Intermec PD42 User Manual

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User’s Guide

EasyCoder® PD42 Printer

Page 2

Intermec Technologies Corporation

Worldwide Headquarters 6001 36th Ave.W. Everett, WA 98203 U.S.A.

www.intermec.com

The information contained herein is provided solely for the purpose of allowing customers to operate and service Intermec-manufactured equipment and is not to be released, reproduced, or used for any other purpose without written permission of Intermec Technologies Corporation.

Information and specifications contained in this document are subject to change without prior notice and do not represent a commitment on the part of Intermec Technologies Corporation.

The word Intermec, the Intermec logo, Norand, ArciTech, Beverage Routebook, CrossBar, dcBrowser, Duratherm, EasyADC, EasyCoder, EasySet, Fingerprint, INCA (under license), igistics, Intellitag, Intellitag Gen2, JANUS, LabelShop, MobileLAN, Picolink, Ready-to-Work, RoutePower, Sabre, ScanPlus, ShopScan, Smart Mobile Computing, SmartSystems, TE 2000, Trakker Antares, and Vista Powered are either trademarks or registered trademarks of Intermec Technologies Corporation.

There are U.S. and foreign patents as well as U.S. and foreign patents pending.

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Contents

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Global Services and Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Web Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Telephone Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Who Should Read This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Using the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Introducing the EasyCoder PD42 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Features of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Front View of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Back View of the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Media Compartment and Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 4

Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Working With the Print Button and LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . 6

Working With the Display and the Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installing the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Connecting the Printer to Your System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Connecting the Printer Through the USB Interface . . . . . . . . . . . . . . . . . .10

Connecting the Printer Through the Serial Port . . . . . . . . . . . . . . . . . . . . . 11

Connecting the Printer Through the Parallel Port. . . . . . . . . . . . . . . . . . . . 11

Connecting the Printer to a Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Connecting Peripherals Through USB Host . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Connecting a Mass Storage Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Connecting a Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Connecting a Bar Code Scanner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Connecting a USB Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Loading Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Loading Media for Tear-Off (Straight-Through) Operation . . . . . . . . . . . . 14

Loading Media for Peel-Off (Self-Strip) Operation. . . . . . . . . . . . . . . . . . . 17

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Loading Thermal Transfer Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Plugging in the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Printing Test Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Creating and Printing a Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Configuring the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Understanding Printer States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Understanding the Printer Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Changing Configuration Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Changing Configuration Settings From the Display . . . . . . . . . . . . . . . . . 31

Changing Configuration Settings With PrintSet 4. . . . . . . . . . . . . . . . . . . 33

Changing Configuration Settings From the Printer Home Page . . . . . . . . 33

Changing Configuration Settings Using the Command Line. . . . . . . . . . . 33

Running Testmode and Extended Testmode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Running Testmode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Running Extended Testmode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Upgrading the Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Troubleshooting and Maintaining the Printer . . . . . . . . . . . 39

Printer Operation Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Troubleshooting Communication Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Using the Line Analyzer (Fingerprint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Using Dumpmode (IPL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Contacting Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Adjusting the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Preventing Ribbon Wrinkling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Clearing Media Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Adjusting the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Adjusting Printhead Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Adjusting Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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Adjusting Printhead Dot Line . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Adjusting the Label Gap Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Maintaining the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Cleaning the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Cleaning the Media Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Cleaning the Exterior of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Specification, Interfaces, and Options. . . . . . . . . . . . . . . . . . . . . 59

Printer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

RS-232 Serial Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Interface Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

USB Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

USB Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

EasyLAN Ethernet Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Parallel IEEE 1284 Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Interface Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

EasyLAN Ethernet Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Parallel IEEE 1284 Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Cutter Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Internal Rewinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Printhead Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Real Time Clock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Media Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Media Roll Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Internal Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Ribbon Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Paper Types and Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Non-Adhesive Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Self-Adhesive Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Self-Adhesive Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Tickets With Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Tickets With Black Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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Setup Parameters (Fingerprint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Setup Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Navigating the Setup Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Serial Communication Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Com Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Emulation Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Feed Adjust Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Media Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Print Defs Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Network Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Setup Parameters (IPL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Setup Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Printing Test Labels With IPL Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Navigating the Setup Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Serial Communication Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Com Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Test/Service Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Media Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Configuration Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Network Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Returning to Factory Default Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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Before You Begin

This section provides you with safety information, technical support information, and sources for additional product information.

Safety Information

Your safety is extremely important. Read and follow all warnings and cautions in this document 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.

This section explains how to identify and understand warnings, cautions, and notes that are in this document.

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.

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.

Before You Begin

Note: Notes either provide extra information about a topic or contain special instructions for handling a particular condition or set of circumstances.

Global Services and Support

Warranty Information

To understand the warranty for your Intermec product, visit the Intermec web site at www.intermec.com and click Service & Support > Warranty.

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Before You Begin

Disclaimer of warranties: The sample code included in this document is presented for reference only. The code does not necessarily represent complete, tested programs. The code is provided “as is with all faults.” All warranties are expressly disclaimed, including the implied warranties of merchantability and fitness for a particular purpose.

Web Support

Visit the Intermec web site at www.intermec.com to download our current manuals (in PDF). To order printed versions of the Intermec manuals, contact your local Intermec representative or distributor.

Visit the Intermec technical knowledge base (Knowledge Central) at intermec.custhelp.com to review technical information or to request technical support for your Intermec product.

Telephone Support

These services are available from Intermec.

In the USA and Canada call 1-800755-5505 and

Services Description

Order Intermec products

Order Intermec media

Order spare parts

Te c h n i ca l Support

• Place an order.

• Ask about an existing order.

Order printer labels and ribbons.

Order spare parts. 1 or 2 and then

Talk to technical support about your Intermec product.

choose this option

1 and then choose 2

1 and then choose 1

choose 4

2 and then choose 2

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Services Description

Before You Begin

In the USA and Canada call 1-800755-5505 and choose this option

Service • Get a return authorization

Service contracts

Outside the U.S.A. and Canada, contact your local Intermec representative. To search for your local representative, from the Intermec web site, click Contact.

Who Should Read This Manual

This user’s guide is for the person who is responsible for installing, using, configuring, and maintaining the PD42 printer.

This document provides you with information about the features of the PD42, and how to install, configure, operate, maintain, and troubleshoot it.

Using the Printer

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Chapter 1 — Using the Printer

Introducing the EasyCoder PD42 Printer

The EasyCoder PD42 printer is a dependable and versatile printer suitable for medium-duty applications in manufacturing, transportation and warehouse environments. It has all-metal chassis and covers, proven printing mechanics, and powerful electronics providing sturdiness, performance, and reliability. It features an intuitive user interface with a large graphical display and programmable buttons.

Features of the Printer

This section describes the exterior of the printer, connectors, and the media compartment.

Front View of the Printer

Display

Soft keys (5)

Control LEDs (4)

Print button

Side door

Front View

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Back View of the Printer

Ethernet RJ-45 port

USB port

MAC address label

RS-232 serial port

IEEE 1284 parallel port

CompactFlash socket

Power switch

AC power cord socket

USB host port

Side door

Back View

Chapter 1 — Using the Printer

Intake for external media supply

Machine labels

Back View: Connectors

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Chapter 1 — Using the Printer

Ink position lever

Edge guide

Media supply post

Ribbon supply shaft

Ribbon rewind shaft

Media Compartment and Print Mechanism

Media Compartment

Printhead balance boxes

Ribbon rod

Printhead lever

Media feed rods

Label taken

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sensor

Print Mechanism

Thermal printhead

Tear bar

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Firmware

Chapter 1 — Using the Printer

Your PD42 printer comes with either Fingerprint or IPL (Intermec Printer Language) firmware. The choice of firmware affects the functionality of the printer and how you interact with it. This manual contains information that applies exclusively to the type of firmware, so it is strongly recommended that you familiarize yourself enough with your PD42 to know whether it runs Fingerprint or IPL.

The current firmware type and version is displayed on the printer’s LCD, when the printer is fully operational and in “idle” mode (awaiting print jobs).

Fingerprint

10.1.0

Test

The display window of a PD42 running Fingerprint firmware.

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Chapter 1 — Using the Printer

Working With the Print Button and LED Indicators

The blue button on the front panel is the Print button. The primary function of the Print button is to feed media and pause print jobs. However, the functionality varies depending on which state the printer is in, and which firmware it is running. All this is explained in detail in “Understanding Printer States” on

page 26.

There are four LEDs (Light Emitting Diodes) surrounding the Print button.

LEDs and the Print Button

Control LEDs

Symbol LED Color Function

Power Green Power indicator

Ready/Data Green Printer ready

Error Red Error indicator

Ready-to-Work™ Blue Intermec Ready-to-Work™

indicator

The four LED indicators are on, off, or flashing depending on which state the printer is in. The Power LED ( ) is always on for all states except Power Off.

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Chapter 1 — Using the Printer

The blue Ready-to-Work LED ( )shows the operational status of the printer. In simple terms, it is turned on when the printer is operational. The indicator is set to flash when the printer is receiving data or under certain “mild” error conditions, for example when the printer is awaiting an IP address from the network, when the printhead is lifted, or when media is loaded incorrectly. It also flashes when the printer is in Setup mode, Testmode, and Extended Testmode (see Chapter 3, “Configuring

the Printer.”).

When more serious errors occur, the indicator turns off completely, and the red Error LED ( ) turns on or flashes. There are a number of conditions that can cause this behavior; for help, see Chapter 4, “Troubleshooting and Maintenance.”

The green Ready/Data LED ( ) turns on, off, or flashes depending on the current state of the printer. A more thorough description of this behavior can be found in “Understanding

Printer States” on page 26.

Working With the Display and the Soft Keys

The display communicates detailed information about the current state of the printer. Using the display, the printer tells you if a specific error has occurred or if it is waiting for input from you.

Current state (Setup)

Text or error messages

Active soft keys

The different areas of the display and the soft keys.

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Chapter 1 — Using the Printer

Test

Below the display are five buttons that act as “soft keys,” which means that the function of each button depends on the state of the printer. The function is indicated with a small icon in the display just above the key itself.

You can use the buttons for things like pausing a print job, running a testfeed or changing setup parameters.

Note: If the printer is running a Fingerprint application, access to Setup mode is controlled by the application.

The function of each soft key is described below.

Soft Key Functions

Soft Key Function Soft Key Function

F1 to F5 Defined by Fingerprint

application

Enter/Exit setup Edit value

Feed Exit editing/cancel/exit test

Testfeed Decrease selected digit

Right/next state

mode/exit dumpmode

Enter/Exit i-mode Increase selected digit

Left/previous state Pause

Up Continue

apply/acknowledge/select Save to file

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This chapter contains the following sections:

• Connecting the Printer to Your System

• Connecting Peripherals Through USB Host

• Loading Media

• Loading Thermal Transfer Ribbon

• Plugging in the Printer

•Printing Test Labels

• Creating and Printing a Label

Installing the Printer

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Chapter 2 — Installing the Printer

Connecting the Printer to Your System

There are a number of ways you can connect the PD42 to your system. As a standard, the printer is equipped with:

• one USB Type B connector for the USB interface port.

• one USB Type A connector for the USB host interface port.

• one 9-pin D-style subminiature (DB9) socket for the RS-232 serial interface port.

Optional interfaces include:

• one 36-pin socket for the parallel (IEEE 1284) port.

• one RJ-45 socket for the Ethernet network connection.

Information on the socket and connector types can be found in Appendix A, “Specification, Interfaces, and Options.”

Note: USB and Parallel IEEE 1284 cannot be used at the same time. Select the active interface in Setup (see “Changing

Configuration Settings” on page 31).

There are advantages and disadvantages associated with each of these interfaces, which are described in the following sections. Your current system setup will most likely tell you what connection method is most suitable.

Connecting the Printer Through the USB Interface

To use the USB connection, you need to install the Intermec InterDriver software on your computer. To ensure you get the latest version, check the Intermec web site first. This software can also be found on the PrinterCompanion CD along with instructions on how to install it. The USB interface is not suitable for terminal connections and thus not for programming.

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Connecting the Printer Through the Serial Port

You can use the serial connection with either LabelShop or the Intermec InterDriver. You can also use it to send commands directly to the printer through a terminal connection, for instance with Telnet. The printer’s default serial communication settings are: baud rate 9600, 8 data bits, no parity, 1 stop bit and no flow control. Appendixes C and D contain information about serial communication setup parameters for IPL and Fingerprint, respectively.

Connecting the Printer Through the Parallel Port

You can use the parallel connection with LabelShop or the Intermec InterDriver. The parallel port supports Windows plugn-play and additional status reporting through IEEE 1284 nibble ID mode. Cable is not included with the kit.

Connecting the Printer to a Network

With an optional EasyLAN Ethernet card installed in your PD42, you can set it up as a network printer. The printer is set to automatically retreive an IP number from the network (DHCP) once it is turned on. You can use the network connection either with LabelShop or the Intermec InterDriver. You can also use it to directly send commands to the printer through a terminal connection (Telnet), or you can send instructions via FTP. For terminal connections, it utilizes the Raw TCP protocol through port 9100.

To connect the PD42 to your network

1 Plug a connected Ethernet cable into the Ethernet port in the

rear of the printer.

2 Turn the printer on. Wait for the blue Ready-to-Work LED to

stop blinking, and for the message “IP configuration error” to disappear from the screen.

3 Enter i-mode by pressing ( ).

i-mode cycles through the interfaces installed on the printer in five-second intervals and displays them on the screen. The IP address is displayed under net1: in Fingerprint and net in IPL.

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4 Enter the printer’s IP address in the address field of your web

browser (for example http://255.255.255.001). This brings up the printer’s home page, where it is possible to check and modify various printer settings. Modifying settings requires a login name and a password: by default, these are set to “admin” and “pass” respectively.

Please refer to the EasyLAN User’s Guide (P/N 1-960590-xx) for more information on how to set up and operate the PD42 in your network environment.

If your network does not assign IP numbers automatically, or the Ready-to-Work indicator is flashing to indicate a network error, you can use PrintSet 4 (available on the PrinterCompanion CD) to correct the network settings. Alternatively, set up a terminal connection through the serial interface and use the Fingerprint Setup command. See “Changing Configuration Settings” on

page 31, or refer to the Intermec Fingerprint Programmer’s

Reference Manual (P/N 937-005-xxx).

Connecting Peripherals Through USB Host

The USB host interface supports the following external devices:

• Mass storage device

•Keyboard

• Bar code scanner

•USB hub

Connecting a Mass Storage Device

You can use a USB mass storage device (the “thumbdrive” or “dongle” type) to store additional fonts and images. You can also use the device to upgrade your firmware (see “Upgrading the

Firmware” on page 38).

Connecting a Keyboard

You can use an external USB keyboard to:

• input data in Fingerprint applications. Some applications may require more complex input from users than the simple push of a button.

