Intermec 3240 User Guide

User’s Manual

P/N 063015-003

3240 Bar Code Label Printer

Norand Mobile Systems Division

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.

Information and specifications in this manual are subject to change without notice.  1997 by Intermec Corporation

Print, PrintSet, Virtual Wedge, and CrossBar are either trademarks or registered trademarks of Intermec Corporation.

Novell is a registered trademark of Novell, Inc. Kimdura is a registered trademark of Kimberly Clark. Kapton is a registered trademark of Dupont. Speedo, Dutch, and Swiss are registered trademarks of Bitstream Inc. The name Centronics is wholly 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 ( or ®)

symbol in 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.

Manual Change Record

This page records the changes to this manual, which was originally released as version 001.

Version Date Description of Change

002 10/96 These two addenda were added:

• Self-strip addendum Part No. 064196-001

• Top of form addendum Part No. 064522-001

Other minor corrections and changes were made throughout the manual.

003 11/97 Removed Chapters 5 and 6, which pertained to IPL commands. This

information is now contained in the IPL Programming Reference Manual.

Contents

Before You Begin xi

Warranty Information xi Safety Summary xi Warnings and Cautions xii About This Manual xiii

Getting Started

Unpacking the 3240 Printer 1-3

Checking the Order for Completeness 1-4 Reporting Damage or Defects 1-4

Getting to Know Your 3240 Printer 1-5

Preparing the Printer for Installation 1-7

Plugging In the Printer 1-7 Opening the Printer 1-8 Loading a Roll of Media 1-9 Printing the Hardware Configuration Test Label 1-12

What the Hardware Configuration Test Label Tells You 1-13 If the Hardware Configuration Test Label Does Not Print 1-13

Connecting the Printer to Your System 1-13

Connecting the 3240 to a PC 1-14

Connecting the Printer to a PC Serial Port 1-14

Connecting the Printer to a PC Parallel Port 1-15 Connecting the 3240 to a Network 1-15 Connecting the 3240 to an AS/400 1-16 Connecting the 3240 to a Mainframe 1-16

Configuring the Serial Port 1-17

Verifying Printer Communications With Your System 1-19

Operating the Printer

Learning How to Operate the Printer 2-3

Understanding the Front Panel 2-3

Using the Front Panel LEDs 2-4 Using the Front Panel LEDs for Troubleshooting 2-4

3240 Bar Code Label Printer Users Manual

Using the Feed/Pause Button 2-5

Loading Media Into the Printer 2-6

Loading Media for Fanfold Printing 2-6 Loading Media for Self-Strip Printing 2-8

Loading Thermal Transfer Ribbon 2-11

Setting the Media Sensitivity Number 2-13

Setting the Media Sensitivity Number for Intermec Media and Ribbon 2-14 Setting the Media Sensitivity Number for Other Media and Ribbon 2-15

Communicating With the Printer 2-17

Using the PrintSet Software 2-17 Using Third-Party Software 2-17 Using the Intermec Printer Language (IPL) Commands 2-17 Printing a Test Label 2-18 Using a Different Platform Than a PC 2-19

Maintaining the Printer

Inspecting the Printer 3-3

Cleaning the Printer 3-3

Maintenance Schedule 3-4

Cleaning the Printhead 3-6 Cleaning the Printer Covers 3-7 Cleaning the Rollers and the Tear Bar 3-8 Cleaning the Media Guides and Media Path 3-10 Cleaning the Label Sensors 3-12

Troubleshooting

Troubleshooting Checklist 4-3

Printer Operation Problems 4-3

Print Quality Problems 4-5

Communications Problems 4-7

Preventing Data Loss 4-8

Optimizing and Maintaining Print Quality 4-9

Selecting the Correct Media 4-9 Setting the Print Speed 4-10 Selecting the Correct Media Sensitivity Number 4-10 Selecting the Correct Bar Code Orientation 4-10 Adjusting the Print Darkness 4-11 Adjusting the Printer for Self-Strip Printing 4-12 Using Precision Print Technology to Print High Registration Labels 4-13

Correcting the Lateral Position of the Label Image 4-13

Accurately Detecting the Start of a Label 4-15

Correcting Uneven Print Quality 4-17

Fine-Tuning the Top of Form Position 4-19

Performing Advanced Procedures

Contents

Using the Printer Memory Efficiently 5-3

How Is the 3240 RAM Used? 5-3 Making the Most of Your RAM 5-4

Maximizing Throughput 5-5

What Is an Image Band? 5-5 How the Image Bands Command Works 5-6 Optimizing Print Speed and Image Band Setting 5-6 Reimaging Modified Fields 5-7 Optimizing Image Bands for Batch Printing 5-7

