To Move When You Want To

[Select] Outwards towards the Select a menu choice.
edge of the circle.
[Menu] In towards the center of Return to a menu.
the circle. Note: Use this key to enter the Main
menu.
[Enter] Activate a setting.
[Cont] Back into the center. Exit menus and return to READY.
[↑] or [↓] Around the circle. Scroll through menu choices.
Control Panel Tips

• To stop printing immediately, without losing data, press: [Online/Offline].
• To determine the printer’s present configuration, print a configuration test label.
• To go directly back to the screen where the last adjustment was made, press [Select] at the
ONLINE READY or OFFLINE READY display. This feature saves many keystrokes when
making trial-and-error adjustments.
• To go directly back to the menu where the last adjustment was made, press [Menu] at the
ONLINE READY or OFFLINE READY display. This feature saves many keystrokes when
making trial-and-error adjustments.

• To return to the previous menu, press [Menu] from within a menu. This feature is convenient
if you are making many setting changes.
• When you finish making an offline adjustment and wish to go right back to online printing,
press [Online/Offline]. This feature returns you directly to the ONLINE READY display.
Control Panel Security

If you want to restrict access to certain menus in the printer, you can do so by setting a security
level. Restricting access not only prevents unauthorized tampering with printer settings, but also
eliminates the number of choices you scroll through when selecting menus and options.
This table shows the restrictions imposed by different security levels.
Security Setting Menus Allowed

Level 0 Allows access to all menus (default setting).
Level 1 Operator and Configuration menus.
Level 2 Operator menu only. The audible alarm beeps (if
enabled) at an attempt to scroll to other menus.
Level 3 Access not allowed to any menus.
Note:

Bypassing Security Levels

You can bypass a security level if you need to access a restricted menu.
To bypass a security level
#
- 8 +Feed/Reload,

9

Control Panel Error Messages

If the printer encounters a problem that prevents it from operating properly, the Alert light
flashes and an error message appears on the display. An alarm will also sound at regular intervals
until the problem is corrected. If the problem affects printing, the printer will stop and wait for
you to clear the error message.

Communication Setup
Using Printer Serial Port

To connect the printer to your PC serial port, you need a shielded EIA
RS-232, RS-422, or RS-485 electrical interface with a 25-pin D-style subminiature connector
with pins on the printer end and an appropriate serial port connector on the other end.
For connecting to Use Intermec cable part number

IBM PC AT 048693 (25-pin printer to 9-pin serial port)
IBM PC XT 048668 (25-pin printer to 25-pin serial port)
To connect your printer to a PC serial port

1. Turn the printer power off.
2. Plug the 25-pin plug into the serial communications port on the rear of the printer.
3. Plug the other end of the cable into a serial port on the PC (COM port).
4. If necessary, change the PC serial port configuration to match your printer. The
default configuration settings for the printer are: 9600 baud, even parity, 7 data bits,
1 stop bit, and Standard protocol.
Configuring the Main Serial Port

The main serial port settings of the printer should match those of your PC or network controlling
device. If the default settings do not match your configuration needs, use the menu panel to
access the Main Port menu to change them.
The main port settings are listed below. The default values are shown in bolded italics.
Command Settings Description

Baud Rate 110, 300, 600, 1200, The rate (bps) at which the host exchanges data
2400, 4800, 9600, 19.2k with the printer.
Data Bits 7 or 8 The number of bits that represent the ASCII
characters.
Message 255, 512 Determines the maximum number of characters
Length in a block (including overhead) that is sent to
the printer in Standard, Polling Mode D and
Multi-Drop protocols.
Parity Odd, Even, Mark, Checks each transmitted character for errors.
Space, Off
Stop Bits 1 or 2 Bits that follow each character to synchronize
character transmission.
Protocol Standard, Xon/XOff*, The type of network used to connect the printer,
Multi-Drop, Polling host and the rest of the data collection system.
Mode D

Device A to Z, or 0 to 5 Unique address for each device connected with
Address Multi-Drop protocol.
* Use for READY/BUSY buffer control.
To configure the printer’s main serial port

# $ %&" '"()* +Menu,
- . +↑, +↓,
OFFLINE
INSTALL MENU
/ . +Select,
INSTALL MENU
SECURITY
4 . +↑, +↓,
INSTALL MENU
MAIN PORT
5 . +Select,
MAIN PORT
BAUD RATE
6 . +↑, +↓,

7 . +Select,

1:2
; . +↑, +↓,

< +Enter, 1:2 !

#9 . +Cont, $ %&" '"()*

+Menu, 6 <
Note:


Printing a Configuration Label
To review your printer’s current configuration, you can print a Configuration Test Label that
shows either the user-defined software or hardware configuration of your printer.
User-Defined This label lists current configuration parameters that are set from the
Configuration, Operator and Install menus, as well as defined pages, formats, graphics, and
fonts. Any installed options also appear on this label.
Hardware This label shows the amount of memory installed in your printer (static and
dynamic RAM), the width and dot size of the printhead, and the printhead mileage. The
printhead mileage consists of both the amount of media that has been processed (passed
underneath the printhead) and the amount of media that has been burned (printed on).
Printing a Configuration Test Label

# $ %&" '"()*
- . +Menu, +↑, +↓,
OFFLINE
SERVICE MENU
/ . +Select,
+↑, +↓,

SERVICE MENU
PRINT CONFIG
4 . +Select,
PRINT CONFIG
USER DEFINED
5 . +↑, +↓,
= 8
. +Select,
6 ">"0?" " . +Enter, 0

%
Testing Printer Communication

Once you have the printer connected to your system, you need to test for communication with
your system. The easiest way to test communications is to set the printer to Data Line Print mode
and send down a character string from your system.
To verify communication with your system
1. Start at the OFFLINE READY display and press [Menu].
2. From the main menu, press [↑] or [↓] until you reach the Service menu and then
press [Select].
3. From the Service menu, press [↑] or [↓] until the display shows:
SERVICE MENU
DATA LINE PRINT
4. Press [Select]. The display shows:

DATA LINE PRINT
DISABLED*
5. Press [↑] or [↓] to change to Enabled, and then press [Enter]. The display shows:
DATA LINE PRINT
ENABLED*
The printer will now print characters received from the host. The data line print automatically
returns to DISABLED after you exit this menu. Press [On line/Off line] to return to normal
printing.
Sample Print - Data Line Print Mode
3600G.009
Note:

!"

#
$%

Printing Input Buffer Contents

You can print the data that is stored in the printer memory when the printer is offline. This clears
the printer’s data buffer so you can print the labels stored in the buffer before turning off the
printer.
To print the buffer contents
# ( $&%&" '"()* +Online/Offline,

OFFLINE
READY
- . +Cont,

/

Reset Printer to Factory Defaults
If the priner is not operating consistently or you are not sure the printer is configured properly,
resetting the printer to a known condition (factory defaults) may be the answer.
Control Panel - Memory Reset

# $ %&" '"()*
- . +Menu, +↑, +↓,
OFFLINE
SERVICE MENU
/ . +↑,
SERVICE MENU
MEMORY RESET
4 . +Select,
MEMORY RESET
ALL
5 . +↓,
MEMORY RESET
CONFIGURATION
6 . +Enter,

Note: & '

()('

Reset with Online Command

To reset the printer to factory defaults from the host, send the following command.
<STX><ESC>T;D;R;<ETX>

Factory Default Settings
After you complete the procedure on restoring the factory default settings with the Memory
Reset command, your configuration parameters match the ones shown below:
Command Factory Setting Command Factory

Setting
ASCII Zero Not Slashed Media Length 0
Baud Rate 9600 Media Type Direct
Thermal
Character Set US ASCII Message Length 255
Cutter* Disabled Parity Even
Dark Adjust 0 Power-On Online
Data Bits 7 Print Speed 3.5 ips
Device Address A Protocol Standard
External Options None Security Level 0
Forms Adjust 0 Self-Strip* Disabled
Internal Options None Set Warning Disabled
Label Rest Point 0 Stop Bits 1
Label Retract Enabled Translation Disabled
Label Stock Gap Units Inches
Low Media Warn 0 X Forms Adjust 0
Max Label Length 5 Inches Y Forms Adjust 0
Max Print Speed 8 ips (4630)
5 ips (4830)
*Option—the software driver is installed at the factory and is Enabled.

Using Printer Parallel Port
If you are using a parallel port to communicate with the printer, you need:
• a parallel cable to run between the printer and the PC.
You can purchase a parallel cable from Intermec (part number 051211) or from your local
computer store.
To connect your printer to a PC parallel port
1. Turn the printer power off.
2. Plug the Centronics connector into the parallel communications port on the rear
of the printer.
3. Plug the other end of the cable into a parallel port on the PC.
Connecting to a Network
You can connect the printer to Novell NetWare networks, Token Ring networks, or TCP/IP
networks. To connect the printer to a network, you must purchase a network interface adapter
(for example, Ethernet) that connects to the parallel port.
Connecting to a AS400
To connect the printer directly to an AS400 or midrange system, you need:
• a twinax adapter card.
• a twinaxial cable equivalent to IBM part number 7362267 or 7362062.
The maximum cable length for the twinax interface is 5000 feet (1525 meters).
If the twinax card was not installed in the printer at the factory, you can have the field installable
option (part number 056835) installed in your printer.
Refer to the manual that comes with the interface adapter for more information on cabling and
communications.
Note: *

&(+,,

Connecting to a MainFrame
To connect the printer directly to an IBM mainframe, you need:
• a coax adapter card.
• a coaxial cable equivalent to IBM part number 2577672 or 1833108.
The maximum cable length allowed is 4920 feet (1500 meters). See the IBM specification
Installation and Assembly of Coaxial Cable and Accessories, part number GA27-2805-4,
for further information.
If the coax card was not installed in the printer at the factory, you can have the field installable
option (Intermec part number 056836) installed in your printer.
Refer to the manual that comes with the interface adapter for more information on cabling and
communications.

Specifications for 4630/4830
Printing
Type Direct thermal or thermal transfer

Resolution 300 dots per inch (11.8 dots/mm)
Print Speed 4630 2.0" (51 mm) to 8.0" (203.2 mm) per second
4830 2.0" (51 mm) to 5.0" (127 mm) per second
Bar Code Modules 3.3 mil to 110 mil "X" dimension in picket or ladder
orientation
Maximum Print 4630 6.4" (162.6 mm)
Width
4830 8.5" (216 mm)
Maximum Print 4630 10.0" (254 mm) with standard memory
Length
4830 8.0" (203 mm) with standard memory
These values are expandable to 64" (1625.6 mm) with the
optional on board memory expansion module.
Minimum Print 0.5" (12.7 mm)
Length
White Space Slew 2.0" (51 mm) per second to 10.0" (254 mm) per second
Rate
Maximum Fields Per 200; 10K data per label maximum
Label format
Minimum Dot Size 0.0033" (0.085 mm) square
Label Backfeed For use with optional cutter
Fonts
Resident Fonts 21 resident bitmapped fonts (includes OCR-A and

OCR-B) and 3 resident outline fonts scaleable to 4 inches
in height.
Optional Fonts Proportional and monospaced available.
Font Expansion All fonts expandable vertically and horizontally up to
4x; fonts and graphics can be printed in four directions:
0°, 90°, 180° and 270°.
4x30 - Appendix 4x30 Page A - 1

Resident Font Examples
4x30 Page A - 2 4x30 - Appendix

Media
Width 4630 2.0" (50.8 mm) to 6.7" (170.2 mm)

4830 3.0" (76.2 mm) to 9.0" (228.6 mm)
Length 0.50" (13 mm) to 99.99" (2539 mm)
Thickness 0.0025" (0.0635 mm) to 0.0100" (0.254 mm)
Type Roll-fed, die-cut continuous, or fan-fold labels, tags or
tickets; most direct thermal or thermal transfer materials
Supply Roll 8" (203mm) maximum diameter on 1.5" (38 mm) to 3" (76
mm) cores
Internal Rewind Accepts full 8” roll of label or label backing. Rewind
spindle accepts standard “core” of 1.5” and 3”.
Label Material Thermal transfer plain-coated papers, vinyl, Mylar,
metalized paper, non-woven fabric, fine woven fabric,
thermal-visible light scannable paper, infrared scannable
paper, thermal ticket/tag stock, thermally sensitive
plastic stock.
Thermal Ribbons Standard widths are 3.0" (77 mm), 4.1" 104 mm, 5.4" 137
mm, and 6.7" (170 mm). The 4830 can also use an 8.6"
(218 mm) wide thermal ribbon.
Media Sensing Moveable “see-through” for die-cut labels and reflective
for tags with black striping.
Note: -

-

Indicators and Keys
LCD Display 2 x 16 characters for error messages, print status, and

recalling stored formats
Control Panel Lights Alert, Online, Power
Control Panel Keys Feed/Reload, Online/Offline, Cancel
Menu Panel Keys Select, Enter, Menu, Cont, ↑, ↓

Communications Interfacing
IEEE RS-232C or RS-422 at 300, 600, 1200, 2400, 4800, 9600, or 19,200 baud, with
Twinax/Coax optional.
Character Set ANSI ASCII character set

Word Length Selectable 7-bit or 8-bit data format
Handshaking XON/XOFF (in receive mode only) and CTS/DTR
Input Buffer Approximately 7000 bytes.
XOFF is transmitted and DTR goes low when 750 bytes
are available in the buffer.
XON is transmitted and DTR goes high when 750 bytes
are left in the buffer.
Characters are transmitted with no parity from the
printer.
Electrical
Power Source 115/230 VAC, 50/60 Hz, auto ranging, switching power
supply.
Circuit Protection (2) 8 amp, 250V fast-blo fuses
Grounding Unit must be connected to a properly grounded
receptacle.
Environmental
Operating 40ºF to 100ºF (4ºC to 38ºC)
Temperature
Storage Temperature 32ºF to 120ºF (0ºC to 49ºC)
Humidity 10% to 95% non-condensing
Ventilation Forced air movement
Dust Non-conducting, non-corrosive
Physical
Dimensions 4630 13.5" H x 12.5" W x 18" D
(343 mm x 317.5 mm x 457 mm)
4830 14.2" H x 15.3" W X 18" D
(360 mm x 387 mm x 457 mm)
Weight 4630 55 lbs. (24.8 kg)
4830 64 lbs. (29 kg)

Options
Internal Rewind 8" (203 mm) maximum outside diameter capacity (full
supply roll)
Cutter with Tray Maximum media thickness of 0.0075" (0.190 mm).
Certain types of medial are excluded.
Heavy Stock Cutter For media thicknesses greater than 0.006" (0.152 mm).
with Tray
SRAM Storage 2MB for temporary or permanent storage of fonts,
Memory Card formats, and graphics. A maximum of two memory
cards can be used for a total of 4MB.
DRAM Image 4MB DRAM SIMM used for faster image processing and
Memory printing longer, complex labels.
Self-Strip Adapter Peels and presents labels one at a time.
wtih Sensor
Twinax Adapter For connection to IBM AS/400 hosts.
Coax Adapter For connection to IBM S/370 and S/390 hosts.
Printer Option - Operation
Internal Rewind
When large quantities of labels must be printed as single batches or for later use, the printer may
be equipped with a rewind hub that automatically spools label media after it is printed. The
rewind hub is also used in conjunction with the peel and present option to spool the used media
backing after labels have been peeled off.
To use the media rewind hub

# $

- #;

/ %

4 =
5 $ @

6 @

7 0


NVRam and Flash Memory Cards
NVRam memory cards were used on 4x30 printers with version 2.0 firmware. NVRam and cards
Flash memory cards can be used in printers with version 3.0 firmware. 4meg Flash p/n: 064575
The printer has 128K of battery-backed RAM used to store label formats, fonts, and graphics.
The printer is also equipped with two 32-bit external memory card slots, which can be used to
increase printer storage memory.
Optional 2 Meg NVRam, and 1 or 4 Meg Flash memory cards can be inserted into these slots to
increase storage for custom fonts, graphics, and formats used to print labels
Note: U
'.

+'.

Sending fonts, graphics, and formats to the SRAM/NVRAM memory cards is accomplished via
printer commands from the host or by using a label design software package.
The memory card slots are located just above the label supply holder, inside the media access
door.