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• manage setup in Fingerprint/Direct Protocol and IPL. In the installed keyboard layouts, the arrow keys on the keyboard are mapped to the up/down/right/left functions in the Setup menu. The five function keys F1-F5 correspond to the five soft keys on the front panel, starting from the left. The Enter key will have the same apply/acknowledge function.

The printer comes with four keyboard layouts installed (US, Swedish, French, and German).

To change keyboard layout

1 Plug your USB-keyboard into the USB connector in the back

of the printer.

2 Turn the printer on.

3 Press Setup ().

4 Navigate to COM > USB KEYBOARD.

5 Choose a keyboard layout.

6 Exit Setup by pressing ( ).

Fingerprint users can create their own custom keyboard layouts. For help, see the Fingerprint Programmer’s Reference Manual (P/N 937-005-xxx).

Connecting a Bar Code Scanner

Note: Only printers running Fingerprint firmware can use a bar code scanner.

You can connect a bar code scanner of HID (Human Interface Device) type to the printer. The scanner will send data to the “console:” device in the same way as a USB keyboard. This data can then be used in a Fingerprint application.

The keyboard map chosen in setup (see above) applies for connected scanners as well.

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Connecting a USB Hub

A USB hub makes it possible to connect several USB devices to the printer at the same time.

Note: Only one of the devices connected to the USB hub can be a mass storage device, and only one device can be a Human Interface Device (keyboard or bar code scanner).

Loading Media

The EasyCoder PD42 can print on labels, tickets, tags, and continuous stock in various formats. Refer to Appendix B,

“Media Specifications” for more detailed information about

media types, media dimensions and other media specifications.

Loading Media for Tear-Off (Straight-Through) Operation

This section describes the case when media is torn off manually against the printer’s tear bar. This method is also known as “straight-through” printing. You can use different types of media in Tear-Off operation:

• Non-adhesive continuous stock

• Self-adhesive continuous stock with liner

• Self-adhesive labels with liner

• Tickets with gaps, with or without perforations

• Tickets with black marks, with or without perforations

To load media for tear-off operation

1 Open the printer’s side door.

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Label feed guide

Printhead lever

2 Pull out the printhead lever and turn it counterclockwise. Lift

the label feed guide.

3 Load a media roll onto the media supply hub. Be sure to push

it all the way in.

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4 Route the media through the print mechanism.

5 If you are using fan-fold media, load it through the rear intake

and route the it the same way as you would a media roll.

6 Reset the label feed guide and the printhead lever.

7 Close the side door.

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8 Press the Print button to advance the media (“Feed”). If you

are switching to a new type of media, for instance going from tickets with gaps to ticket with black marks, you must run a “Testfeed” ( ) to calibrate the printer’s sensors.

Loading Media for Peel-Off (Self-Strip) Operation

This section describes the case when self-adhesive labels are separated from the liner immediately after printing. This method is also known as self-strip operation. The label-taken sensor can hold the printing of the next label in a batch until the present label has been removed. You can only use self-adhesive labels with liner in peel-off operation. Use the same procedure when installing media for Batch Takeup, with the difference that both label and liner is rewound, and the label-taken sensor is not used.

Note: These modes of operation require an internal rewinder unit, for more information see Appendix A, “Specification,

Interfaces, and Options.”

To load media for peel-off operation

1 Remove the thumbscrew to remove the front cover.

2 Open the side door, mount the media roll, and route the

media through the media feed rods (refer to Steps 1-4 in “To

load media for tear-off operation” on page 14).

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3 Route the label liner through the print mechanism and back

into the media compartment.

4 Wrap the liner around the takeup roll and lock it in place.

5 Reset the label feed guide and the printhead lever.

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6 Reattach the front cover.

7 Push in on the lower part of the label-taken sensor and bring

it out to a fully horizontal position.

8 Close the side door.

9 Press the Print button to advance the media.

Loading Thermal Transfer Ribbon

Thermal transfer printing makes it possible to use a wide range of receiving face materials and gives a durable printout that is less vulnerable to fat, chemicals, heat, sunlight and so on than direct thermal printing. Make sure to select a ribbon type that matches the type of receiving material and set up the printer accordingly.

The ribbon is normally loaded at the same time as a new media roll. For clarity, the following illustrations do not show the media roll. See the previous sections for information on how to load media for your type of operation.

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The EasyCoder PD42 can use transfer ribbon rolls wound with the ink-coated side facing either outward or inward. To determine which type of ribbon you have, use a pen or another sharp object to scratch through the ribbon against a piece of paper. If it leaves a mark, your ribbon is wound ink in or ink out according to the following model.

Test to determine whether your transfer ribbon is wound ink-in or ink-out.

To load thermal transfer ribbon

= Ink in

= Ink out

1 Open the side door of the printer.

2 Pull out the printhead lever (1) and turn it counterclockwise

(2) to raise the printhead.

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3 Slide the ribbon roll onto the right ribbon hub, and the

empty ribbon core on the left hub.

4 “Ink out” ribbon only: route the ribbon and set the ink

position lever as indicated below.

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5 “Ink in” ribbon only: route the ribbon and set the ink

position lever as indicated below.

6 Load media in the printer, if you have not already done so.

7 Restart the printer and print test labels (See “Printing Test

Labels” on page 23).

Plugging in the Printer

1 Make sure the Power switch is turned off.

2 Connect the power cable to the printer.

3 Plug the power cable into your electrical outlet.

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Printing Test Labels

In order to verify that the printer is fully functional and to obtain its current configuration, you can print test labels for the various printer functions (for instance ,hardware and software configuration).

To print a set of test labels from startup

1 Make sure the printer is turned off.

2 Load media as described in “Loading Media” on page 14.

3 Press and hold the blue Print button.

4 Keep the Print button pressed down, and turn on the power

switch. After approximately ten seconds the printer enters Testmode and three of the front LEDs start flashing one at a time.

The display window lights up, and the printer runs a media setup routine.

5 Continue to press the Print button until the printer starts

cycling through the selectable media types (Gap/Mark/ Continuous). For help, see Appendix B, “Media

Specifications.”

Chapter 2 — Installing the Printer

6 Select your media type by releasing the Print button at the

appropriate time.

SELECT MEDIA

MARK

SELECT MEDIA

GAP

SELECT MEDIA

CONTINUOUS

The printer will print several test labels containing the printer’s setup parameters. It will then enter Dumpmode.

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7 Press the Print button once, or press Cancel () to exit

Dumpmode.

Creating and Printing a Label

There are many different ways you can create a label and send it to your printer. You can design labels in Fingerprint or IPL, use dedicated label design tools (such as LabelShop and XMLLabel), or use word processing software like Microsoft Word. Your choice of design tool will likely be influenced by your system setup and communication interface (Ethernet, USB, serial or parallel). Please refer to the manual of each respective tool for information on how to create and print labels.

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This chapter contains the following sections:

• Understanding Printer States

•The Printer Startup Sequence

• Changing Configuration Settings

• Running Testmode and Extended Testmode

• Upgrading the Firmware

Configuring the Printer

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Understanding Printer States

The PD42 printer can enter a number of different states, which in turn indicate its current mode of operation. Information about the state of the printer is provided via the LEDs and the display.

PD42 Printer States

State Explanation

Power Off

Upgrading Firmware is being upgraded.

TestMode See page 34.

Extended TestMode See page 36.

Setup Mode Setup mode is accessed from the display

i-mode i-mode is accessed from the display when

PUP Power-UP (starting up)

Idle The printer is operational and is waiting for

Application running The printer is running a (Fingerprint)

Printing

Printing (wait for LTS) Waiting for Label Taken Sensor to indicate

Paused Paused during print job

Error Error state

Dumpmode In Dumpmode, the printer listens on all

(this may require a password if the printer is running a Fingerprint application). In Setup mode, you can change various printer settings.

the printer is idle. In i-mode the printer will cycle through the various interfaces with 5 second intervals.

print jobs.

application

that label has been taken.

communication ports and prints incoming characters.

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The Print button has different functionality depending on the state of the printer. Different actions can be carried out by pressing the button less than and more than one second respectively. An empty field means no action is performed.

Print Button Function

Button pressed

State

Power Off

Upgrading

Testmode See “Running

Extended Te s t m o de

Setup mode

Idle (FP) Formfeed/

Idle (IPL) Formfeed Continuous feed

Application running

Printing Pause print job

Paused (FP) Continue print job Cancel print job

Paused (IPL) Continue print job Continue print job

Error See Chapter 4, “Troubleshooting and

< 1 s

Tes t m od e a nd Extended Tes t m od e” o n page 34

See “Running

Tes t m od e a nd Extended Tes t m od e” o n page 34

Printfeed

Defined by application

Maintaining the Printer.”

Button pressed > 1 s

See “Running

Testmode and Extended Tes tm od e” o n page 34

See “Running

Testmode and Extended Tes tm od e” o n page 34

Testfeed

while button is pressed

Defined by application

“Doubleclick”

Enter Pause mode

Defined by application

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The behavior of the green Data/Ready LED and red Error LED in various states is shown in the table below.

Ready/Data and Error LED Behavior

State Ready/Data LED Error LED

Power Off Off Off Upgrading LEDs turned on one after the other. Testmode See Chapter 5 for description. Extended Testmode See Chapter 5 for description. PUP On Off Idle On/Flash Application running On Off Printing On/Flash Printing (wait for LTS) Quick flashes Paused Flash Error Off On / Flash

Footnotes:

1 Flashing with 50% duty cycle, 0.8 second period when receiving

data, synchronized with Ready-to-Work LED. 2 Two fast flashes, 1.6 second period. 3 Flashing with 50% duty cycle, 0.8 second period, not synchronized

with Ready-to-Work LED. 4 Error LED will be lit for these conditions: Out of Paper, Out of

Ribbon, Head Lifted, Cutter Error, and Testfeed not Done. Will

flash as (2), when thermal printhead is too hot. Will flash as (3) for

other error conditions caught by the Direct Protocol error handler.

Off

Off Off Off

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The state of the printer also determines what functions/icons are active in the display window:

Fingerprint

10.2.0

F1 F2 F3 F4 F5

Test

Idle

Running application

Paused

Testmode

TEST

Setup, navigation

Setup, edit value

Extended Testmode

TEST

Dumpmode

i-mode

Printing

Upgrading

Active soft keys in different printer states.

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Understanding the Printer Startup Sequence

When you switch on the printer, it will go through a sequence of steps in which it determines what settings should be set and what application (if any) should be started. Users that run Fingerprint firmware on their PD42 are given more options and more control over the printer’s startup behavior.

Printer Startup Sequence (Fingerprint)

1 Check for firmware binary file on CompactFlash card. If

found, upgrade.

2 Check for firmware binary file on USB mass storage device. If

found, upgrade.

Note: The printer will install the firmware stored on the CompactFlash card even if it is older than the version currently loaded on the printer.

3 Check if printhead is lifted and button is pressed. If so, go to

Extended Testmode, otherwise continue startup with step 3.

4 Check for the presence of a startup file (AUTOEXEC.BAT),

first on CompactFlash, then on “c/”. If found, run the startup file.

5 Check to see if button is pressed. If so, go to Testmode.

6 Continue power-up. Check APPLICATION file in “c/:” for

program file name. If found, run. If empty, go to idle state.

This means you can control the printer’s behavior after startup in a variety of ways: you can create an autoexec.bat file and save it on a memory card or in the printer’s permanent memory (device “c/”), you can write an application and store the link to it in the APPLICATION file, or you can choose to enter Testmode.

It is recommended to start custom applications by writing the name of the desired program (“ProgramName.PRG”) in the APPLICATION file in “c/”.

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Starting a custom application can also be done by creating a startup file (autoexec.bat) which will execute on startup. This file must contain Fingerprint commands that are interpreted immediately. Normal commands are LOAD and RUN. See the Intermec Fingerprint Programmer’s Reference Manual (P/N 937005-xxx) to learn how to create and save such a file to the printer.

Printer Startup Sequence (IPL)

1 Check for firmware binary on CompactFlash card. If found,

upgrade.

2 Check for firmware binary on USB mass storage device. If

found, upgrade.

Note: The printer will install the firmware stored on the CompactFlash card or USB mass storage device even if it is older than the version currently loaded on the printer.

3 Check if printhead is lifted and button is pressed. If so, go to

Extended Testmode, otherwise continue startup with step 3.

4 Check to see if button is pressed. If so, go to Testmode.

5 Continue power-up. Run a testfeed.

The process of entering and using Testmode and Extended Testmode is described later in this chapter.

Changing Configuration Settings

There are several different ways you can change the configuration settings of the printer. You can do it directly from the display, or remotely from the host PC using a USB, serial or ethernet connection.

Refer to Appendixes C and D for a detailed view of the Setup tree in Fingerprint and IPL, and for more extensive information about the various setup parameters.

Changing Configuration Settings From the Display

In order to change configuration settings, you need to enter Setup mode. Access Setup mode from the display by pressing Setup ().

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While in Setup mode, use the soft keys to navigate through the various options in the setup tree.

Navigating in Setup Mode

Soft Key Function

The main nodes of the setup tree are organized in a loop, as shown below (detailed overviews are provided in Appendix C (Fingerprint) and Appendix D (IPL)). Each main node branches out to a number of sub-nodes. At startup, the firmware determines if optional equipment such as a cutter or an interface board is installed in the printer, and these are added to the Setup tree.

Move one menu item to the left on the same level.

Move one menu item to the right on the same level.

Move up one level.

Acknowledge/Move down one level.

Edit value

Increase value

Decrease value

Exit Setup mode.

Starting point

SETUP: NET-COM, NET1

SETUP: EMULATION

SETUP: COM

SETUP: NETWORK

Option

SETUP: PRINT DEFS

SETUP: MEDIA

SETUP: FEEDADJ

SETUP: SER-COM, UART1

The main nodes of the Setup tree (Fingerprint).

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Starting point

Chapter 3 — Configuring the Printer

SETUP: SER-COM

SETUP: CONFIGURATION

SETUP: MEDIA

The main nodes of the Setup tree (IPL).

SETUP: TEST/SERVICE

SETUP: COM

SETUP: NETWORK

Option

Changing Configuration Settings With PrintSet 4

PrintSet 4 is a printer configuration tool which is available on the PrinterCompanion CD, and for download from the Intermec website. PrintSet 4 can communicate with your printer either via a serial cable or a network connection, and works on all PCs running Windows 98 (or later). The program allows you to easily change all of the setup parameters. It also includes setup wizards, which guide you through common configuration tasks.

Changing Configuration Settings From the Printer Home Page

If you have an optional EasyLAN network card and the printer is connected to your network, you can use your web browser to browse to the printer home page and make any desired setup changes there. Follow the instructions provided in “Connecting

the Printer to a Network” on page 11.

Once on the home page, click Configuration on the left side of the screen to access the setup parameters of the printer.