Using Test and Service Mode 5-8

Printing Test Labels 5-10 Using Data Line Print 5-10 Performing Selective Transfer 5-11 Using Memory Reset 5-12

Changing Configuration Commands in Test and Service Mode 5-13

Setting the Number of Dot Increments 5-14 Adjusting the Label Rest Point 5-15 Setting Emulation Mode 5-17

Replacing an 86XX, 4100, or 3400 Printer With a 3240 Printer 5-19

Differences Between 86XX Printers and 86XX Emulation 5-19

No BEL Status Response 5-19

Prints Erroneous Labels 5-20

Limited User-Defined Protocol 5-20

Added Auto-Transmit 3 and SI Configuration Commands 5-22

Increased Storage Capacity 5-22

Features Not Implemented 5-22

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3240 Bar Code Label Printer Users Manual

Differences Between the 3240 Printer and the 4100 Printer 5-23

DIP Switches 5-23 Communications 5-23 Entering Test and Service Mode 5-23 No Cutter 5-23 Front Panel 5-24 RAM Differences 5-24

Differences Between the 3400 Printer and the 3240 Printer 5-24

Printhead Size 5-24 Fonts 5-25 DPI Emulation Modes 5-25

Printer Reference

3240 Printer Specifications A-3

Factory Default Settings A-6

Communications Protocol Characters A-7

Configuration Parameters Upload A-8

Printer Functional Boundaries A-9

Printer Options A-11

Bar Code Symbologies A-13

International Character Sets A-16

Extended Character Sets A-19

DIP Switch Settings A-24

Full ASCII Chart A-25

Cabling and Communications

viii

Communications Reference B-3

Interface Cables and Connectors B-11

Connecting the Printer to a Network or Modem B-15

Contents

Glossary

Index

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. A documentation roadmap is also provided to guide you in finding the appropriate 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 1-800-755-5505, and in Canada call 1-800-688-7043. Otherwise, refer to the Worldwide Sales & Service list that came 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

under any circumstances. Someone capable of providing first aid must always be present for your safety.

First aid

injury. Never neglect an injury, no matter how slight it seems.

Resuscitation

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

by a responsible authority. Energized electrical equipment is dangerous. Electrical shock from energized equipment can cause death. If you must perform authorized emergency work on energized equipment, be sure that you comply strictly with approved safety regulations.

Always obtain first aid or medical attention immediately after an

Begin resuscitation immediately if someone is injured and stops

Never work on energized equipment unless authorized

Do not repair or adjust energized equipment alone

3240 Bar Code Label Printer Users Manual

Warnings and Cautions

The warnings and cautions in this manual use the following format.

Warning

A warning alerts you of an operating procedure, practice, condition, or statement that must be strictly observed to avoid death or serious injury to the persons working on the equipment.

Avertissement

Un avertissement vous avertit d’une procédure de fonctionnement, d’une méthode, d’un état ou d’un rapport qui doit être strictement respecté pour éviter l’occurrence de mort ou de blessures 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.

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.

xii

Before You Begin

About This Manual

This manual contains all of the information necessary to install, operate, configure, design labels, troubleshoot, and maintain the printer.

This manual was written for analysts and programmers who operate, program, and connect the printer to a network or system. A basic understanding of DOS, programming, and data communications is necessary.

What You Will Find in This Manual

This table summarizes the information in each chapter of this manual:

For information on Refer to

Installing the printer Chapter 1, “Getting Started.” Tells you how to plug in the

printer, load a small roll of media, configure the printer, and print a configuration test label.

Operating the printer Chapter 2, “Operating the Printer.” Explains the printer

front panel, tells you how to load media for fanfold and self-strip applications, how to load ribbon, and how to test for communications.

Routine maintenance Chapter 3, “Maintaining the Printer.” Tells you how to

maintain the printer.

Troubleshooting Chapter 4, “Troubleshooting.” Instructs you on how to

clear error messages and troubleshoot programming or configuration problems. It also tells you how to control print quality.

