PD42 Easy Coder Printer

Product Information

The EasyCoder PD42 Printer is a high-performance label printer
designed for industrial and commercial use. It offers reliable and
efficient printing of labels, tags, and receipts. With its
user-friendly interface and advanced features, the PD42 Printer is
suitable for a wide range of applications.

Specifications

• Printing Technology: Thermal transfer and direct thermal

• Resolution: 203 dpi (8 dots/mm) or 300 dpi (12 dots/mm)

• Print Width: Up to 4.25 inches (108 mm)

• Print Speed: Up to 6 inches (152 mm) per second

• Connectivity: USB, Serial, Parallel, Ethernet

• Media Type: Roll-fed or fan-fold labels, tags, and
  receipts

• Media Width: 1.0 inch (25.4 mm) to 4.65 inches (118 mm)

• Media Length: Minimum 0.5 inch (12.7 mm), Maximum 99 inches
  (2515 mm)

• Memory: 16 MB Flash, 32 MB SDRAM

Product Usage Instructions

1. Using the Printer

To start using the EasyCoder PD42 Printer, follow these
steps:

1. Connect the printer to your system using the appropriate
   interface (USB, Serial, Parallel, or Ethernet).

2. Load the media into the printer according to the desired
   operation mode (Tear-Off or Peel-Off).

3. Plug in the printer to a power source.

4. Print test labels to ensure the printer is functioning
   properly.

5. Create and print labels for your specific needs.

2. Installing the Printer

Before using the EasyCoder PD42 Printer, you need to install it
properly. Follow these steps:

Connecting the Printer to Your System

To connect the printer to your system, use one of the following
methods:

Connecting the Printer Through the USB Interface

1. Locate the USB port on your computer.

2. Connect one end of the USB cable to the USB port on the
   printer.

3. Connect the other end of the USB cable to the USB port on your
   computer.

Connecting the Printer Through the Serial Port

1. Locate the serial port on your computer.

2. Connect one end of the serial cable to the serial port on the
   printer.

3. Connect the other end of the serial cable to the serial port on
   your computer.

Connecting the Printer Through the Parallel Port

1. Locate the parallel port on your computer.

2. Connect one end of the parallel cable to the parallel port on
   the printer.

3. Connect the other end of the parallel cable to the parallel
   port on your computer.

Connecting the Printer to a Network

1. Connect an Ethernet cable to the Ethernet port on the
   printer.

2. Connect the other end of the Ethernet cable to your network
   switch or router.

Loading Media

To load media into the EasyCoder PD42 Printer, follow these
steps:

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

1. Open the media cover.

2. Adjust the media guides to match the width of your media.

3. Place the roll-fed or fan-fold media into the printer, ensuring
   it is aligned with the guides.

4. Close the media cover.

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

1. Open the media cover.

2. Adjust the media guides to match the width of your media.

3. Thread the leading edge of the media through the peel-off
   mechanism.

4. Close the media cover.

Loading Thermal Transfer Ribbon

If you are using thermal transfer printing, you need to load the
thermal transfer ribbon. Follow these steps:

1. Open the printhead assembly.
2. Insert the ribbon core onto the ribbon supply spindle.
3. Route the ribbon through the printhead mechanism.
4. Attach the ribbon take-up spindle to the ribbon core.
5. Close the printhead assembly.

Plugging in the Printer

After connecting the printer to your system and loading the
media, plug in the printer to a power source using the provided
power cable.

Printing Test Labels

To ensure the printer is functioning properly, you can print
test labels. Follow these steps:

1. Ensure that the printer is loaded with media and connected to
   your system.

2. Press and hold the “Feed” button until the printer starts
   printing.

3. Inspect the printed labels for any issues.

Creating and Printing a Label

To create and print a label using the EasyCoder PD42 Printer,
follow these steps:

1. Install the printer driver on your computer (refer to the
   provided documentation).

2. Open the label design software on your computer.

3. Create or import the label design.

4. Select the EasyCoder PD42 Printer as the printing device.

5. Preview the label design and make any necessary
   adjustments.

6. Send the label design to the printer for printing.

3. Configuring the Printer

To configure the settings of the EasyCoder PD42 Printer, follow
these steps:

1. Access the printer’s configuration menu by pressing the “Menu”
   button on the printer’s display.

2. Navigate through the menu using the arrow keys.

3. Select the desired configuration option.

4. Adjust the settings according to your requirements.

5. Save the changes and exit the configuration menu.

FAQ

Q: Can I use the EasyCoder PD42 Printer with both thermal

transfer and direct thermal media?