Changing Configuration Settings Using the Command Line

You can change setup parameters by sending commands directly to the printer using your terminal program (either through serial or network connection). The Fingerprint command to use is SETUP, followed by the node, subnode and parameter setting. For example, to set your media settings to labels with gaps, send the following instruction:

SETUP “MEDIA,MEDIA TYPE,LABEL (w GAPS)”

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The corresponding instruction in IPL is:

Note: IPL users should first verify that they have the correct HyperTerminal settings. See the screen capture below.

Hyperterminal settings (IPL only)

For more information on how to change setup parameters, see the Fingerprint Programmer’s Reference Manual (P/N 937-005- xxx), or the IPL Programmer’s Reference Manual (P/N 066396- xxx).

Running Testmode and Extended Testmode

Use Testmode and Extended testmode when you want to verify printer settings, print test labels, restore factory default settings, or enter Dumpmode for troubleshooting purposes. Two testmodes are available, Testmode and Extended Testmode. Testmode is a simple linear sequence which requires little input, while Extended Testmode gives the user more options.

Running Testmode

Testmode performs the following sequence:

1 Select media type (gaps/mark/continuous).

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2 Perform a sensor calibration (Testfeed).

3 Print test labels.

4 Enter Dumpmode.

To run testmode

1 Make sure the printer is turned off, loaded with media and

that the printhead is lowered.

2 Press and hold the blue Print button.

3 Keep the Print button pressed down, and turn on the power

switch. After approximately ten seconds the printer enters Testmode and three of the front LEDs start flashing one at a time. The display window lights up, and the printer runs a media setup routine.

As long as you keep the Print button pressed, the printer cycles through the selectable media types (Gap/Mark/ Continuous).

SELECT MEDIA

MARK

SELECT MEDIA

GAP

SELECT MEDIA

CONTINUOUS

4 Select your media type by releasing the Print button at the

appropriate time.

The printer automatically performs a sensor calibration (Testfeed) based on your selection, and selects thermal transfer printing if ribbon is installed, otherwise direct thermal is selected as default.

The printer prints several test labels containing the printer’s setup parameters. To skip test labels, tap the Print button.

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The printer is now in Dumpmode and scans the communication ports. Any characters received on the communication ports will be printed on a label when Dumpmode is exited.

5 Press the Print button once to exit Dumpmode.

You also have the option to save the dump by pressing Save ()

For more information about Dumpmode, see

“Troubleshooting Communication Problems” on page 45

The printer will start as on rebooted status. Once operational, the Data/Ready and Ready-to-Work LEDs light up.

Running Extended Testmode

Extended Testmode can be used to run additional tests. This includes the option to print test labels, running a testfeed in slow mode, entering Dumpmode, and resetting to factory defaults.

To run Extended Testmode

1 Make sure the printer is turned off, loaded with media, and

that the printhead is lifted.

2 Press and hold the blue Print button.

3 Keep the Print button pressed down, and turn on the power

switch. After approximately ten seconds the printer enters Extended Testmode.

All three LEDs flash rapidly four times to signal that Extended testmode is activated.

4 Release the Print button.

5 Lower the printhead.

6 You are now in Extended Testmode. Press Right ( ) to cycle

through the different options.

To select a test function, press Acknowledge ().

To exit Extended Testmode, press Cancel ().

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SELECT MEDIA

TEST

Functions in Extended Testmode

Function Description

Select Media This is the same media setup function as in

Test mode, with the important difference that the printer performs a slow sensor calibration (slow testfeed). Performing a Slow testfeed can be a way to resolve gap/ mark detection problems.

Tes t L ab el s Se tu p In fo Print configuration labels, one at a time.

Press Acknowledge ( ) to print the next label. The display indicates which test label is next.

Dumpmode Enter Dumpmode. For more information

about running Dumpmode, see

“Troubleshooting Communication Problems” on page 45.

Factory Default Restore factory default settings. Select the

option, and follow instructions in the display.

Setup and Exit Exit Extended Testmode, enter Setup

mode.

Exit Exit Extended Testmode.

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Upgrading the Firmware

The latest firmware and software is always available for download from the Intermec web site at www.intermec.com.

To download firmware updates

1 Visit the Intermec web site at www.intermec.com.

2 Click Service & Support > Downloads.

3 In the Select a Product field, choose the EasyCoder PD42

and you will be presented with the latest software available.

4 Download the latest firmware version to your computer.

5 Extract the zip file to a folder on your computer. Normally,

three versions of the firmware are included with the following differences and naming conventions:

• No suffix: Normal firmware upgrade.

• FD suffix: Firmware upgrade resetting Factory Default. Only applicable when upgrading through a CompactFlash card.

• NU suffix: Boots with new firmware, yet printer returns to previous firmware version on reboot (No Upgrade). Only applicable when upgrading through a Compact Flash card.

To upgrade your printer with new firmware

• Use PrintSet 4 and follow the firmware upgrade procedure.

• If you have a network connection, browse to the printer’s home page (see “Connecting the Printer to a Network” on

page 11), and select Maintenance. Upload the firmware file.

• Copy the firmware binary file to a CompactFlash card. Turn the printer off, insert the card into the printer’s CompactFlash socket and switch on the printer. The printer will be upgraded automatically.

• Copy the firmware binary file to a USB mass storage device. Put the firmware binary file in a directory named /d/upgrade, and the printer will use that file to upgrade unless the printer is already running that firmware. The printer will look for a file named FIRMWARE.BIN first. If there is no such file, it will look for any firmware file.

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Troubleshooting and Maintaining the Printer

This chapter covers the following topics:

• Printer Operation Problems

•Print Quality Problems

• Troubleshooting Communication Problems

• Contacting Product Support

• Adjusting the Printer

• Maintaining the Printer

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Test

Printer Operation Problems

The following tables list problems that affect the ability of the printer to operate.

Note: Fingerprint users can obtain an error diagnosis with the command through a terminal connection to receive the printer’s Ready-toWork st at us .

Display Error Messages (Blue Ready-to-Work LED Blinks)

Error Symbol Error Message Solution

SYSHEALTH$. Enter the line PRINT SYSHEALTH$

Printhead lifted. Lower printhead.

Maintenance. The printer is upgrading its

IP link error. Check if the network cable has

firmware. Wait for it to complete the task.

been unplugged

Press feed not done. Press Feed( ) or Testfeed( )

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Display Error Messages (Blue Ready-to-Work LED Blinks)

Error Symbol Error Message Solution

Label not taken. Printing has been halted because

a label is obstructing the LTS sensor.Remove label to resume printing.

LSS too high, LSS too low.

IP Configuration Error.

These errors can occur when you run a testfeed without any media installed, or if you have incorrect media settings.

Load the printer with media (see “Loading Media” on

page 14). Restart the printer in

Test mode (see “Running

Testmode” on page 34) and

select the appropriate media type.

The printer is trying to acquire an IP address from the network.

Wait for it to complete the task.

Display Error Messages (Error LED Blinks)

Error Symbol Error Message Solution

Field out of label. You are attempting to print in

an area that extends beyond the “print window.” See appendices C (Fingerprint) and D (IPL) information on how to set the media parameters.

Out of media. Load media in printer. See

“Loading Media” on page 14.

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Chapter 4 — Troubleshooting and Maintaining the Printer

Test

Display Error Messages (Error LED Blinks) (continued)

Error Symbol Error Message Solution

Ribbon empty. Load transfer ribbon. See

Label not found. The printer does not find a label

Printhead hot. The printhead is overheated and

Testfeed not done. Press Testfeed ( ).

“Loading Thermal Transfer Ribbon” on page 19. This error

could also occur if you have just switched to direct thermal media, and the printer is expecting ribbon to be loaded. If this is the case, change Paper Typ e in Se tu p .

gap or black mark.

• Go into Setup mode and verify that the label length parameter is correct (see

“Media Setup” on page 91

for Fingerprint and page 109 for IPL).

• Verify that the Media type settings are correct. This error can occur if you are, for instance, using continuous media but your media settings are set to labels with gaps.

needs to cool down.Wait for printing to be resumed automatically.

Cutter not found. A cut-command has been sent

but the printer cannot find the cutter. Check that the cutter is installed properly.

Cutter not responding.

Check that the cutter is installed properly.

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Test

Print Quality Problems

Problem Solution / Reason

Printout is faded or weak. • Fingerprint users: Adjust the media

settings: Constant, Factor and Contrast.

• IPL users: Adjust the Sensitivity setting.

• Check if printhead needs cleaning, see

“Cleaning the Printhead” on page 57.

• Check printhead pressure, see

“Adjusting Printhead Pressure” on page 51.

• Check printhead dotline position, see

“Adjusting Printhead Dot Line” on page 51.

Printer is working but nothing is printed.

Only partial labels are printed.

Part of the images is not printed along the feed direction.

• Printing on Direct Thermal media: check that media is loaded with the heat-sensitive side facing the printhead.

• Printing with Thermal Transfer ribbon: Check that the ink-side of the ribbon faces the media. See “Loading Thermal

Transfer Ribbon” on page 19.

• Select the correct media type (labels with gaps, black mark or continuous), and the correct paper type (direct thermal or thermal transfer).

• Check that the printhead is correctly connected to the print mechanism.

Check printhead balance, see “Ad j us ti ng

Printhead Balance” on page 50.

• Check if printhead needs cleaning, see

“Cleaning the Printhead” on page 57

• Check that the ribbon does not wrinkle, see “Preventing Ribbon

Wrinkling” on page 47.

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Print Quality Problems (continued)

Problem Solution / Reason

Printout darkness is uneven across media path.

Printout is not in desired position.

• Check printhead balance, see

“Adjusting Printhead Balance” on page 50.

• Check printhead pressure, see

“Adjusting Printhead Pressure” on page 51.

• Check for errors in software

application.

• Check if label gap sensor is disturbed

by media, dust or ribbon.

• Check the lateral position of label gap

sensor.

• Check the edge guide and media guide.

• Check the media (insufficient

transparency, interfering preprint lines in black mark operation, and so on).

• Check if platen roller needs cleaning or

replacement.

Troubleshooting Communication Problems

Use Dumpmode to verify that the printer is receiving data from the host correctly.

Using the Line Analyzer (Fingerprint)

In Dumpmode, the printer runs a Fingerprint program called Line Analyzer. As the name implies, the Line Analyzer captures incoming characters on the communication ports and prints them on one or more labels. Line Analyzer uses “autohunt” which means the program scans all applicable ports for data.

The easiest way to enter Dumpmode is through Testmode or Extended Testmode (see “Running Testmode and Extended

Testmode” on page 34)

When Dumpmode has been entered, the Printer will tell you this by printing “DumpMode entered” on a label. The display shows the Dumpmode icon, and the printer is ready to receive data.

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While the printer is receiving data, the Ready/Data LED blinks. There is a half-second timeout which means that if no more characters have been received after 0.5 seconds, the program considers the transmission terminated and prints out a label.

Printable characters are printed in black-on-white, whereas control characters and space characters (ASCII 000–032 dec) are printed in white-on-black.

As long as a continuous string of characters is being received, the program wraps the lines until the label is full and then starts to print another label. After each character transmission, the following information is printed:

• Page number

• Number of characters printed on the label

• Total number of characters received so far

Before you exit Dumpmode, you can choose to save the dump in the printer’s internal memory. The printer prints a label with the location of the saved file (the maximum size of the saved file is 128 kB).

When you exit Dumpmode, a final label with the text “Exit from Dump Mode” is printed.

Using Dumpmode (IPL)

When Dumpmode is activated, the printer captures incoming characters on the communication ports and prints them on one or more labels.

Users that run IPL firmware on their printer can access Dumpmode in two different ways, which produce slightly different results:

• Access Dumpmode through Testmode or Extended Testmode and you will receive printouts that look exactly as those produced with the Line Analyzer program on Fingerprintoperated machines. See “Using the Line Analyzer

(Fingerprint)” on page 45 for information on how to

interpret the labels.

• Access Dumpmode from Setup, and characters will be printed on a continuous line, along with corresponding hexadecimal numbers.

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To enter Dumpmode from Setup

1 Enter Setup by pressing ( ).

2 Navigate to Te s t / S e r v i c e > Data Dump.

3 Select Ye s.

4 To exit Dumpmode, reboot the printer.

Contacting Product Support

If you cannot find the answer to your problem in the “Troubleshooting and Maintaining the Printer” section, you can visit the Intermec technical knowledge base (Knowledge Central) at intermec.custhelp.com to review technical information or to request technical support. If you still need help after visiting Knowledge Central, you may need to call Product Support. To talk to an Intermec Product Support representative in the U.S.A. or Canada, call:

1-800-755-5505

Outside the U.S.A. and Canada, contact your local Intermec representative.

Before you call Intermec Product Support, make sure you have information about your printer model ready.

The machine and serial number labels are attached to the printer’s rear plate, and contain information on type, model and serial number as well as AC voltage and frequency.

Adjusting the Printer

This section describes some of the adjustments you can perform to solve problems related to printout quality.

Preventing Ribbon Wrinkling

If you have problems with transfer ribbon getting wrinkled, you can attempt to adjust ribbon tension or ribbon shield.

To adjust ribbon tension

1 Push the knob on the ribbon supply hub.

2 Rotate it clockwise to increase breaking force or

counterclockwise to decrease breaking force.

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If your labels look as depicted below, you may want to try adjusting the ribbon shield.

Test Label A

1234567890

Printouts of low quality caused by ribbon wrinkling.

The ribbon shield mechanism is located on the thermal printhead. It has two adjustable screws, A and B, as shown below.

Ribbon shield adjustment screws

To adjust ribbon shield

Test Label B

1234567890

1 If the label printout matches Test label A, turn screw A

clockwise. If the printout matches Test label B, turn screw B clockwise.

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Clearing Media Jams

Chapter 4 — Troubleshooting and Maintaining the Printer

2 Twist the screw half a turn and perform a new test print.

3 Continue until you achieve a smooth printout quality.

Screw adjustment must not exceed two full turns or paper may not feed smoothly. In such a case, turn the screws counterclockwise completely and start over.

To clear media jam in print mechanism

1 Switch off the power to the printer.

2 Pull the printhead lever out and turn it counterclockwise to

lift the printhead.

3 Pull out the media from the print mechanism.

If the media has been wound up or is stuck on the platen roller, carefully remove it by hand without using any sharp tools that can damage the platen roller or the printhead. Avoid rotating the platen roller.

Take care to avoid causing the platen roller to rotate. The electronic components may be damaged permanently.

4 Cut off any damaged or wrinkled part of the media.

5 Check to see if there adhesive is sticking to parts of the print

mechanism. If so, clean as described in “Maintaining the

Printer” on page 56.

6 Reload the media as described in “Loading Media” on

page 14.

7 Switch on the power.

8 Press the Print button to readjust the media feed.

Adjusting the Printhead

Keeping the printhead properly balanced is crucial for obtaining printouts of high quality.

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Adjusting Printhead Balance

The printer is factory-adjusted for full-size media width. If you are using media with less than full media width, Intermec recommends that you adjust the position of the printhead balance boxes so that the printhead is appropriately pressured against the media. If your printouts are weaker on one side than on the other, this is most likely due to an unbalanced printhead.

To adjust the printhead balance

1 Open the side door.

2 If transfer ribbon has been installed, remove it.

3 Lift the printhead by pulling the printhead lever out and

turning it a quarter of a turn counterclockwise.

4 Move the balance box on the right side (outer) to the right

(outward) for wider media, and inwards (to the left) for narrower media.

Balance box

5 Engage the printhead and load the ribbon.

6 Test and readjust if necessary. (Tip: Use direct thermal media

to avoid loading and unloading of ribbon multiple times.)

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Adjusting Printhead Pressure

The pressure of the thermal printhead against the platen roller is factory-adjusted. However, if the printing is weaker on one side of the media, or if the thermal transfer ribbon starts to crease (indicated by unprinted white streaks along the media feed direction), it may be necessary to readjust the printhead pressure.

Note: Before readjusting the printhead pressure, try to move the outer balance box as described in the previous Adjusting Printhead Balance procedure.

To adjust printhead pressure

1 Open the side door.

2 Remove the ribbon.

3 Lift the printhead by pulling the printhead lever out and

flipping it a quarter of a turn counterclockwise.

4 Use a straight-slot screwdriver to turn the screw at the top of

the balance boxes clockwise to increase the pressure, or counterclockwise to decrease the pressure.

5 Engage the printhead and load the ribbon.

6 Test and readjust if necessary. (Tip: Use direct thermal media

to avoid loading and unloading of ribbon multiple times.)

Adjusting Printhead Dot Line

When using thick or stiff media, the printhead needs to be moved forward so the dot line is aligned precisely with the top of the platen roller. It is also important to ensure that the printhead dot line and the platen roller are parallel.

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Chapter 4 — Troubleshooting and Maintaining the Printer

To adjust printhead dot line

1 Open the side door.

2 Remove the ribbon and engage the printhead.

3 Use a straight-slot screwdriver to turn the two screws at the

top of the printhead bracket counterclockwise a single turn.

4 Lift the printhead by pulling the printhead lever and flipping

it counterclockwise a quarter of a turn.

5 Carefully turn both screws at the front of the printhead

clockwise a quarter of a turn at a time (a full turn corresponds to 0.55 mm, which is a lot). Make sure to make identical adjustments on both screws. If you are unsure, tighten both screws completely by turning them counterclockwise as far as they go and start over.

6 Engage the printhead and lock it by tightening the two screws

at the top of the printhead bracket, that is, the reverse action of Step 3.

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7 Load the ribbon (if any).

8 Test and readjust if necessary. (Tip: Use direct thermal media

to avoid loading and unloading of ribbon multiple times.)

Adjusting the Label Gap Sensor

The label gap/black mark sensor (also called Label Stop Sensor or LSS) is a photoelectric sensor that controls the media feed by detecting gaps between labels, or slots or black marks in continuous stock. This requires the label gap sensor to be aligned with the gaps, slots or marks on the media. If you are using irregularly shaped labels, align the sensor with the front tip of the labels.

To adjust the label gap sensor position

1 Use the sensor lever at the rear side of the print mechanism to

move the sensor inward or outward.

Sensor lever

2 Check the point of detection from the front (with the

printhead lifted.)

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Chapter 4 — Troubleshooting and Maintaining the Printer

If you are having detection problems, you can test the LSS in Setup mode. The tests can determine if the sensor unit is not in position, if it is blocked by dust or stuck labels, or is defective in some way. There are two test functions:

• LSS Auto – this is the standard function for checking that the label stop sensor works properly and is able to detect gaps, slots and black marks.

• LSS Manual – shows the sensor setting established by the latest Testfeed. It is also possible to try other settings. LSS Manual is intended for service and is not described in this document.

Point of detection

To run the LSS Auto test function

1 Check that the printer is correctly set up for the type of media

loaded in the printer (Setup () > Media > Media Type).

2 Press Testfeed ().

Test

3 Make sure that there is a label–not a gap or mark–at the

sensor (“point of detection” as described above)

4 Check that the media runs as close to the center of the printer

as the guides allow.

5 Press Setup ().

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6 Navigate to Print Defs > LSS Test > LSS Auto. The cursor

should be placed in the center, as below.

LSS AUTO

7 Gap or slot detection: Lift the printhead and slowly pull out

the media (in the media feed direction). When the LSS detects a gap or a detection slot, the cursor moves to the right.

LSS AUTO

8 Black mark detection: Lift the printhead and slowly pull out

the media (in the media feed direction). When the LSS detects a black mark, the cursor moves to the left.

LSS AUTO

9 If the cursor behaves as decribed in Steps 7 and 8, the LSS is

working and is properly aligned with the gaps, slots or black marks.

10 If the cursor does not react on a gap, slot or black mark,

control the following:

• Is the LSS laterally aligned with the slots or black marks?

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• Is the transfer ribbon properly loaded so it does not

interfere with the LSS? (see “Loading Thermal Transfer

Ribbon” on page 19).

• Are the LSS guides clean, or are there partial labels or

residue stuck on them? If so, clean as described in the next section.

• Does the media have some kind of preprint that can make

detection harder?

• Is there too little difference between the black marks and

the surrounding areas?

• Is the label liner not transparent enough?

• Does the LSS work with another type of media?

(Remember to change the Media Type setup and perform a new Testfeed.)

Maintaining the Printer

In order to attain high productivity and a long life for your printer, Intermec recommends that you regularly inspect the printer and its environment to ensure that it is operated under optimal conditions.

Keep the printer in a dry area, away from larger electrical motors, welders and similar which might affect printer operation.

Clean your printer regularly, as described in the procedures below, in order to maintain the quality of your labels and extend the life of your printer.

If you open the electronics cover, you will void the warranty and may cause damage to the internal components. Opening the electronics cover exposes the user to shock hazards which may result in injury or death.

Always unplug the power cord before cleaning the printer.

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Cleaning the Printhead

Cleaning the printhead on a regular basis prolongs the life of the printhead and ensures you maintain high printout quality. You should clean the printhead with cleaning cards or a cotton swab moistened with isopropyl alcohol. Ideally, you should do this every time you load a new supply of transfer ribbon.

Isopropyl alcohol [(CH3)2CHOH] is a highly flammable, moderately toxic, and mildly irritating substance.

To clean the printhead

1 Open the side door.

2 Remove the media and ribbon.

3 Pull out the printhead lever and flip it counterclockwise a

quarter of turn.

4 Use a cleaning card or a soft cotton swab moistened with

isopropyl alcohol to dissolve any contamination on the line of heat-emitting dots at the front/bottom of the printhead.

Chapter 4 — Troubleshooting and Maintaining the Printer

5 Wait 30 seconds and carefully rub off any contamination.

Repeat if necessary.

Never use any hard or sharp tools to peel away stuck labels or similar,. The printhead is delicate and can easily be damaged.

6 Allow the printhead to dry for a minute or more before

loading a new supply of media and ribbon.

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Cleaning the Media Compartment

Regular cleaning of the printer’s media compartment ensures smoother printing operation and avoids problems with media jams.

Use a soft cloth moistened with isopropyl alcohol to clean the inside of the printer. Be sure to keep the following parts clean:

• Drive roller and tear bar

• Media edge guides and media path

•Label sensors

Isopropyl alcohol [(CH3)2CHOH;CAS67-63-0] is a highly flammable, moderately toxic, and mildly irritating substance.

If there are stuck labels, or adhesive residue from labels, peel as much as possible with your fingers, and then use isopropyl alcohol to dissolve the remaining adhesive.

Cleaning the Exterior of the Printer

Make sure to keep the exterior of the printer clean, this will reduce the risk of dust or foreign particles reaching the inside of the printer and affect printer functionality.

Use a soft cloth, possibly moistened with water or a mild detergent when cleaning the printer externally. Make sure to keep the surface surrounding the printer clean as well.

If the printer is used in an environment where the premises are cleaned by a water hose or steam, move the printer to another room or cover it very carefully with a plastic sheet and make sure that the power cord is unplugged.

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Specification, Interfaces, and Options

This appendix contains a general technical specification, as well as information about the printer interfaces and available options.

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Appendix A — Specification, Interfaces, and Options

Printer Specifications

Physical Dimensions

Dimensions (WxLxH) 276 x 454.4 x 283.0 mm

(10.9 x 17.9 x 11.2 in)

Weight (excl. media) 13 kg (28.7 pounds)

Power Supply

Input rating ~100-240V 2-1A 50/60 Hz

Power consumption •Stand-by: 12 W

• Normal operation/printing: 80 W

• Peak: 250 inW

Printing

Print technique Direct Thermal/Thermal Transfer

Printhead resolutions 8 dots/mm (203.2 dpi) or

11.8 dots/mm (300 dpi)

Print speed 8 dots/mm (203 dpi)

11.8 dots/mm (300dpi)

Print Width Max. 8 dots/mm (203 dpi)

11.8 dots/mm (300dpi)

Print Length Max. 8 dots/mm (203 dpi)

11.8 dots/mm (300dpi)

Modes of Operation

50.8 to 152.4 mm/sec (2 to 6 in/sec)

50.8 to 101.6 mm/sec (2 to 4 in/sec)

104 mm (4.1 in)

105.7 mm (4.2 in)

Fingerprint 1270 mm (50 in)

558.2 mm (22 in)

IPL 600 mm (23 in)

406.4 mm (16 in)

Tear-off (straightthrough)

Cut-off Option with cutter

Peel-off (self-strip) Option with internal

Firmware (Fingerprint)

Operating system Fingerprint v10.x.x Includes Direct

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Yes

rewinder

Protocol

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Appendix A — Specification, Interfaces, and Options

Printer Specifications (continued)

Smooth fonts TrueType and TrueDoc fonts

Resident scaleable fonts 15

Character sets • 23 single-byte character sets standard.

• UTF-8 support as standard.

Resident bar codes 61

Firmware (IPL)

Operating system IPL v10.x.x

Smooth fonts TrueType and TrueDoc fonts

Resident scaleable fonts 13 (+21 simulated bitmap)

Character sets • 23 single-byte character sets standard

• UTF-8 support as standard

Resident bar codes 31

Environment

Operating temperature +5°C to +40°C (+41°F to 104°F)

Storage temperature -20

Operating humidity 20 to 80% non-condensing

Storage humidity 10 to 90% non-condensing

Media

°C to 70°C (-4°F to 122°F)

Media width 25 to 118 mm (1 to 4.6 in)

Max 114 mm (4.5 in) with cutter

Media roll diameter 213 mm (8.4 in) max.

190 mm (7.5 in) with internal rewinder

Internal rewinder diameter

Media roll core diameter

Media thickness 60 μm to 250 μm (2.3 to 9.8 mils)

Transfer Ribbon

Material Wax, hybrid, or resin

Winding Ink on either inside or outside of roll

Ribbon width 30 to 110 mm (1.18 to 4.33 in)

Ribbon roll diameter (outer)

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Max 140 mm (5.51 in)

38.1 to 76.2 mm (1.5 to 3 in)

76 mm (2.99 in) equivalent to 450 m (1471 ft) of ribbon.

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Appendix A — Specification, Interfaces, and Options

Printer Specifications (continued)

Inner core diameter 25.2 to 25.6 mm (1 in)

Sensors

Label gap/black mark/ out of media

Printhead lifted Yes

Label taken Yes

Ribbon end Yes

Controls

Graphical display LCD, 240*160 pixels with LED backlight

LED indicators Power, Data/Ready, Error, Ready-to-Work™

Keys 1 Print Button + 5 Soft Keys

Electronics

Microprocessor ARM 9

Standard memory 8 MB flash, 16 MB SDRAM.

Interfaces

RS-232 serial Yes

USB Ye s

Ethernet Option

IEEE 1284 parallel Option

CompactFlash Yes

USB host Yes

Yes

Accessories and Options

Internal rewinder and batch takeup

Cutter

Printhead 203/300 dpi

EasyLAN ethernet interface

Parallel IEEE 1284 interface

Real time clock

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Interfaces

This section describes the standard interfaces, as well as the optional kits that add functionality to your EasyCoder PD42.

RS-232 Serial Interface

Protocol

Parameter Default

Baud rate 9600

Character Length 8 bits

Parity None

Stop bits 1

Handshaking XON/XOFF and RTS/CTS

To change the serial settings, see Chapter 3, “Configuring the

Printer.”

Interface Cable

The computer end of the cable depends on the computer model. The printer end is a DB9 pin plug, as shown below.

Appendix A — Specification, Interfaces, and Options

RS-232 DB9 pins

DB-9 Signal Meaning

1 External +5V DC Max 500 mA

2 TXD Transmit data

3 RXD Receive data

5GNDGround

7CTSClear to send

8 RTS Request to send

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Appendix A — Specification, Interfaces, and Options

USB Interface

The printer supports USB v1.1 (also called USB 2.0 full speed). To use the USB interface to print from a PC, you need to have the Intermec USB printer driver installed on your PC. You will find this driver (InterDriver) on the PrinterCompanion CD along with installation instructions.

The printer is a “self-powered device.” Intermec recommends that you only connect one printer to each USB port on the host, either directly or via a hub. Other devices, like a keyboard and a mouse, can be connected to the same hub. If you need more than one Intermec USB printer to a host, you should use different USB ports.

The USB cable included with the EasyCoder PD42 has a USB Type A connector on one end to connect to a PC, and a USB Type B connector to connect to the printer.

There is no communication setup for the USB port.

USB Type A Connector (Connects to PC or Hub)

USB Type B Connector (Connects to Printer)

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USB Host Interface

Ethernet RJ-45

Ethernet RJ-45 connector

socket

Network status LEDs

The PD42 printer is equipped with a USB host interface, which means you can connect various USB devices (bar code scanners and keyboards of HID type, memory sticks and USB hubs) for use with the printer.

Pin Function

1VBUS

2 D-

3D+

4 Gnd

EasyLAN Ethernet Interface

The EasyLAN Ethernet interface has an RJ-45 socket for use with a standard RJ-45 cable. The interface supports 10/100 Mbps Fast Ethernet (10BASE-T, 100BASE-TX) and is fully compliant with the IEEE 802.3u standard. The network card MAC address can be found on the label below the socket.

Appendix A — Specification, Interfaces, and Options

One yellow and one green LED indicate the network status as follows:

Network Status LEDs

Green On Link

Off No link

Blinking Activity

Yellow On 100BASE-TX

Off 10BASE-T

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Appendix A — Specification, Interfaces, and Options

Parallel IEEE 1284 Interface

The parallel port supports Windows plug-n-play and additional status reporting through IEEE 1284 nibble ID mode.