Advanced procedures Chapter 5, “Performing Advanced Procedures.” Tells you

how to perform advanced procedures on the 3240 printer such as decreasing processing time.

Printer specifications Appendix A, “Printer Reference.” Contains operating

specifications, extended character sets, and reference tables.

Cabling and communication protocols

Appendix B, “Cabling and Communications.” Provides information on correct cables and communication protocols for your system.

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3240 Bar Code Label Printer Users Manual

Terms and Conventions

The following special terms and conventions occur throughout the manual. Refer to the glossary for a complete list of terms.

Terms

“Printer” or “3240” refer to the 3240 bar code label printer. “Media” is the label stock on which the printer prints labels. “Host” refers to a personal computer or other computer that communicates

with the printer.

Conventions

The following conventions are used throughout this manual for operating procedures and descriptions of the printer.

• Feed/Pause refers to the Feed/Pause button on the printer front panel.

• Downloaded commands appear in the order that you enter them into the

printer with the following conventions:

Convention Description

< > Angle brackets < > enclose mnemonic representations of ASCII control

characters. For example, <ETX> represents the ASCII “End of Text” control character.

[

] Italic text within brackets represents optional data.

data

Ctrl Bold text represents a key on your keypad. For example, Ctrl

represents the Ctrl key.

Ctrl-C When two keys are joined with a dash, press them simultaneously. For

example, if you see the command Ctrl-C, press the two keys at the same time.

E3;F3

Type all characters that appear in the Courier font by pressing an individual key on the keypad.

xiv

Before You Begin

Other Intermec Manuals

The following manuals provide additional information about printing labels with your bar code printer.

Manual Intermec Part No.

Data Communications Reference Manual IPL Programming Reference Manual 066396 The Bar Code Book 3240 Bar Code Label Printer Getting Started Guide 9154 Multi-Drop Line Controller System Manual 9161B Installation Manual 9180 Network Controller User’s Manual RF System User’s Manual

by Roger C. Palmer 051241

044737

063257 048517 049572 054292 053574

Getting Started

This chapter introduces the 3240 printer and explains how to get your new printer up and running for the first time.

Unpacking the 3240 Printer

Remove the accessories, packing material, and the printer from the shipping container. Set the printer on a clean, stable, flat surface and remove the packing material. Save the shipping container and packing materials in case you need to move or ship your printer.

Contents of the 3240 Printer Package

Getting Started

3240 Printer

AC power cord

Power

Alert

Empty/Pause

Feed/Pause

Intermec

3240

Ribbon core

Intermec

Media Roll

Getting

Started

Guide

3240 Bar Code Label Printer

3240U.001

1-3

3240 Bar Code Label Printer Users Manual

Checking the Order for Completeness

Verify the contents of the shipping container against the list below and the figure on the previous page. If any parts are missing, please contact your local Intermec representative.

•

3240 printer

•

AC power cord

•

Ribbon core

• 3240 Label Printer Getting Started Guide

•

Media roll (a 50-foot direct thermal media roll)

Reporting Damage or Defects

Intermec thoroughly tests and inspects your 3240 before shipping it from the factory. If you receive any items damaged, please take the following steps to correct the problem.

•

Take photographs if necessary.

•

Contact the transport carrier.

Note: The customer is responsible for all damage claims against the carrier. See the “Intermec Terms of Sale” printed on your sales invoice.

1-4

Getting to Know Your 3240 Printer

Features of the 3240 printer include:

• Support for direct thermal and thermal transfer printing applications.

Chapters 1 and 2 instruct you on how to load both types of media.

• An internal self-strip with integral liner takeup. See Chapter 2, “Operating

the Printer,” for more information.

• Precision Print technology that produces high registration labels. See

Chapter 4, “Troubleshooting,” for more information.

• Minimal supervision and maintenance. Use the following figures to familiarize yourself with the 3240 printer.

Front View

Getting Started

Media window

Power on LED

Alert LED

Empty/Pause LED

Feed/Pause button

3240 Printer

Power

Alert

Empty/Pause

Feed/Pause

Intermec

3240

Media access door

Media cover

3240U.002

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3240 Bar Code Label Printer Users Manual

Back View

Darkness adjust control

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Fanfold media access slot

DIP switches

Optional I/O board port

Serial communications port

ON/OFF switch

AC power cord receptacle

3240U.003

Several options are available for use with the 3240 printer. See Appendix A, “Printer Reference,” for complete descriptions of these options.

1-6

Preparing the Printer for Installation

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Serial communications port

ON/OFF switch

AC power cord receptacle

DIP switches

1 2 3 4 5 6 7 8

OFF

1 2 3 4 5 6 7 8

OFF

Factory

Default Settings

3240U.004

Before connecting your 3240 to your data collection system, you need to:

• plug in your printer.

• open the printer and load media.

• print a configuration test label.

Plugging In the Printer

The back of the 3240 printer contains the AC power cord receptacle, the serial communications port, the (I/O) switch, and two banks of DIP switches.

To plug in the printer

1. Turn the switch to the off (O) position.

2. Make sure you set the DIP switches to their factory default settings.

Top Bank Bottom Bank

For a description of the DIP switch settings, see “Configuring the Serial Port” later in this chapter.

Set switch 1 on. Set switches 2 through 8 off.

Set switches 1 through 8 off.

Getting Started

3. Plug the AC power cord into the receptacle at the back of the printer.

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3240 Bar Code Label Printer Users Manual

4. Plug the other end of the power cord into a grounded wall outlet or surge protector.

5. Set the ON/OFF switch to the on (|) position. The Power On LED lights, the Empty/Pause LED flashes, and the printer (platen roller) advances. The Empty/Pause LED stays lit because you have not loaded media yet.

Opening the Printer

You need to open the printer every time you load media or perform maintenance procedures.

To open the printer

1. Place the fingers of your right hand between the two notches on the lower edge of the media cover (the media cover release) and pull the bottom of the media cover away from the base of the printer.

2. Grasp the front of the media cover with your left hand and lift the front of the media cover upward to release it from the printer frame.

3. Lift the media cover away from the top of the printer.

Power

Alert

Empty/Pause

Feed/Pause

IntermecIntermec

3240

Media cover release (between the two notches)

Media cover

3240U.005

1-8

Getting Started

Loading a Roll of Media

In straight-through printing, you load a roll of media on the supply roll post and feed it straight through the printer mechanism and out the front of the printer. As the 3240 prints individual labels, you can remove them from the roll by pulling them down across the tear bar. Use the small roll of media that came with the printer to perform this procedure.

Note: This procedure covers how to load media for straight-through print mode using a roll of direct thermal or thermal transfer label media. The default setting for the printer is direct thermal mode.

Note: Attached to the media bag is a small label with a three-digit sensitivity number printed on it. Make sure you save this label. You need this information to set the correct media sensitivity number. See “Setting the Media Sensitivity Number” in Chapter 2 for more information.

To load the media

1. Open the printer.

2. Raise the printhead by rotating the head lift lever clockwise to release it.

3. Turn the supply roll retainer counterclockwise to release it and slide it to the outer end of the supply roll post. Turn it clockwise to lock it in place.

Note: You do not need to perform this step when replenishing media of the same width.

4. Lift the media brake up and slide it towards the front of the printer until it reaches its resting position.

5. Place the media roll on the supply roll post and position it firmly against the inside wall of the printer.

6. Lift up on the media brake, slide it toward the back of the printer, and lower it onto the media roll.

7. Turn the supply roll retainer counterclockwise and slide it up to the edge of the media roll. Turn the supply roll retainer clockwise to secure.

Note: If you are using a narrow roll of media (less than 1 inch), insert the media support between the roll of media and the supply roll retainer before you secure it in place.

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3240 Bar Code Label Printer Users Manual

Loading Media Into the 3240 Printer

Media

Media backing

Tear bar

Printhead

Label gap sensor

Head lift lever

Edge guide

Lateral printhead adjust

Lower media guide

Upper media guide

➤

Media brake

3240U.006

8. Unscrew the edge guide and slide it all the way to the outer edge of the lower media guide. Screw it in place.

Media support

Media roll

Supply roll post

Supply roll retainer

Note: If you are replacing the empty media roll with a new roll of the same width, you do not need to adjust the edge guide or the supply roll retainer.

9. Pull down on the lower media guide to allow access to the media path.

10. Unroll several inches of media and insert it between the two media guides and out the front of the printer. Release the lower media guide.

11. If you are using thermal transfer media, you need to load ribbon now. For help, see “Loading Thermal Transfer Ribbon” in Chapter 2.

12. Rotate the head lift lever counterclockwise until it locks in place.

13. Press the Feed/Pause button until the printer feeds out approximately 6 inches of media.

14. Unscrew the edge guide and slide it inward until it touches the edge of the media. Screw it in place.

Note: Adjust the label gap sensor if you are using narrow media (less than 1 inch wide). For help, see “Accurately Detecting the Start of a Label” in Chapter 4.

1-10

Getting Started

15. If you are loading continuous media or mark label stock, use PrintSet, your third-party software or the printer command set to tell the printer what kind of media you are using.

16. Press Feed/Pause to advance several inches of media through the printer and out the label opening in the front cover. Your printer is now ready to print labels.

Note: Refer to the label located on the inside of the media cover for directions on loading media. For your convenience, you may want to refer to it when loading media in the future.

Note: If you are loading narrow media (1 inch or less) you need to adjust the bias adjust screw to achieve the highest print quality. For help, see “Correcting Uneven Print Quality,” in Chapter 4.

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3240 Bar Code Label Printer Users Manual

Printing the Hardware Configuration Test Label

Now that you have loaded media in the printer, you are ready to print the hardware configuration test label. Use this label for reference when installing your 3240 printer and for verifying proper printer operation.

To print the hardware configuration test label

1. Turn the ON/OFF switch to the off position.

2. Press and hold the Feed/Pause button while turning the printer power on. The Alert and Empty/Pause LEDs blink during the printer self-test.

3. Release the Feed/Pause button when the media starts moving. The printer feeds out one or two blank labels (to verify the label length) and then prints the hardware configuration test label.

4. Turn the printer power off and then on to enter Print mode.

Note: For the entire hardware configuration label to print out, you must use media that is at least 2.6 inches wide.

3240 Hardware Configuration Test Label

3240 Hardware Configuration

Memory Installed

Storage RAM

Image RAM

Flash RAM

Mileage

Inches Processed Inches Burned

Printhead

Width Dot Size

Burn Pot Setting Hardware Options

I/O Option Internal Option External Option

Firmware Checksum

ROM0 (U9) : CDE3 ROM1 (U8): 0A1E

Program : 063103 VERSION: 0.9

: 128 kilobytes : 375 kilobytes : none

: 36 : 12

: 1024 dots : 2.5 mil : 231

: none : none : Self Strip

3240U.007

1-12

What the Hardware Configuration Test Label Tells You

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Serial communications port

3240U.011

Optional I/O board port

The hardware test label provides statistics on:

• the amount of installed memory.

• the amount of media printed.

• the printhead configuration.

• the program and version numbers.

If the Hardware Configuration Test Label Does Not Print

If you are unable to print a hardware configuration test label, please refer to Chapter 4, “Troubleshooting,” for help.

Connecting the Printer to Your System

You can connect your 3240 printer to a PC, a local area network, an AS/400 (or other midrange), or a mainframe. This section tells you how to connect your printer to any of these systems.

Getting Started

This illustration shows you where to connect your system to the printer. You can use either of these two ports on the back of the printer:

• Serial communications port

• Optional I/O board port (if you have an adapter card installed)

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3240 Bar Code Label Printer Users Manual

Connecting the 3240 to a PC

You can connect the 3240 to either a serial port or parallel port (if you have the option installed) on your PC. You must provide the correct cables for connecting the printer. Refer to the following instructions for cable information. Contact your Intermec representative for ordering assistance if you do not have the appropriate cables.

Connecting the Printer to a PC Serial Port

To connect the 3240 to your PC serial port, you need a shielded EIA RS-232, RS422, or RS-485 electrical interface with a 25-pin D-style subminiature connector. It must have pins on the printer end and an appropriate serial port connector on the other end.

Use the following table to determine the correct Intermec cable for your application.

For Connecting To Use Intermec Cable Part Number

IBM PC AT 048693 (25-pin printer to 9-pin serial port straight-through) IBM PC XT 048668 (25-pin printer to 25-pin serial port null modem)

To connect your printer to a PC serial port

1. Turn the ON/OFF switch to the off position.

2. Plug the 25-pin connector into the serial communications port on the back of the 3240 printer.

3. Plug the other end of the cable into a serial COM port on the PC.

4. If necessary, change the PC serial port configuration to match your printer. The default configuration settings for the 3240 printer are:

• 9600 baud

• even parity

• 7 bit word length

• XON/XOFF no status response protocol

• device address A

• direct thermal media

See “Configuring the Serial Port” later in this chapter for more information.

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