A: Yes, the printer supports both thermal transfer and direct
thermal printing technologies. You can switch between the two modes
depending on your needs.

Q: What is the maximum print speed of the EasyCoder PD42

Printer?

A: The printer can print at a maximum speed of 6 inches (152 mm)
per second, ensuring fast and efficient label production.

Q: How do I clean the printhead of the EasyCoder PD42

Printer?

A: To clean the printhead, use a soft cloth or cotton swab
moistened with isopropyl alcohol. Gently wipe the printhead surface
to remove any debris or residue.

User’s Guide
EasyCoder® PD42 Printer

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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.
© 2007 by Intermec Technologies Corporation. All rights reserved.
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
1 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
2 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
3 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
4 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
A 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
B 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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C 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
D 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
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.
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.

Services

Description

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

Order Intermec · Place an order.

products

· Ask about an existing

order.

1 and then choose 2

Order Intermec Order printer labels and

media

ribbons.

1 and then choose 1

Order spare parts

Order spare parts.

1 or 2 and then choose 4

Technical Support

Talk to technical support

2 and then choose 2

about your Intermec product.

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Before You Begin

Services Service
Service contracts

Description

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

· Get a return authorization 2 and then choose 1 number for authorized service center repair.
· Request an on-site repair technician.

· Ask about an existing

1 or 2 and then

contract.

choose 3

· Renew a contract.

· Inquire about repair billing

or other service invoicing

questions.

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.
Related Documents
This table contains a list of related Intermec documents and their part numbers.

Document Title
Intemec Fingerprint Programmer’s Reference Manual IPL Programmer’s Reference Manual EasyLAN User’s Guide

Part Number
937-005-xxx 066396-xxx 1-960590-xx

The Intermec web site at www.intermec.com contains our documents (as PDF files) that you can download for free.

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Before You Begin

To download documents
1 Visit the Intermec web site at www.intermec.com.
2 Click Service & Support > Manuals.
3 In the Select a Product field, choose the product whose documentation you want to download.
To order printed versions of the Intermec manuals, contact your local Intermec representative or distributor.

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1 Using the Printer
This chapter includes the following sections: · Introducing the EasyCoder PD42 Printer · Features of the Printer · Working With the Print Button and LED Indicators · Working With the Display and the Soft Keys

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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
Front View

Side door

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Back View of the Printer

Chapter 1 — Using the Printer
Intake for external media supply

Side door Back View

Machine labels
USB host port Ethernet RJ-45 port USB port MAC address label RS-232 serial port
IEEE 1284 parallel port CompactFlash socket
I O
Power switch
AC power cord socket

Back View: Connectors

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Media Compartment and Print Mechanism

Ink position lever Edge guide

Media Compartment

Media supply post
Ribbon supply shaft Ribbon rewind shaft

Printhead balance boxes

Label taken sensor

Thermal Tear bar printhead

Print Mechanism

Ribbon rod
Printhead lever
Media feed rods

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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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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 Power

Color Green

Ready/Data

Green

Error

Red

Ready-to-WorkTM Blue

Function Power indicator
Printer ready
Error indicator
Intermec Ready-to-WorkTM 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.

Text or error messages

Current state (Setup)

Active soft keys

The different areas of the display and the soft keys.

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Chapter 1 — Using the Printer
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 F1 to F5

Function
Defined by Fingerprint application Enter/Exit setup
Feed

Test

Testfeed
Enter/Exit i-mode Left/previous state Up apply/acknowledge/select

Soft Key Function Right/next state
Edit value Exit editing/cancel/exit test mode/exit dumpmode Decrease selected digit
Increase selected digit Pause
Continue Save to file

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2 Installing the Printer
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

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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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Chapter 2 — Installing the Printer
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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Chapter 2 — Installing the Printer
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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Chapter 2 — Installing the Printer
· 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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Chapter 2 — Installing the Printer
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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2 Pull out the printhead lever and turn it counterclockwise. Lift the label feed guide.
Label feed guide
Printhead lever 3 Load a media roll onto the media supply hub. Be sure to push
it all the way in.