To install an NVRam or Flash memory card
# @

$

-

A

Communications Reference
Communications Boundaries
The information below applies to all the printer’s supported protocols.
Parameter Maximum Capacity

Printer buffer in bytes 2096 (Standard protocol) 3372
(XON/XOFF, READY/BUSY)
Number of bytes in the buffer when the 1841 (Standard Protocol)
printer stops accepting data. 3116 (XON/XOFF, READY/BUSY)
Number of bytes in the buffer when the 1840 (Standard)
printer resumes accepting data. 2604 (XON/XOFF, READY, BUSY)
Message block size 255, 512 (Standard, Polling Mode D,
Multi-Drop)
Receivable characters after “Busy” 256
Message delay 9999 ms
Character delay 9999 ms
Device Address number A to Z, 0 to 5
(Multi-Drop only)

Communication Interfaces
The printer supports serial communications with the following EIA interfaces: RS-232C,
RS-422, RS-485.
RS-232C 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 following table to operate properly
under RS-232.
RS-422 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 following table to operate properly under RS-422.
RS-485 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 following table
to operate properly under RS-485.
Printer Serial Ports

The serial port connectors are located on the printer’s rear panel. They are 25-pin “D” style
subminiature receptacles. The RS-232/422/485 ports are wired as a data terminal equipment
(DTE) device.
Pin Description
1 Chassis ground (shield)
2 TXD (RS-232)
25
3 RXD (RS-232)
4 RTS (4.7kΩ to +5VDC)
TXD-
5 CTS (input) TXD+
7 Signal ground DTR
RXD- SG
20 DTR (output)
RXD+
9 TXD + (RS-422) CTS
10 TXD - (RS-422)
RTS
18 RXD + (RS-422)
RXD
19 RXD - (RS-422)
TXD
Unlisted pins are not used. GND
4630-18
Interface Cables and Connectors

There are many different cabling options available with the printer. Your choice of cabling
depends on the network configuration, hardware interface, protocol used, cabling distance, and
the electrical and environmental conditions in which you are operating the printer.
Cable Part Numbers

For 25 to 25 pin, use 048668. For 9 to 25 pin, use 048693.

For typical installations, Intermec recommends the following:
•
-4
• -5= B)C

• 0

• "( '=-/- '=4-- '=4;5

Intermec Cables
Intermec offers a full line of interface cables. These cables are not included with the printer and
must be ordered separately. Refer to our Product Catalog or Product Supports ‘Technical
Reference Guide’ for RS-232 cables.
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
RS-232 Null Modem Cable for AT

RS-422 Intermec Pin Assignments
Note: - /
*

()+ 0
)
*

Straight Through- DTE to DTE -Cable for XON/XOFF Flow Control
RS-485 (Multi-Drop) Cables

Refer to the following manuals for information on Multi-Drop cabling and connections.
• <#54 3=) % 0 3 1

. & 94;5#72
• <#6#A 3 1

. & 94<57-2
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 printer:
• %
• %

• (

• 3

•


Following are several suggestions for reducing the effects of electrical noise if any of the items
listed above are located near the printer. Some experimentation may be required to eliminate the
problems. If you need help, ask your Intermec representative for assistance.
• (
0

Install ferrite cable clamps.

• 0

Connecting the Printer to a Network or Modem

The proper way to connect the printer depends on the way your system is configured. This
section contains a procedure for non-switched modem installations and references for network
installations.
Using a Modem With Your Printer

Modems let the printer communicate with the host computer from a remote location that is not
accessible through direct cabling. You must use an asynchronous, dedicated (non-switched or
manually switched), full-duplex modem to communicate with the printer. Communication
requirements should be described in the modem documentation.
To connect the printer to a host with a modem
# 0
-5= -5= '=-/-

1
. & 94/-/72
- 0

/ 0

4 *

@

B0 3 . C 0 # BD C
Installing Your Printer in a Network

If you are installing your printer into a network environment, you may need to change the main
port configuration settings to match those of the rest 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 installation instructions and information on the necessary cabling and connections.
• <#54 3=) % 0 3
• <#6#A 3
• ' E<#;9 0 ?F 3
• ' E<#;5 0 ?@ 3
• ) 0
'
3
If you need to change the printer's communication parameters, follow the procedures for
“Configuring the Main Port”.

International Character Sets
The following tables show which hex codes to download for international characters not
available in the U.S. character set. To use the tables, find the hex code for the U.S. character that
corresponds with the character in your language.
4630/4830 Character Table

Use this table to find the correct hex codes for the international character sets listed.
For a selected character set,

enter the hex value for the US # $ @ [ \ ] ^ ` { | } ~
characters at the right to print
the characters below. 23 24 40 5B 5C 5D 5E 60 7B 7C 7D 7E
U.S. ASCII # $ @ [ \ ] ^ ` { | } ~
U.K. ASCII £ $ @ [ \ ] ^ ` { | } ¯
Germany # $ § Ä Ö Ü ^ ` ä ö ü ß
France £ $ à ° ç § ^ ` é ù è ¨
Norway/Denmark # $ @ Æ Ø Å ^ ` æ ø å ¯
Sweden/Finland # ¤ É Ä Ö Å Ü é ä ö å ü
Spain £ $ § ¡ Ñ ¿ ^ ` ° ñ ç ~
Italy £ $ § ° ç é ^ ù à ò è ì
Switzerland # $ à ° ç é ^ ù ä ö ü è
Translation Character Table

If you are running your printer with Translation enabled, use this table to find the right hex codes
for the international character sets.
For a selected
character set, enter the
hex value for the US
characters at the right ! # $ @ [ \ ] ^ ` { | } ~
to print the characters
below. 21 23 24 40 5B 5C 5D 5E 60 7B 7C 7D 7E
U.S. ASCII | # $ @ ¢ \ ! ¬ ` { | } ~
U.K. ASCII | # £ @ $ \ ! ¬ ` { | } ¯
Germany ! # $ § Ä Ö Ü ^ ` ä ö ü ß
France ! £ $ à ° ç § ^ ` é ù è ¨
Norway/Denmark ! Æ Å Ø # \ ¤ ^ ` æ ø å ü
Sweden/Finland ! Ä Å Ö § É ¤ ^ é ä ö å ü
Spain | Ñ Pt @ [ \ ] ¬ ` { ñ } ¨
Italy ! £ $ § ° ç é ^ ù à ò è ì
Switzerland ! # $ à ° ç é ^ ù ä ö ü è

Component Locations for Service
Media Side
4x30 - Service 4x30 Page S - 1

Electronics Side
Main Electronics Board Component Locations
4x30 Page S - 2 4x30 - Service

Component Description - Main Electronics Boards
J1 - Printhead Connector. Provides connection for control signals to and from the Printhead.
Also supplies logic voltage to the Printhead.
J2 - Standard Centronics-type Bi-directional Parallel Port.
J3 - General Purpose I/O Connector. Provides 8 general purpose output and input bits.
J4 - DRAM Socket. - Provides connection for SIMM DRAM package. The factory installed
standard 1 MB of DRAM may be expanded to a maximum of 5 Meg.
J5 - Bi-directional Serial Ports. This connector contains two serial ports, Port A and B. Both
ports are capable of either RS-232 or RS-422 communications protocols. In RS-422 mode,
either channel may be independently enabled or disabled through software.
J11 - TWINAX/COAX (Matrix) Expansion Port. Allows the addition of an optional
TWINAX/COAX expansion board. Allows the Printer to communicate with mainframe
systems.
J13 - Head Home Sensor Connector - Connects the sensor that monitors the "head down"
status of the Printhead.
J15 - Ribbon Save Interface - Provides control signals and voltages for the Ribbon Save option
board.
S1 - Four Position DIP Switch. Position 1 toggles the operator panel lockout feature.
Positions 3 and 4 set the Terminator resistor function when in RS-422 mode. Position 2 is
not used.
J6 - Ribbon Sensor Connector.
J7 - Label Present Sensor Connector - Used when the Peel and Present option is
installed.
J8 - Media Sensor Connector.
J9 -Front Panel interface. Connects the Operator’s Panel PC Board with the Main PC
Board. Also provides operating voltages for the optional Cutter mechanism.
J10 - Power Supply interface. Provides voltages and logic ground from the power supply
to the Main Logic Board.
J12 - Power Supply interface. Provides control signals from the Main Logic Board to the
Stepper motors and Printhead.
J14 - Power Take-off Connector. Provides voltages for electronic accessories that may be
added in future models of the Printer.
J16 & 17 - Memory Card interface. Provides an interface for plugging in 32 bit memory
cards. The interface will accept FLASH, SRAM, NVRAM or One-time-
programmable EPROM cards. Cards may be inserted or removed with power on. J16
and 17 may be used interchangeably or both together.
J18 - PCMCIA interface. Provides an interface for one or two PCMCIA device cards.
The interface will accept either Type 1 or Type 2 cards and either 5v. or 3.3v.
versions.

Main Electronics Board Component Locations

4630/4830 Maintenance
Cleaning the Printhead

Cleaning media debris from the printhead maintains close contact between the media and
printhead, which provides good print quality. The printhead should be cleaned after every 5 rolls
of media. Always clean the printhead immediately if a label jams in the printer.
Note:

To clean the printhead

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Cleaning the Rollers and the Tear Bar

Cleaning the rollers and the tear bar preserves print quality by ensuring close contact between the
media and the printhead.
To clean the rollers and tear bar

.

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Cleaning the Cutter Blades
The cutter blades (optional) require a minimal amount of maintenance. After every 5,000 to
10,000 label cuts, 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 moistened with isopropyl alcohol. 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.
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.
Cleaning the Media Guides and Media Path

You should clean the media guides and media path regularly to keep debris off the media surface
and printhead where irregularities can spoil print quality or damage the printhead. Cleaning the
guides also prevents the media from skewing or improperly tracking as it travels through the
paper path, which can result in smeared images and print off the side of the label. Always clean
the media guides immediately after a label jam in the printer.
Media debris may accumulate around the printer mechanism and along the media path during
normal operation of the printer. Clean the debris away regularly using a soft bristle brush or
vacuum cleaner. Remove all traces of dust, paper, and adhesive. Clean the flat surfaces of the
media path (including the edge guide) with a lint-free cloth and isopropyl alcohol.
To clean the media guides and media path

1
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Cleaning the Label Sensors

There are three label sensors on the printer that require regular cleaning: the label taken sensor,
the label mark sensor, and the label gap sensor.
To clean the label sensors

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Cleaning the Printer Covers

Clean the printer covers with a general purpose cleaner (soapy water/mild detergent). Do not use
abrasive cleansers or solvents. Be sure to clean the transparent panel on the stock door so that the
media supply inside the printer is visible when the cover is closed.
4Meg Image DRAM Installation
Installing the optional SIMM module to the main PCB increases the amount of image DRAM
from 1 Meg to 5 Meg.
5 6-//

70# 1

6

Installing Image DRAM
/ 8 +*0, !/" !' /"
DRAM Jumper Settings
E-16 E-17 E-16 E-17
E-20 E-21 E-20 E-21
1 Meg setting 5 Meg setting
Change the jumper to the 2nd from the bottom (E20-E21) for 5 meg upgrade.

4630/4830 Adjustments
There are 5 adjustment points on the 4630/4830 printers
1- Printhead Alignment or Printhead Burn Point

2- Bias Adjustment or Head Level Cam
3- Media Width Guide
4- Media Sensor
5- Head Home Sensor
Printhead Alignment or Burn Point Adjustment

The Printhead Burn Point is the place where the flat surface of the printhead heater line actually
meets the surface of the media (and ribbon, in thermal transfer mode).
The Burn Point Adjustment is performed by loosing the two Printhead Assembly Anchor screws
(only enough to move the carriage) and rotating the two spring-loaded Allen screws situated on
top of the Printhead housing. Rotating the screws moves either side of the printhead forward and
backward along the media path to adjust the burn point for maximum print quality. When the
adjustment is complete, tighten the Printhead Assembly Anchor screws.
When out of adjustment, the skewed position of the Printhead causes the print to fade out toward
one side of the label.
CAUTION - Do not force or over tighten the adjustment screws
Printhead Alignment or Burn Point Adjustment

Printhead Bias or Leveling Cam Adjustment
The Printer can use a variety of media widths and thicknesses. To ensure even print quality
across the media regardless of changes in media dimensions, the Printhead has a leveling cam
adjustment. The Cam raises and lowers the right side of the Printhead to keep the Printhead level
across the media.
The Printer is factory set using a standard 4 mil thick, six inch wide print media. The Cam
Adjustment is designed to compensate when narrower width stock is used. When out of
adjustment, print along one side of the label will be missing. The print drops off suddenly, rather
than gradually fading out.
The adjustment knob is designed with detents which allow it to turn a specific distance, one click
at a time. The knob is numbered for the convenience of the operator. (The numbers do not
relate to specific media sizes). Turn the knob one click at a time until the desired print quality is
achieved.
When changing to media of different thickness, it may also be necessary to reset the Cam
Adjustment Bracket. To reset the Bracket (1.) Turn the Adjustment Knob counter-clockwise
until it stops; (2.) Loosen the two screws securing the Bracket; (3.) Load the new sized media;
(4.) Slide the Bracket up or down to contact the Cam Adjustment; (5.) Tighten the two screws
to secure the Bracket. Print a test label and turn the Cam Adjustment Knob if necessary to fine
tune the print quality.
Caution - Do not force or over tighten the adjustment knob
Printhead Bias or Leveling Cam Adjustment

Media Sensor Adjustment
The Media Sensor performs two functions. It acts both as a Position sensor, which allows the
Printer to monitor the position of a label along the media path, and as a Media Present sensor,
which informs the Printer when stock must be replaced. The Printer’s firmware controls whether
the sensor detects the Top Of Form position or an Out Of Stock condition This sensor must be
correctly adjusted for proper Printer operation.
Transmissive (Gap) Sensor adjustment

When using transmissive label backing, the transmissive sensor detects the position of each label
by passing light from an LED through the label backing material. Because more light passes
through the backing alone than through the label plus backing, the sensor is able to discriminate
between the two situations, and thus identify the position of the label. To adjust this sensor
value:
1

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(
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1

1

Transmissive (Gap) Sensor Adjustment

Reflective (Black Mark) Edge Sensor Adjustment
When using stock with reflective label backing, the sensor detects the position of each label by
reflecting a light signal off the label backing material. This sensing method requires the use of
special label backing that contains a carbon black stripe. The sensor detects the Top Of Form
position by sensing the voltage drop when the reflected light is absorbed by the black stripe.
1

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9 1 / 9 %
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Media must pass

through the Sensor
Media Sensor Location and detail
TOF Sensor
Printhead Carriage
Mounting Frame
Ribbon Hubs
Upper Media
Guide

,

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5

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5

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4 1
1

1 2 8
Reflective (Black Mark) Sensing
Light travels from LED, reflects

Light is absorbed by the
from the media and is detected
black mark, not detected
by the sensor
by the sensor
Media Sensor Assembly - Mechanical Adjustment

In order to be able to detect the label edge and/or carbon black stripe for all media sizes, the
Media Sensor is adjustable across half of the media path. The position of the Media Sensor may
need to be adjusted when changing from a wider to a narrower media stock size to ensure that
the sensor is positioned to detect the label edge.
Rotating the knurled adjustment knob clockwise sets the sensor for wider media. In general, if
the knob is kept in the full counter-clockwise position it will correctly sense media. However, if
there is a problem in sensing Top Of Form, try rotating this knob clockwise, one half turn at a
time, until the error is eliminated.
CAUTION - Do not force or over tighten this adjustment knob

Media Sensor Assembly - Adjustment
Media Width Guide

To ensure smooth passage of the media through its path, the Media Width Guide should be
adjusted with every change in media width.
The Upper Width Guide should always be kept adjusted. The rear and bottom Feed Slots are
not equipped Width Guides.
To adjust, slide the guide in or out until it just touches the edge of the media.

Head Home Sensor Adjustment
In factory production, the Head Home Sensor is adjusted using an oscilloscope. This adjustment
can be made in the field using a Multimeter. Use the following procedure:
. 1

6 / .

1;

9
1 1# / 9
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7 / 9 %
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Test Point 12 Location

Head Home Sensor Location
Head Home Sensor Adjustment
Note:


Removal and Replacement
Printhead Removal
== 1;

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Printhead Replacement
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Printhead Home Sensor Removal

The Printhead Home Sensor and Interlock is designed to prevent the Printhead from being
activated when not in the normal printing position. The Interlock switch is actuated when the
Home Sensor detects that the Printhead is not locked in the Down position. Use the following
procedure to remove the Home Sensor:
1;

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5.
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Printhead Home Sensor Removal

Printhead Home Sensor Replacement
5

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Media Sensor Removal

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NOTE: The shaft washers and spacers are held in position by the “E” Clip and Media
Sensor Shaft - when the shaft is removed, they will fall.
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NOTE
Media Sensor Replacement

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Main PCB Assy. Replacement

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Drive Roller Replacement
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Drive Roller Replacement
Note: !"!

Timing Belts - Removal

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Timing Belt - Replacement

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Ribbon Spool Assembly - Removal
1;

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Ribbon Spool Assembly - Removal
Ribbon Supply Hub Clutch Assy. - Removal

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Ribbon Supply Hub Clutch Assy. - Removal
NOTE: #

Ribbon Shaft (Rewind) Clutch Assy. - Removal

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6 5

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Ribbon Rewind Clutch Assy. - Removal
Media Spool Assy. Option - Removal

The Media Spool assembly Option is driven by the main drive motor.
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Media Spool Assy. Option - Replacement

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Main Drive Motor - Removal
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Main Drive Motor - Removal
Main Drive Motor - Replacement

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Media Hub Assembly Removal
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Power Supply Fuse Replacement
WARNING - For continued protection against fire replace with same Fuse type and
rating.
1;

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1
6

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=
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= 3 5/1

NOTE: Use caution when replacing Fuse F1 if blown. This fuse will blow only if a
failure occurred in the primary switching circuit and may be an indication of
a more serious problem.

Power Supply Fuse Replacement
* 0

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Power Supply Replacement
1 == 5.

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Front Panel Replacement
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Note:

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Printer
Assembly
Drawing

Cover Assemblies
ITEM PART NUMBER DESCRIPTION
1 11-4167-01 COVER, SIDE

2 16-2212-02 PANEL FRONT
3 16-2203-01 BLOCK, TOP, ACCESS
4 11-4227-01 COVER, ACCESS
5 11-4189-01 HINGE
6 10-2534-01 SCREW, M3 X 6 PHIL
7 130938 SCREW, M3 X .5 X 6 PHIL EXT/SEM
8 130938 SCREW, M3 X 6.0 LONG
9 16-2237-01 DOOR
10 16-2238-04 KEY, ON LINE
11 16-2238-02 KEY, FEED
12 16-2238-03 KEY, CANCEL
13 17-2398-01 DOOR LATCH (NOT SHOWN)
14 16-2236-01 WINDOW, MEDIA
15 10-2540-01 ADHESIVE TAPE

Final Assembly
1 of 3
1 24-2323-01 POWER SUPPLY ASSEMBLY

2 16-2242-01 PULLEY, TIMING, 36 TEETH, 2.03P
3 10-2532-01 RING, RETAINING
4 15-2400-01 FRAME ASSEMBLY
5 11-4151-01 BRACKET, PAPER TEAR
6 11-4350-01 BRACKET, REWIND
7 10-2539-02 CAP 175 X 12
8 17-2240-01 THUMB SCREW KNOB, M5
9 11-4187-01 GUIDE, MEDIA, LOWER
10 13-2226-01 ROLLER, DRIVE
11 11-4165-01 PLATE, SIDE, OUTER
12 17-2311-01 BEARING, FLANGED, 6.0 ID X 12.0 OD
13 12-2385-01 ROLLER, IDLER
14 130938 SCREW, M3 X .5 X 6.0
15 12-2499-01 PLATE, CENTER
16 16-2217-01 SPACER
17 12-2388-01 SHAFT, IDLER
18 12-2448-01 BLOCK, SPACER
19 10-0252-01 RING, RETAINING, EXTERNAL E, 5/16
20 17-2324-01 SPRING, TORSION
21 13-2226-01 ROLLER, DRIVE "Ribbon saver option"
22 17-2311-01 BEARING, FLANGED "Ribbon saver option"
23 10-2532-01 RING, RETAINING "Ribbon saver option"
24 16-2242-01 PULLEY, TIMING, 36 TEETH, 2.03P "Ribbon saver option"
25 897144 CLIP, RETAINING

Final Assembly
2 of 3
1 16-2205-01 HOUSING, SENSOR

2 11-4153-01 GUIDE, MEDIA
3 11-4478-01 PLATE, GUIDE
4 130938 SCREW, M3 X 6.0
5 17-2417-01 LATCH
6 10-2575-01 SPACER
7 130943 SCREW, M5 X 12
8 17-2318-01 BUSHING "Not shown - part of item 1"
9 12-2447-01 BLOCK, ALIGNMENT
10 11-4348-01 GUIDE, MEDIA, FRONT
11 12-2400-01 * ROLLER, IDLER "Ribbon Saver option"
12 16-2219-01 * BLOCK, BEARING "Ribbon Saver option"
13 17-2415-06 * SPRING, COMPRESSION "Ribbon Saver option"
14 12-2402-01 SHAFT, SENSOR
15 899325 SPACER
16 10-2444-01 RING, RETAINING, 5/32
17 130854 PIN
18 899297 KNOB, SENSOR ADJUST
19 17-2403-01 WASHER, FENDER
20 17-2447-01 WASHER, NYLON
21 13-2256-01 WEAR STRIP
22 11-4470-01 GUIDE, MEDIA, ADJUSTABLE
23 10-2514-03 SCREW, FLAT HEAD, M3 X 10
24 10-0530-01 NUT, SQUARE, .164-32 UNC
25 24-2350-01 ASSEMBLY, SENSOR, MEDIA
26 12-2499-01 PLATE, CENTER
12-2495-01 * PLATE, CENTER (shown) "Ribbon Saver Option"
27 11-4158-01 BRACKET, ADJUSTMENT
28 17-2445-01 NUT, KNURLED THUMB
29 17-2446-01 WASHER, #6 BELLEVILLE SPRING

Final Assembly
3 of 3
1 51-2126-01 MAIN LOGIC BOARD (i960)

2 130938 SCREW, M3 X .5 X 6.0
3 32-2220-01 CABLE ASSY, PRINTHEAD DATA
4 17-2410-05 BELT, TIMING, 2.03P, 340 TEETH
5 10-2518-01 WASHER, FLAT, CRES
6 17-2410-01 BELT, TIMING, 2.03P, 120 TEETH
17-2410-02 * BELT, TIMING, 2.03P, 125 TEETH "Ribbon saver"
7 11-4288-01 PLATE, COVER
8 10-2446-01 RING, RETAINING
9 12-2436-01 SHAFT, MOUNTING, CLUTCH
10 10-2506-01 WASHER, FLAT, NYLON
11 17-2407-01 PULLEY, CLUTCHED
12 140073 FOOT, RUBBER BUMPER
13 10-2519-02 SCREW,
14 24-2354-01 SENSOR ASSY, HEAD HOME
15 32-2268-01 CABLE ASSY, GENERAL PURPOSE
16 10-0252-01 RING, RETAINING, EXTERNAL E, 5/16
17 12-2382-01 SHAFT, IDLER
18 17-2416-01 BUSHING, FLANGED
19 11-4156-01 PLATE, TENSIONER
20 10-2514-01 SCREW, FLAT HEAD, M3 X 6
21 16-2240-01 COVER, HOUSING

Datamax Printer Service PART MATRIX: CROSS REFERENCE
Printer Part Numbers

Model 4630A 4630A 4830A 4830A
DESCRIPTION P/N Datamax Pn P/N Datamax Pn
ADAPTER, CORE 589287-001 16-2269-01 589287-001 16-2269-01
ASSEMBLY RIBBON REWIND HUB 15-2486-01 15-2499-01
ASSEMBLY, RIBBON SENSOR BOARD 589235-001 51-2162-01 589235-001 51-2162-01
ASSEMBLY, RIBBON SUPPLY HUB 15-2482-01 15-2497-01
ASSEMBLY, SENSOR TBD 24-2318-01
ASSEMBLY, SENSOR, MEDIA 589236-001 24-2350-01 589236-001 24-2350-01
ASSY FRONT PANEL TBD 51-2129-00 TBD 51-2129-00
ASSY POWER SUPPLY 589229-001 51-2128-00 589229-001 51-2128-00
ASSY PWR SUPPLY CNT 589227-001 51-2127-00 589227-001 51-2127-00
ASSY, PRINTHEAD POWER CABLE 589246-001 32-2219-01 589245-001 32-2284-01
BALL, CRES - .2187 DIA 17-2438-01 PART DELETED
BEARING, FLANGE 17-2464-01 17-2464-01
BEARING, FLANGED, .375 ID X.875 OD 589263-001 17-2310-01 589263-001 17-2310-01
BEARING, FLANGED, 6.0 ID X 12.0 OD 589262-001 17-2311-01 589262-001 17-2311-01
BEARING, MEDIA HUB 589293-001 12-2508-01 589293-001 12-2508-01
BELT, TIMING, 2.03P, 120 TEETH 589244-001 17-2410-01 589244-001 17-2410-01
BLADE, 1.5" MEDIA HUB 11-4476-01 T.B.D.
BLADE, 3" MEDIA HUB 11-4475-01 11-4582-01
BLOCK, ALIGNMENT 12-2447-01 12-2464-01
BLOCK, SPACER 12-2448-01 12-2465-01
BLOCK, TOP, ACCESS 589286-001 16-2203-03 TBD 16-2297-03
BRACKET, ADJUSTMENT 11-4158-01 11-4158-01
BRACKET, PAPER TEAR 589285-001 11-4151-01 TBD 11-4353-01
BRACKET, REWIND TBD 11-4350-01 TBD 11-4352-01
BRACKET, ROLLER 11-4469-01 11-4469-01
BRACKET, SENSOR TBD 11-4319-01 TBD 11-4319-01
BRACKET, SUPPORT, MOTOR 11-4316-01 11-4316-01
BRAKE, RIBBON SHAFT 12-2409-01
BUMPER, SELF-STICK "Attaches to media 17-2448-01 17-2448-01
guide"
BUSHING TBD 17-2318-01 TBD 17-2318-01
BUSHING 17-0149-01
BUSHING, FLANGED 17-2416-01 17-2416-01
CABLE ASSEMBLY, 16 PIN TBD 32-2217-01 TBD 32-2217-01
CABLE ASSEMBLY, FRONT PANEL TBD 32-2221-01 TBD 32-2221-01
CABLE ASSY, GENERAL PURPOSE TBD 32-2268-01 TBD 32-2268-01
CABLE ASSY, PRINTHEAD DATA TBD 32-2220-01 589239-001 32-2285-01
CAP 175 X 12 TBD 10-2539-02 TBD 10-2539-02
CCA, FRONT TBD 51-2129-01 TBD 51-2129-01
CLAMP, SPRING 899144 899144
CLAMP, SPRING SHORT TBD 11-4514-01 TBD 11-4514-01


Model 4630A 4630A 4830A 4830A
CLIP, RETAINING TBD 897144

CLUTCH ASSY, 44 TEETH 589261-001 17-2413-01 589261-001 17-2413-01
CLUTCH ASSY, 65 TEETH 589260-001 17-2414-01 589260-001 17-2414-01
CLUTCH ASSY, BACK TENSION 589259-001 17-2290-01 589259-001 17-2290-01
COVER, ACCESS 11-4227-03 11-4355-03
COVER, HOUSING 16-2240-01 16-2240-01
COVER, PROTECTIVE ,LCD 16-2213-01 16-2213-01
COVER, SIDE TBD 11-4167-03 TBD 11-4388-03
DISC, FRICTION (Installed inside media hub 16-2316-01 13-2262-01
before adding bearing P/N: 12-2508-01)
DOOR TBD 16-2237-03 TBD 16-2237-03
DOOR LATCH (NOT SHOWN) TBD 17-2398-01 TBD 17-2398-01
FAN, 24V BRUSHLESS 589269-001 20-2126-01 589269-001 20-2126-01
FOOT, RUBBER BUMPER TBD 140073 TBD 140073
GUARD, FAN (INCL. FILTER) TBD 17-2432-01 TBD 17-2432-01
GUIDE, MEDIA 11-4153-01 11-4354-01
GUIDE, MEDIA, ADJUSTABLE 11-4470-01 11-4470-01
GUIDE, MEDIA, FRONT 11-4348-01 11-4346-01
GUIDE, MEDIA, LOWER 11-4187-01 11-4351-01
HEAKSINK, PRINTHEAD 12-2500-01 12-2480-01
HINGE 589292-001 11-4189-01 TBD 11-4387-01
HOUSING, MEDIA SPOOL 12-2444-01 12-2444-01
HOUSING, RIBBON SPOOL 12-2445-01 12-2445-01
HOUSING, SENSOR TBD 16-2205-01 TBD 16-2205-01
HUB, MEDIA 12-2505-01 12-2559-01
HUB, TAKE-UP 16-2283-01 16-2283-01
J-HOOK, RIBBON REWIND 589256-001 12-2530-01 589270-001 12-2547-01
KEY, CANCEL TBD 16-2238-09 TBD 16-2238-09
KEY, FEED 589284-001 16-2238-08 589284-001 16-2238-08
KEY, ON LINE 589283-001 16-2238-07 589283-001 16-2238-07
KNOB, SENSOR ADJUST 899297 899297
KNURLED HEAD SCREW ASSY. TBD 15-2345-02 TBD 15-2345-02
KNURLED HEAD SCREW ASSY. TBD 15-2345-01
LABEL, RIBBON SENSOR 764243 764243
LATCH 589282-001 17-2417-01 589282-001 17-2417-01
LCD, 16 X 2 589271-001 45-2009-01 589272-001 24-2344-01
MAIN LOGIC BOARD (i960) 589234-001 51-2126-01 589234-001 51-2126-01
MOTOR ASSEMBLY 589231-001 24-2345-01 589231-001 24-2345-01
MOTOR, STEPPER 589241-001 20-2079-01 589241-001 20-2079-01
NUT, KNURLED THUMB 17-2445-01 17-2445-01
NUT, SQUARE, .164-32 UNC 10-0530-01 10-0530-01
PAD, SCREW TBD 16-2268-01 TBD 16-2268-01


Model 4630A 4630A 4830A 4830A
PANEL FRONT TBD 16-2212-03 TBD 16-2296-03

PANEL, MEMBRANE SWITCH 589257-001 52-2007-04 589257-001 52-2007-04
PCB, REWIND SENSOR 589258-001 51-2107-01
PIN TBD 130854 TBD 130854
PIN, STRAIGHT .094 DIA. X .437 LONG 17-2426-01 17-2426-01
PLATE, ADJUSTMENT - PRINTHEAD 589281-001 11-4142-01 589254-001 11-4360-01
PLATE, CENTER 12-2499-01 12-2499-01
PLATE, COVER 11-4288-01 11-4288-01
PLATE, GUIDE 11-4478-01 11-4478-01
PLATE, MOUNTING - PRINTHEAD 11-4144-01 11-4361-01
PLATE, NUT TBD 11-4313-01 TBD 11-4313-01
PLATE, RIBBON TBD 11-4145-01 TBD 11-4362-01
PLATE, SIDE, OUTER 11-4165-01 11-4165-01
PLATE, TENSIONER 11-4156-01 11-4156-01
PLATE, UPPER - PRINTHEAD 11-4147-01 11-4363-01
PLATE-DETENT, HEAD CAM 11-4432-01 11-4432-01
POWER SUPPLY ASSEMBLY 589228-001 24-2323-01 589228-001 24-2323-01
PRINTHEAD 589232-001 20-2118-01 589233-001 20-2132-01
PRINTHEAD CAM 589291-001 16-2183-01 589291-001 16-2183-01
PULLEY, CLUTCHED 589255-001 17-2407-01 589255-001 17-2407-01
PULLEY, TIMING 20 TEETH 12-2438-01
PULLEY, TIMING, 36 TEETH, 2.03P 589264-001 16-2242-01 589264-001 16-2242-01
PULLEY, TIMING, COMPOUND 589265-001 17-2409-01 589265-001 17-2409-01
RETAINER TBD 11-4315-01 TBD 11-4315-01
RETAINER TBD 11-4386-01 TBD 11-4386-01
RETAINER, MEDIA TBD 16-2267-01 TBD 16-2267-01
RETAINING RING, .375 589290-001 10-0563-01 589290-001 10-0563-01
RING, RETAINING 589280-001 10-0447-01 589280-001 10-0447-01
RING, RETAINING 589289-001 10-2446-01 589289-001 10-2446-01
RING, RETAINING 589288-001 10-2532-01 589288-001 10-2532-01
RING, RETAINING, 5/32 10-2444-01 10-2444-01
RING, RETAINING, EXTERNAL E, 5/16 589279-001 10-0252-01 589279-001 10-0252-01
ROLLER, BOUNCER 16-2310-01 16-2310-01
ROLLER, DRIVE 589230-001 13-2226-01 589240-001 13-2246-01
ROLLER, IDLER 589237-001 12-2385-01
SCREW, BUTTON HD SOCKCAP 4-0 X .1 10-2571-01 10-2571-01
SCREW, FLAT HEAD, M3 X 10 10-2514-03 10-2514-03
SCREW, FLAT HEAD, M3 X 6 10-2514-01 10-2514-01
SCREW, M3 X .5 X 6 PHIL EXT/SEM 130938 130938
SCREW, M5 X 12 130943 130943
SCREW, PANHD SEMS M3 X 8 10-2519-02 10-2519-02
SCREW, PHIL, SEM, M3 X 16 10-2519-06 10-2515-06


Model 4630A 4630A 4830A 4830A
SCREW, SOC HD 10-2568-01 10-2568-01

SCREW, SOCK SET M4 X 4 10-2378-01 10-2378-01
SCREW, SOCKET HEAD CAP, 3M X 10 10-2515-03 10-2515-03
SCREW, SOCKET HEAD CAP, M5 X 10 10-2539-01 10-2539-01
SCREW, THREAD FORMING M2.5 X 6 10-2541-01 10-2541-01
SENSOR ASSY, HEAD HOME 589238-001 24-2354-01 589238-001 24-2354-01
SHAFT - RIBBON REWIND TBD 12-2528-01 TBD 12-2528-01
SHAFT - RIBBON SUPPLY HUB 12-2503-01 12-2503-01
SHAFT, IDLER 589266-001 12-2382-01 589268-001 12-2562-01
SHAFT, IDLER 589267-001 12-2388-01
SHAFT, IDLER TBD 12-2388-02
SHAFT, MEDIA HUB 12-2507-01 12-2558-01
SHAFT, MOUNTING - PRINTHEAD TBD 12-2381-01 TBD 12-2466-01
SHAFT, MOUNTING, CLUTCH TBD 12-2436-01 TBD 12-2436-01
SHAFT, MOUNTING, PULLEY TBD 12-2437-01 TBD 12-2437-01
SHAFT, PIVOT 12-2492-01 12-2492-01
SHAFT, ROLLER 12-2491-01 12-2553-01
SHAFT, SENSOR 12-2402-01 12-2402-02
SLIP CLUTCH TBD 15-2548-01 TBD 15-2548-01
SPACER TBD 10-2575-01 TBD 10-2575-01
SPACER TBD 16-2217-04 TBD 16-2217-04
SPACER TBD 16-2217-01
SPACER 899325 899325
SPACER, HEAD CAM TBD 12-2411-01 589277-001 12-2411-01
SPACER, PIVOT SHAFT 899210 899210
SPRING 17-2439-01 17-2439-01
SPRING, COMPRESSION 589278-001 17-2314-03 589278-001 17-2314-03
SPRING, COMPRESSION 589276-001 17-2402-01 589276-001 17-2402-01
SPRING, COMPRESSION 17-2314-02 17-2314-02
SPRING, EXTENSION 589275-001 17-2313-01 589275-001 17-2313-01
SPRING, MEDIA HUB 17-2450-01 17-2450-01
SPRING, TORSION 589273-001 17-2324-01
SPRING, TORSION 17-2442-01 17-2442-01
TENSION BAR 16-2260-01 11-4343-01
THUMB SCREW KNOB, M5 TBD 17-2240-01 TBD 17-2240-01
TIMING PULLY TBD 17-2409-07 TBD 17-2409-07
WASHER, #6 BELLEVILLE SPRING 17-2446-01
WASHER, FENDER 17-2403-01 17-2403-01
WASHER, FLAT 10-2505-01 10-2560-01
WASHER, FLAT, CRES 10-2518-01 10-2518-01


Model 4630A 4630A 4830A 4830A
WASHER, FLAT, NYLON 10-2506-01 10-2506-01

WASHER, KEYED 11-4477-01 11-4477-01
WASHER, NYLON 17-2447-01 17-2447-01
WASHER, WAVE TBD 17-2317-01 TBD 17-2317-01
WEAR STRIP 13-2256-01 13-2256-01
WINDOW, MEDIA TBD 16-2236-01 TBD 16-2236-01

4630/4830 Electronic Theory
In the design of the 4630/4830 Printer, the majority of the electronic functions are combined on a
single circuit board, utilizing the Intel i960 type microprocessor.
The microprocessor is responsible for overseeing the data flow throughout the system; for
processing and formatting print data; for managing the print cycle in which print data is sent to
the Printhead and the Printhead elements activated; and for monitoring the sensors for alarm
conditions.
Microprocessor
The 32 bit Intel 80960 JA Microprocessor (U22) formats label data, and sends it to the thermal
print head control circuits.
The 80960 JA calculates the proper strobe times for each print cycle based on print head
temperature. The four 8-bit latches (U41 ,U42, U44 and U45) are used to latch the 32 address
bits during each address interval.
Thermal Printhead Control circuit.

This circuit operates during a print cycle as follows:

!
" #$ %! &'() %
"
!
% # &'() * #+( !
# * , -(( -((

. / # * , * & *,
# *

#
The Printhead contains two buffers. While the first (input) buffer is loaded with print data, the
second (output) buffer transmits its data to the printhead. When the first buffer has been filled
with print data, it transfers the data in parallel to the second buffer. This clears the input buffer
and prepares it to receive the next block of print data.
The Programmable Interrupt Controller at U67 expands the total number of available interrupts
on the i960 board to 10.
Programmable Timer
The programmable timer (U64) provides three independent timing signals.
Timer0 0 $ , ! $

Timer1 0 & ,

, #
Timer2 0 + 0 , ( - 1"!

Analog to Digital (A to D) Converter (U72)
Converts analog input signals to digital data. Four channels are used :
0 ) ) 2, &

0 ) #

0 ) # 3 ,
0 ) - $4
DRAM Memory
The Printer is factory equipped with 1 Megabyte of DRAM (U43, U52). The 1 MB consists of
two 256K by 16 bit chips, producing a total of is 256K by 32 bits. DRAM is expandable to a
maximum 5 MB.
Address are multiplexed into DRAM by the DRAM address multiplexer (U53,U54 and U60).
EPROM Memory
The Printer is factory equipped with 2 MB of EPROM (U28, U29, U30 and U31). Each chip
consists of 4 megabits of ROM arranged as 512K by 8 bits, forming a 512K by 32 bit (2 MB)
array.
Real-Time-Clock (RTC)
The RTC chip, located at U61, provides time information, and contains 114 bytes of non-volatile
data storage, used to store set-up data for the Printer.
Note:

Ribbon Sensor
The ribbon sensor circuit is comprised of a voltage comparator (U58- pins 1,6, and 7), 4 resistors
(R111, R132, R133, and R202), 1 diode (D10), and 1 capacitor (C7). In thermal transfer mode,
the circuit insures that the Ribbon Rewind Hub is functioning properly.
Paper Motion Sensor

The paper motion sensor circuit, comprised of a voltage comparator (U58, pins 2,4, and 5), 4
resistors (R189, R190, R201 and R238), 1 diode (D11, and 1 capacitor (C6), operates in direct
thermal mode paper motion to insure that the Media Rewind Hub is functioning properly.
Head Home Sensor

The head home sensor circuit is comprised of a voltage comparator (U58, pins 10,11 and 13)and
4 resistors (R191, R192, R208 and R230). The circuit is designed to ensure that the Printhead is
locked in the down position.

Paper Edge Sensor
The paper edge sensor circuits consists of three invertors (U59-10,11, U59-12,13 and U59-8,9),
two potentiometers (R1 and R2), and one transistor (Q7).
The paper edge sensor operates in both reflective type and transmissive sensing modes. In the
transmissive mode the transmissive LED is turned ON and the reflective LED is turned OFF. In
the reflective mode the reflective LED is turn ON and the transmissive LED is turned OFF.
Potentiometer R1 controls the gain of the detector (photo transistor) by controlling the value of
the collector load resistor.
Potentiometer R2 controls the gain of the reflective sensor by controlling the amount of current
in the reflective LED.
Front Panel Interface

The 34-position connector J9 provides the interface connections between the I960 board and the
front panel P.C. board.
The inputs on U39-2 through U39-9 and U68-9 come from the nine keypad switches located on
the Control and Operator's panels.
Three LED's located on the front panel are driven by U47 and U8.
They are: U47-12 = On Line/Pause, U47-13 = Media/Ribbon, and U8-6 = Power.
Signals labeled TX, DTR, RX and CTS are connected to the RS232 phone jack connector located
on the Operator's Panel PC board . These lines are used when the Printer is connected to a
remote terminal.
The J9 connector also provides the +24v and +24v return signals used to supply power to the
Cutter option DC motor (J9-32 and J9-34), when that option is installed.
Bi-directional Parallel Port

The bi-directional parallel port consists of a portion of the U40 (UART), all of U21 (octal D-type
flip-flops), all of U18 (octal tri-state buffer), all of U25 (gal) and invertors U12-9,8, U12-11,10,
U12-12,13 and U35-11,12,13. The timing and pin connections are fully Centronics compatible.
Serial Ports (A and B)

The two bi-directional serial ports (A and B) are totally compatible with both RS232 or RS422
communications protocol levels.
The Serial ports are comprised of connector J5, RS232 driver chip U57, RS232 receiver chip
U49, RS422 driver/receiver chip U37, AND gates U34 (pins 8 through 13) and a portion of U40
(UART).
RS422 outputs can be independently enabled or disabled by software.
PCMCIA Interface
When the optional PCMCIA interface board is plugged into connector J18, the dual connector on
the interface board can accommodate 2 PCMCIA cards (either Type 1 or Type 2).
The interface board has a 208 pin surface mount ASIC chip that provides the interface between
the I960 bus and the PCMCIA bus.
The interface board also has two 5 volt to 3.3 volt converter chips that make it possible to use 3.3
Volt as well as 5 Volt PCMCIA cards.

General Purpose I/O Port
The general purpose I/O port has 16 input and output bits.
The function of each bit is as follows:

Outputs:
(U62-19) - Enables +12v programming voltage for Memory Card 1.
(U62-18) - Enables +12v programming voltage for Memory Card 2.
(U62-17) - Control signal for parallel port.
(U62-16) - Can control the power LED on the front panel bd.
(U62-15) - Control signal for parallel port.
(U62-14) - Turns on +5 volts during a dot check operation.
(U62-13) - Output1 to ribbon save board.
(U62-12) - Output2 to ribbon save board.
(U33-12 through U33-19) - outputs to general purpose I/O (J3)..
Inputs:
(U70-9) - Input from Memory Card 1 (low indicates FLASH memory).
(U70-8) - Input from Memory Card 2 (low indicates FLASH memory)
(U70-7) - Input from Memory Card 1 (low indicates Card 1 present).
(U70-6) - Input from Memory Card 2 (low indicates Card 2 present).
(U70-5) - NINT signal input from Printronics interface board.
(U70-4,3,2) - not used (grounded)
(U24-2 through U24-9) - TTL inputs from general purpose I/O (J3).
Voltages
The general purpose I/O connector J3 also provides voltages at the following pins:
J3-3 (selectable +35v or +24v at 1 amp)

J3-14 (+12 volts at 150 milliamps)
J3-7 (+9 volts at 150 milliamps)
J3-15 (+5 volts at 1 amp)
J3-1 ( logic ground)
J3-25 (+35v/+24v return)

Power Connections
The I960 board has two connectors going to the switching power supply, (J10 to J12).
J10 functions:
J10-1 +35 volts (from power supply)
J10-2 +35/+24 return
J10-3 +24 volts (from the power supply)
J10-4 +35/+24 return
J10-7 logic ground
J10-8 logic ground
J12 functions:
J12-1 High/low stepper motor current .
J12-2 Phase B Enable (transport stepper motor)
J12-3 Phase A Enable (transport stepper motor)
J12-4 Phase B (transport stepper motor)
J12-5 Phase A (transport stepper motor)
J12-6 High side print head voltage programming resistor
J12-7 Low side print head voltage programming resistor
J12-8 Printhead voltage (+24 volts during printing, +4.3 volts during dot check).
J12-9 logic low to turn on the print head voltage (+24v)
J12-10 logic high disables the +24v drain resistor and the +24v LED circuit.
J12-11 (not used)
J12-13 logic ground
J12-14 logic ground
+9V and -9V Converter Circuits

The -9V converter circuit (U66, R203, C101, C102, C10, C11, D1 and D2). is used to convert
+12 volts to -9 volts.
The 9V regulator circuit (VR1, C109, R194, R195 and C103) is used to convert +12 volts to +9
volts.
Ribbon Saver Interface

Connector J15 provides two output control lines and two input control lines for the optional
ribbon saver board. J15 also provides the voltages needed by the ribbon save board (+5v and
+35v).
The ribbon save board drives a stepper motor which is used to raise or lower the Printhead under
software control. Raising the print head from the media allows the Printer to skip over white
space. Since the ribbon does not advance when the Printhead is raised, skipping over white areas
significantly reduces ribbon usage.

Jumpers
The following is a list of the proper settings for jumpers on the i960 Main P.C. Board.
EPROM 2 MB Jumper E6-E7, E12-E13 (Factory setting)

4 MB Jumper E6-E7, E11-E12
DRAM 1 MB Jumper E16-E17 (Factory setting)

5 MB Jumper E18-E19
17 MB Jumper E20-E21
FLASH 2 MB Jumper E5-E6, E4-E12 (Factory setting)
64 MHz Oscillator (Y1) Enabled - No jumper (Factory setting)

Disabled - Jumper E22-E23
i960 Hold Signal Normal - No jumper (Factory setting)

Hold Mode - Jumper E14-E15
Printhead FPGA Normal - Jumper E1-E2 (Factory setting)

4630/4830
Main PCB Test Point Cross-Reference
KA - PCB (2126) JA - PCB (2170)
TP - 1 PrintHead signal Sheet 5-J1 TP - 1 PrintHead signal Sheet 5-A4

TP - 2 PrintHead signal Sheet 5-L1 TP - 2 PrintHead signal Sheet 5-A5
TP - 3 PrintHead signal Sheet 5-J1 TP - 3 PrintHead signal Sheet 5-A3
TP - 4 I960 Reset Sheet 1-A5 TP - 4 Ground Sheet 7-A4
TP - 5 Ground Sheet 7-L0 TP - 5 25 Mhz clock Sheet 1-C8
TP - 6 Media sensor Sheet 2-L4 TP - 6 RESET Sheet 1-C8
TP - 7 I960 failure Sheet 1-C4 TP - 7 RDY/Recover signal Sheet 1-C8
TP - 8 Ground Sheet 7-L0 TP - 8 I960 failure Sheet 1-B6
TP - 9 Ground Sheet 7-L0 TP - 9 Media sensor Sheet 2-B2
TP - 10 Present sensor Sheet 2-L5 TP - 10 Ground Sheet 7-A4
TP - 11 RESET Sheet 6-B1 TP - 11 Ground Sheet 7-A4
TP - 12 Head Home sensor Sheet 2-B2 TP - 12 Present sensor clock Sheet 2-C2
TP - 13 Low Voltage detect Sheet 6-A7
TP - 14 Head Home sensor Sheet 2-B7

Electronic - Block Diagram

“JA” Main Board


4630-4830 Field Training Manual

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Version - 2.1 14-Oct-98

Chapter 1 Introduction Page No.

Chapter 2 Printer Basics Page No.

Appendix Page No.

Table of Contents Page - i

Page - ii Table of Contents

4x30 - Introduction 4x30 Page 1 - 1

4x30 Page 1 - 2 4x30 - Introduction

4x30 - Introduction 4x30 Page 1 - 3

4x30 Page 1 - 4 4x30 - Introduction

4x30 - Introduction 4x30 Page 1 - 5

4x30 Page 1 - 6 4x30 - Introduction

Differences In Intermec’s High Performance Printer Family

Print Resolution 203 dpi 300 dpi 300 dpi

4x30 - Introduction 4x30 Page 1 - 7

Dim Description 4630 4830

4x30 Page 1 - 8 4x30 - Introduction

Contents of the Shipping Container

4630 or 4830 Printer

Front View of Printer

4x30 - Printer Basics 4x30 Page 2 - 1

4x30 Page 2 - 2 4x30 - Printer Basics

Loading Roll Labels

1. Open the stock door

4x30 - Printer Basics 4x30 Page 2 - 3

4x30 Page 2 - 4 4x30 - Printer Basics

To load thermal transfer ribbon

Removing Thermal Transfer Ribbon

4x30 - Printer Basics 4x30 Page 2 - 5

Using the Tear Bar

Using the Control Panel

Reading the Display

Operating Messages                 

4x30 Page 2 - 6 4x30 - Printer Basics

On line/Off line Toggles the printer between

4x30 - Printer Basics 4x30 Page 2 - 7

The six keys on the menu panel allow you to change

Menu Description User

Install Select communication parameters and security Programmers, systems

Configuration Change the operating parameters and activate or Programmers, systems

4x30 Page 2 - 8 4x30 - Printer Basics

Accessing Printer Menus

#  $ %&" '"()*     +Menu,      

4x30 - Printer Basics 4x30 Page 2 - 9

#    $ %&" '"()*   1   $     

- .  +Menu,    3  

5 '  /   4     

7 .  +Cont,   '  

Press To Move When You Want To

Control Panel Tips

4x30 Page 2 - 10 4x30 - Printer Basics

Control Panel Security

Security Setting Menus Allowed

Bypassing Security Levels

- 8     +Feed/Reload,          

Control Panel Error Messages

4x30 - Printer Basics 4x30 Page 2 - 11

Using Printer Serial Port

For connecting to Use Intermec cable part number

To connect your printer to a PC serial port

Configuring the Main Serial Port

Command Settings Description

Operating Messages

# $ %&" '"()* +Menu,

# $ %&" '"()* 1 $

- . +Menu, 3

5 ' / 4

7 . +Cont, '

- 8 +Feed/Reload,

- . +↑, +↓,

< +Enter, 1:2 !

#9 . +Cont, $ %&" '"()*

- . +Menu, +↑, +↓,

6 ">"0?" " . +Enter, 0

/

- . +Menu, +↑, +↓,

Note: & '

Note: -

- #;

4 =

5 $ @

6 @

$

-

• -5= B)C

• "( '=-/- '=4-- '=4;5

• <#54 3=) % 0 3 1

• <#6#A 3 1

• <#54 3=) % 0 3

• <#6#A 3