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Chapter 2 — Installing the Printer
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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Test

Chapter 2 — Installing the Printer
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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Chapter 2 — Installing the Printer
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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Chapter 2 — Installing the Printer
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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Chapter 2 — Installing the Printer
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.
= Ink in
= Ink out
Test to determine whether your transfer ribbon is wound ink-in or ink-out.
To load thermal transfer ribbon 1 Open the side door of the printer. 2 Pull out the printhead lever (1) and turn it counterclockwise
(2) to raise the printhead.
1 2

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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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Chapter 2 — Installing the Printer
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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Chapter 2 — Installing the Printer
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.”
6 Select your media type by releasing the Print button at the appropriate time.

SELECT MEDIA GAP

SELECT MEDIA MARK

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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Chapter 2 — Installing the Printer
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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3 Configuring the Printer
This chapter contains the following sections: · Understanding Printer States · The Printer Startup Sequence · Changing Configuration Settings · Running Testmode and Extended Testmode · Upgrading the Firmware

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Chapter 3 — Configuring the Printer

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 Power Off Upgrading TestMode Extended TestMode Setup Mode
i-mode
PUP Idle Application running Printing Printing (wait for LTS) Paused Error Dumpmode

Explanation
Firmware is being upgraded. See page 34. See page 36. Setup mode is accessed from the display (this may require a password if the printer is running a Fingerprint application). In Setup mode, you can change various printer settings. i-mode is accessed from the display when the printer is idle. In i-mode the printer will cycle through the various interfaces with 5 second intervals. Power-UP (starting up) The printer is operational and is waiting for print jobs. The printer is running a (Fingerprint) application
Waiting for Label Taken Sensor to indicate that label has been taken. Paused during print job Error state In Dumpmode, the printer listens on all communication ports and prints incoming characters.

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Chapter 3 — Configuring the Printer

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

State Power Off Upgrading Testmode
Extended Testmode
Setup mode Idle (FP)
Idle (IPL)
Application running Printing Paused (FP) Paused (IPL) Error

Button pressed Button pressed “Double-

< 1 s

1 s

click”

See “Running Testmode and Extended Testmode” on page 34
See “Running Testmode and Extended Testmode” on page 34

See “Running Testmode and Extended Testmode” on page 34
See “Running Testmode and Extended Testmode” on page 34

Formfeed/ Printfeed

Testfeed

Formfeed

Continuous feed Enter Pause while button is mode pressed

Defined by application

Defined by application

Defined by application

Pause print job

Continue print job Cancel print job

Continue print job Continue print job

See Chapter 4, “Troubleshooting and Maintaining the Printer.”

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Chapter 3 — Configuring the Printer

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/Flash1

Off

Application running On

Printing

On/Flash1

Printing (wait for LTS) Quick flashes2

Paused

Flash3

Error

Off

Off Off Off Off On / Flash4

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.

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Chapter 3 — Configuring the Printer

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

Fingerprint 10.2.0

Idle Running application Setup, navigation

Setup, edit value

F1 F2 F3 F4 F5

i-mode Printing

Test TEST
TEST

Paused Testmode Extended Testmode Dumpmode Upgrading
Active soft keys in different printer states.

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Chapter 3 — Configuring the Printer
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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Chapter 3 — Configuring the Printer
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 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.

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.

Starting point
SETUP: SER-COM, UART1
SETUP: PRINT DEFS

SETUP: NET-COM, NET1
SETUP: COM

SETUP: MEDIA

SETUP: NETWORK
Option

SETUP: FEEDADJ

SETUP: EMULATION

The main nodes of the Setup tree (Fingerprint).

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Starting point
SETUP: SER-COM

SETUP: COM

SETUP: CONFIGURATION

SETUP: NETWORK
Option

SETUP: MEDIA

SETUP: TEST/SERVICE

The main nodes of the Setup tree (IPL).

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: