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User's Manual EasyCoder?4420 and 4440 Bar Code

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2. O D O D O D O D TE TE SE TE 3 E 3 E 44XXU057 eps xI Remove the media cover Note Do not raise the printhead while adjusting the TOF position 2 Press on the front part of the TOF switch Each time you press the TOF switch you move the label format forward 0 127 mm 0 005 in 3 Press the TOF switch repeatedly until the format moves forward to the correct position on the label Label direction from printer 4 3 0poo wey AMEN jonpoag y opoo 197 OUEN jonpoag y 9po9 wey AMEN jonpoag soy opoo 197 ABN jonpoag soy E ES d aj E o o a Adjusting the Label Gap Sensor 54 If you experience problems such as the printer skipping labels or the printer stopping and the yellow LED flashing you may need to adjust the label gap sensor You are most likely to experience any of these problems if you are using very narrow label stock and the label gap sensor is not in the correct position You can adjust the label gap sensor from 0 to 2 5 cm 0 to 1 0 in from the inner edge of the printer EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 5 Optimizing Printer Performance 14 Note Intermec sets the label gap sensor to 1 3 cm 0 5 in from the inner edge of the printer at the factory You should be able to leave it i
3. ON 1 2 3 4 1 2 3 4 Switch settings Switch settings for feeding for retracting label label forward 44XXU064 eps 4 In the bottom bank of the Test and Service mode DIP switches turn on or off the appropriate DIP switches See the Dot increments DIP switch settings illustration earlier in this chapter 5 Press the Feed Pause button The printer prints out the software configuration label and stops at the new location 6 Verify that the Label Rest Point number on the software configuration label matches the number you set in Step 4 7 Try printing again to see if you need to readjust the DIP switches in the bottom bank 8 If you need to readjust the DIP switches in the bottom bank repeat Steps 4 through 6 If not exit Test and Service mode by turning off the printer returning all DIP switches to their original settings and turning on the printer Setting Emulation Mode If you are replacing an Intermec 8636 or 8646 printer with a 4420 or 4440 printer you can keep your existing network hardware software and label formats by using Emulation mode The labels the 4420 or 4440 printer produces will look just like the labels that the 86XX printer prints There are three ways to set the printer to Emulation mode e Use the DIP switches in the Test and Service DIP switch bank For help see the following procedure e Use PrintSet to select either 100 dpi 10 mil or 66 dpi 15 mil mode For help see the PrintSe
4. sse 24 Cabling in Noisy Electrical Environments 00 ccccccsscescessceseceeeeeeeeeeeteeneeeaeees 24 Configuring the Serial Port for Communications sess 25 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual v Contents Communicating With the Printer sess 27 Using the PrintSet SOftWAre sete ie pete eds 27 Using Third Party Software nennen 24 Using Intermec Printer Language IPL Commands sss 27 Using PrintSet to Test Communications sss 28 3 Maintaining the Printer seeeetteenttteen ttt tetnntetttnnnets 29 Inspecting the Prifiter unire a aliada 30 Maintenance Schedule zcssscscesccssssatecassiguagenstectsleascdessnscbagowiavseensde oueevacancezdestaloaseseotduresseduens 30 Tools for Cleaning the Printer unid dani 31 Cleaning the Printhead sese 32 Cleaning the Printer COvVerS seoa o eere 34 Cleaning the Rollers and the Tear Bar sse 34 Cleaning the Media Guides and Media Path ooconcnnnncinncnonnconnconaconnonnnooncconocnonos 36 Cleaning the Label Sensors nner i i a a 37 4 Troubleshooting the Printer sse 39 Troubleshooting Checklist sees enne 40 Printer Operation Problems sese eene enne eene enirn nnne nnne 40 Print Quality Problemi ite eee ano 42 Communication Problems eese eene entente entente teen rr ennenne neni 44 Preventing Data Loss
5. e Setting the media sensitivity number EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 1 Getting Started Learning About the Printer Features of the 4420 and 4440 printer include e High throughput e JEEE 1284 parallel port e 18 000 inch ribbon capacity e Simple user interface e Moveable label gap sensor eUp to 10 inches per second ips print speed with selected media e Thermal transfer and direct thermal printing support Media indow Media cover Feed Pause button Power Data LED Alert LED Empty Pause LED 44XXU001 eps Media access door 4420 and 4440 front view This illustration shows the 4420 and 4440 features on the front of the printers 2 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 1 Getting Started Darkness adjust control DIP switches Optional I O board port Serial communications port Parallel port On Off switch AC power cord receptacle Fanfold media access slot 4420 and 4440 back view This illustration shows the 4420 and 4440 features on 44XXU003 eps the EasyCo back of the printers der 4420 d Several options are available for use with the 4420 and 4440 printer a Bar Bee Code Appendix A Specifications for a complete description of each Label option Printer User s Manual Understanding the Front Panel BN This s
6. or Cancel batch printing lt EM gt However if the printer responds with a lt GS gt to any message block the buffer is already full and it discards the entire message block XON XOFF Protocol Software and Hardware Flow Control XON XOFF protocol uses the ASCII characters lt DC1 gt XON and lt DC3 gt XOFF to start and stop the flow of data from the host to the printer The printer does not restrict the message length for XON XOFF protocol That is the printer processes information as it is being downloaded and stops when there is no more information lt STX gt and lt ETX gt are optional characters However if you send an STX the printer ignores all other characters until you send an ETX Intermec provides two versions of the XON XOFF protocol The Intermec version of XON XOFF has the printer respond to each message with its current status The other version conforms to generally accepted industry standards which include no end of message response being sent to the host other than XOFF In addition a DC3 is sent to the host if the printer is offline or if media fault occurs An XON is sent on power up Since the printer uses DC1 and DC3 for data flow control the printer status characters are different from those of the Standard Protocol XON XOFF Protocol Printer Status Conditions Printer Status Character Buffer already full GS Ribbon fault US No label stock EM Printhead hot SI Buffer now full DC4 Label at s
7. 3C PS IR A 2 RI SrTI SLT e Ez gt S I ES gt 4C 4D En 232 ls 203 50 n Ole nn 2 of em 5C 5D m o e a a o ar EI g Qu 25 2 m um vy i San Smee Ny TE md 3 6 61 63 64 65 66 6C 6D qrixsitulv A 7 71 72 73 74 75 76 TE 78 79 7A 7B TE 7D TE TF 96 97 98 99 9A 9B 9C 9D 9E 9F A AL A2 A3 A4 A5 A6 AT A8 A9 AA AB AC AD AE AF C Cl C2 C3 C4 A D C7 C8 C9 CA CB CC CD CE CF D D1 D2 D3 D4 D5 D6 D7 D8 D8 DA DB DC DD DE DF E El E2 E3 E4 E5 E6 E7 E8 E9 EA EB EC ED EE EF F FL F2 F3 F4 F5 F6 FT F8 F9 FA FB FC FD FE FF 44XXU071 eps EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 91 Appendix B Character Sets Characters in Fonts c24 OCR B Size 2 Aj 2 2 2 2 2 2 2 2 fil La mM f fis fis FE AS ASP I x 5 ag q r3 A r3 ONIN 4 TR ON 20 ha Ef Ok z GAN AH y H B4 TE E gb or gt A 3 oF By Ny 3 NH ES OS GH OF CH Y 1 HO NA 3j O 3 D C3 T Wh Hi a OS LOS 8 3 gt vyY WM oF 7 Oj 9 Ja 11 6 6t 63 6 66 68 69 Gtr G t pa S uv X Y Z re 6 E 95 96 la yl S AS 6 AS A at 3 O3 Pet O3 m S C v i 5E 44XXU072 eps 92 EasyCoder 4420 and 4440 Bar Code Labe
8. drag A method of bar code printing in which all the bars are printed at once in parallel The bar code appears across the width of the label EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Glossary EAN European Article Numbering now also called IAN International Article Numbering International standard bar code for retail food packages corresponding to the Universal Product Code UPC in the United States Emulation mode An operating mode in which the printer has the operating characteristics of another printer For example the 3440 can operate in 8636 46 Emulation which emulates an Intermec 8636 or 8646 printer field A graphic element that is the basic unit of a format The four basic types of fields are bar code graphic line and text fixed data field Bar code and text fields that never vary from one label to the next the data in a fixed field is a permanent part of the format fixed format A format in which the data never varies from one label to the next such as a return address label A fixed format needs no additional data to print a label font A character set of a given type size and style See also character set font file See soft font format file A collection of printer commands and data that determines the arrangement of fields on a label graphic A bitmap picture downloaded to the printer by the host before printing HIBC Health Industry Bar Code standard A m
9. lY y NA Screwdriver M 44XXU046 eps Quis SING aN The print darkness adjust in PrintSet is similar to the dark adjust available on a copier An increase in print darkness increases the energy to the printhead and results in darker print A decrease in print darkness decreases the energy to the printhead and results in lighter print To adjust the print darkness with PrintSet Start PrintSet on your PC 2 Click the Media Type button nn The Media Type dialog box appears 3 On the Print Quality Setup tab adjust the Print Darkness slider bar until the setting that you want appears underneath it EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 5 Optimizing Printer Performance Media Type E x Print Quality Media Setup Print Quality Setup Enter data if known Media Sensitivity Number If you need help select the BE Print Quality Wizard pushbutton Print Darkness Print Lighter Ea Darker Quality Cancel You can adjust the print darkness from 10 to 10 4 Click OK 5 Download your change to the printer by pressing the button to send command updates to the attached printer E Fine Tuning the Top of Form Position If the label format prints too close to the front or back edge of the label you can fine tune the position with
10. printhead is very important Clean after every roll of media 152 m or 6 000 in or ribbon 457 m or 18 000 in Clean more often if necessary There are two ways to clean the printhead e Use the cleaning card e Use a cotton swab and isopropyl alcohol Do not use sharp objects such as knives or screwdrivers to scrape the printhead clean Cleaning with sharp objects will damage the printhead Attention N utilisez pas d objets pointus tels que couteaux ou tournevis pour nettoyer la tj e d imprimante Nettoyer avec des objets pointus endommagera la te d imprimante To clean the printhead using the cleaning card Turn off the printer and remove the power cord 2 Remove the media cover 3 Disengage the printhead by rotating the head lift lever clockwise until the printhead releases This raises the printhead so that you can clean it 4 Remove the media and ribbon 5 Open the pouch and remove the cleaning card EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 3 Maintaining the Printer 6 Insert the cleaning card into the printer following the media path Head lift Upper lever media guide Cleaning card Label gap sensor Edge Lower 44XXU030 eps guide media guide 7 Engage the printhead by rotating the head lift lever counterclockwise until it locks in place 8 Use one hand to hold the printer and use the other hand to pull the clea
11. use XON XOFF protocol for Ready Busy buffer control To configure the printer serial port Use the following DIP Switch Settings Descriptions table to locate the DIP switches you use to configure the serial port 2 Usea small straight slot screwdriver to set the appropriate DIP switches For example if you want to change the media type to thermal transfer set DIP switch 8 on the bottom bank of switches to the on position 3 Turn the printer power off and then on for the configuration changes to take effect 1 Note Make sure you set all Multi Drop switches to off if you are not using a Multi Drop network DIP Switch Settings Descriptions Parameter Description Baud rate The rate in bits per second at which the host exchanges data with the printer Parity Adds one bit 1 or 0 to the character to make the sum of bits always odd or even Data bits The number of bits 7 or 8 that represent the ASCII characters Batch takeup Enables or disables the optional batch takeup self strip motor Multi Drop Unique address for each device connected with Multi Drop address protocol EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 25 Chapter 2 Installing the Printer 26 DIP Switch Settings Descriptions continued Parameter Protocol Media type Description printer and each connecting device transfer media The transmission standards for communication b
12. A Code 49 bar code contains from two to eight adjacent rows each separated by a one module separator bar EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Appendix A Specifications Supported 2D Stacked Symbologies continued Symbology Description PDF417 PDF417 is a stacked 2D symbology that provides the ability to scan across rows of code Each row consists of start stop characters row identifiers and symbol characters called codewords Each codeword consists of four bars and four spaces and contain the actual data In addition to being able to condense a large amount of information into the stacked format PDF417 provides an extensive error detection and correction option Up to 510 characters can be recovered if they are lost due to an error in scanning or if the label is damaged PDF417 codes can be scanned with a laser scanner or imaging device that features 2D code scanning capability MicroPDF417 MicroPDF417 is a 2D symbology derived from PDF 417 You use MicroPDF417 for applications needing improved area efficiency but without the requirement for PDF417 s maximum data capacity MicroPDF417 replaces PDF417 s 17 module wide start stop patterns and left right row indicators with a unique set of 10 module wide Row Address Patterns which were designed both to reduce overall symbol width and to enable linear scanning at row heights as low as 2X 2D Matrix Symbologies 2D matrix symbologies such
13. Intermec media recommended for the print speed Clean printhead platen roller and label path as described in Chapter 3 Maintaining the Printer 42 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 4 Troubleshooting the Printer Print Quality Problems continued Symptom Possible Causes Solution Print quality is poor Uneven print contrast density The Adjust the bias adjust screw See Correcting continued printhead pressure may be set incorrectly Uneven Print Quality in Chapter 5 for the media width Poor quality label or ribbon stock Use only Intermec label and ribbon stock to ensure superior print quality and product performance Ribbon wrinkling The printhead Check to make sure that you installed the pressure may be set incorrectly for the ribbon correctly For help see Loading media width Thermal Transfer Ribbon in Chapter 1 Adjust the bias adjust screw See Correcting Uneven Print Quality in Chapter 5 Ribbon installed upside down Make sure you installed the ribbon correctly For help see Loading Thermal Transfer Ribbon in Chapter 1 You are using the wrong core locking Use the plastic core locking brackets for bracket on the ribbon hub plastic core ribbons and the cardboard core locking brackets for cardboard core ribbons For help see Loading Thermal Transfer Ribbon in Chapter 1 Direct thermal thermal transfer switchSet the switch for the
14. Thermal Media Sensitivity Settings Approximate Sensitivity Sensitivity Ratings Setting 700 Series High 720 Sensitivity 400 Series 480 Medium Sensitivity 470 460 450 440 420 100 Series Low 180 Sensitivity 170 160 140 130 Maximum Recommended Direct Thermal Media Print Speed Duratherm Lightning Plus 2 8 ips Duratherm Lightning IR Tag5 ips Duratherm Lightning 1 5 ips European IR 5 ips Duratherm IR Lightning 1 5 ips European Thermal 5 ips Duratherm Lightning 2 5 ips Duratherm II 1 3 ips European Tag 3 ips Duratherm II Tag 3 ips European Top 3 ips Duratherm II 2 3 ips Thermal Transfer Media and Ribbon Sensitivity Settings Approximate Sensitivity Sensitivity Ratings Setting 800 Series High 864 Sensitivity Paper 854 834 Maximum Recommended Direct Thermal Media Print Speed European 8 ips Uncoated Standard Duratran TTR Paper 6 ips Labels Standard 1 Duratran TTR Paper 6 ips Tags Standard 1 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 1 Getting Started Thermal Transfer Media and Ribbon Sensitivity Settings continued Approximate Maximum Sensitivity Sensitivity Recommended Ratings Setting Direct Thermal Media Print Speed 600 Series 687 Duratran TTR Polyester or 6 ips Medium Valeron Premium 7 Sensitivity Plastic 677 Duratran Syntran Premium 6 ips 7 647 Duratran Tyvek Premium 7 4 ips 643 European Tyvek Premium 4 ips 633 European 8 ips Polyeth
15. a lower print speed or add an expansion DRAM SIMM To print very complex labels at high speeds you must allocate enough image bands to completely image the label before printing Allocate one band for each inch of label length By doing this you can print at any speed However there may be a considerable delay between labels EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 59 Chapter 5 Optimizing Printer Performance EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 60 6 Using Test and Service Mode This chapter explains the different procedures you can perform while the 4420 or 4440 printer is in Test and Service mode This chapter covers these topics e How to use Test and Service mode e Printing test labels e Setting configuration commands EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 61 Chapter 6 Using Test and Service Mode Using Test and Service Mode Procedures 62 When you press the Feed Pause button the current function pauses and the printer enters Test and Service mode and executes all Test and Service mode procedures The printer remains in Test and Service mode until you turn off the power and reset the DIP switches To enter Test and Service mode Turn off the printer 2 Press and hold the Feed Pause button while turning on the power The printer prints out a hardware configuration label and then enters Data Line Print mode 3 Setthe DIP swi
16. connect to modem CTS pin Modem must set CTS true before the printer transmits data If not connected CTS sets itself true EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 99 Appendix C Communications Reference RS 232 RS 422 and RS 485 Serial Interface Pin Assignments continued Interface Pin RS 232 422 485 7 RS 232 422 485 11 RS 422 485 13 RS 422 485 14 RS 422 485 16 RS 422 485 19 RS 232 422 485 20 Name Signal Ground SG Printer Status PS Input B Output A Input A Output B DataTerminal Ready DTR Printer Serial Port 100 Operation To enable communications connect to signal ground of connected device Completes circuit for all RS 232 signals Output When not using software flow control XON XOFF connect to input of connected device for example CTS Indicates printer mechanical status and status of printer input buffer Input Serial differential data to the printer Output Serial differential data from the printer Input Serial differential data to the printer Output Serial differential data from the printer Output When you use a modem connect to modem DTR pin When using Intermec Standard protocol this pin indicates that the printer is switched on When using XON XOFF or hardware flow control this pin indicates the printer mechanical status and the status of the printer input buffer The rear panel of the printer contains the serial port connector I
17. earlier in this chapter 7 Select the type of data that you wish to transfer such as pages formats fonts or UDCs by setting the corresponding DIP switches shown in the Test and Service mode DIP switch settings illustration earlier in this chapter 8 Press the Feed Pause button on the sending printer to initiate selective transfer When the Power Data LED stops flashing the selective transfer is complete 9 Exit Test and Service mode by turning off the printer and returning all DIP switches to their original settings Using Memory Reset Use memory reset if you want to return the printer to its default configuration or if you need to increase the amount of memory available in the printer You can also use memory reset to clear pages and formats user defined characters and fonts configurations tables or all of these parameters EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 65 Chapter 6 Using Test and Service Mode ES To use memory reset Turn off the printer 2 Set the DIP switches to reset a portion or all of the memory by using the Test and Service mode DIP switch settings illustration earlier in this chapter 3 Press and hold the Feed Pause button while turning on the printer The printer prints out a hardware configuration test label 4 Hold the Feed Pause button down for 1 second The printer resets a portion or all of its memory 5 To exit Test and Service mode turn off the pri
18. eps Printer 9 Pin PC Connector This illustration shows the pin assignments for the RS 232 null modem cable for the 9 pin PC connector P N 048693 Note The metal backshell is connected directly to the shield to achieve electrostatic discharge ESD immunity 101 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Appendix C Communications Reference Shield 25 Pin Plug D Sub Metal Backshell 25 Pin Socket D Sub Metal Backshell Chassis Ground Chassis Ground Transmitted Data Transmitted Data Received Data Received Data Request to Send Request to Send Clear to Send Clear to Send Data Terminal Ready Data Terminal Ready Signal Ground s Printer 1 Modem AAXXUOT6 eps Straight Through DTE to DCE Cable This illustration shows the pin assignments for the straight through DTE to DCE cable used with a modem P N 0432375 If you find that you are losing data you may need to isolate the chassis ground from one of the two devices by connecting it to the shield Signal Ground 14 Note The metal backshell is connected directly to the shield to achieve electrostatic discharge ESD immunity Shield X8410 plos ng X84101uM cu V Input RxDA Output TxDA Output TxDB E Nur xr Printer 44XXUO77 eps Host RS 422 serial interface This illustration shows the pin assignments for the RS 422 serial interface The host in this case includes Intermec products that support RS 422 Non Intermec cont
19. in the next sections Chapter 1 Getting Started Connecting the Printer to a Power Source The back of the printer contains the AC power cord receptacle the serial communications port the parallel communications port the accessory port the darkness adjust the On Off switch and two banks of DIP switches To connect the printer to a power source Turn off the printer 2 Make sure the DIP switches on the back of the printer are set to their factory default settings Top Bank Turn on switch 1 Turn off switches 2 through 8 Bottom Bank Turn off switches 1 through 8 44XXU005 eps 3Plug the AC power cord into the receptacle t the rear of the printer 4 Plug the other end of the power cord into a grounded wall outlet or surge protector ES Turn the printer on When you turn on the printer the green light emitting diode LED lights and the platen roller advances The yellow LED lights until you load media 6 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 1 Getting Started Opening the Printer You need to open the printer when you load media or perform maintenance procedures To open the printer Place the fingers of your right hand under the embossed section of the media cover the media cover release and pull the bottom of the media cover away from the base of the printer 72 Grasp the front of the media cover with your left hand and lift the front of the
20. in the printer to store several different label formats and still retain enough memory to store downloaded fonts graphics and data Be careful of how you use the printer memory The printer uses flash memory for storing tables pages formats fonts and user defined characters UDCs The 4420 and 4440 printers have 128K of flash memory available for storage If you require additional storage memory you can purchase flash SIMM for the printer The printer supports these parameters independent of the amount of memory installed or allocated by the printer e Maximum number of formats 99 You can edit formats 1 to 99 You cannot edit default format 0 e Fields per format 200 e Maximum data buffer size for a field 3550 e Maximum number of UDCs 100 e Maximum number of user defined fonts 16 Making the Most of the Memory There are limits to the number of formats fonts graphics or pages that you can store in the printer You can define up to 16 fonts but there may not be enough room depending on the amount of memory being used for other purposes The more formats graphics and fonts you store the less memory is available When you run into a memory usage problem use PrintSet to see how much memory remains available You must upload the memory information from the printer first Refer to the PrintSet online help for more information If you find that it is necessary to increase the available memory you can do one of th
21. label printing 15 specifications printer 76 to 78 speed printing 78 stacked symbologies See 2D symbologies Standard protocol definition 110 described 94 symbologies 2D 82 Codabar 81 Code 11 81 Code 128 81 Code 16K 82 Code 2 of 5 81 Code 39 81 Code 49 82 Code 93 81 Data Matrix 83 EAN 81 116 Interleaved 2 of 5 81 Maxicode 84 MicroPDF417 83 PDF417 83 POSTNET 82 QR Code 84 UPC 82 symbology definition 110 T tear bar cleaning 35 Test and Service mode changing configuration commands from 66 Data Line Print 64 DIP switch settings 63 entering 62 exiting 62 memory reset 65 printing test labels 64 selective transfer 64 setting Emulation mode 69 using forms adjust 71 X forms adjust 72 Y forms adjust 72 test labels printing 64 printing a hardware 28 thermal transfer ribbon loading 11 12 thermal transfer definition 110 third party software using to communicate with the printer 27 throughput increasing 58 tools for cleaning the printer 31 top of form position fine tuning 51 top of form definition 110 troubleshooting checklist 40 communication problems 44 data loss 44 print quality problems 42 printer operation problems 40 using LEDs 4 twinax interface option 80 U UDC definition See graphic definition UDF definition See soft font definition understanding the front panel 3 UPC definition 110 described 82 uploading definition 2
22. media cover upward to release it from the printer frame 3 Lift the media cover away from the top of the printer 44XXU006 eps Loading Media Into the Printer The printer can print on rolls of or fanfold thermal transfer or direct thermal media The default setting for the printer is direct thermal mode However the sample media that shipped with the printer is thermal transfer If you are using thermal transfer media you need to load thermal transfer ribbon and change the media type setting For help loading the ribbon see Loading Thermal Transfer Ribbon later in this chapter To change the media type setting see Configuring the Serial Port for Communications in Chapter 2 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 7 Chapter 1 Getting Started Loading Roll Media Raise the printhead by rotating the head lift lever clockwise until the printhead disengages 2 Turn the supply roll retainer counterclockwise to release it and then slide it to the outer end of the supply roll post Turn it clockwise to lock it in place 1 Note If you are replacing the empty media roll with a new roll of the same width you do not need to adjust the edge guide or the supply roll retainer 3Place the media roll on the supply roll post and position it firmly against the printer 4 Insert the media support between the roll of media and the supply roll retainer before securing it 5 Turn the supply roll
23. part of the media on which data is printed label format The design of a bar code label the arrangement of the text lines and bar codes on a label label gap The space between labels on die cut label stock margin The distance between the edge of a label and where the printing starts on that label See also top of form EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Glossary media The label stock on which the printer prints labels Media can be made of plain paper polyester thermally reactive paper or other materials with adhesive backing and ribbon mnemonic code An acronym or abbreviation for a computer instruction routine or format For example lt STX gt represents the start of text Multi Drop protocol A protocol capable of controlling communications between a single controller and multiple devices nibblized A software term that refers to grouping bits into sets of four called nibbles Usually bits are grouped into sets of eight which are called bytes OCR font A font that is recognized by optical character recognition offline The state in which the printer is not able to carry out two way communication with the host online The state in which the printer is able to carry out two way communication with the host page A group of labels that are always printed together When labels on a page share the same data it reduces the number of commands that must be sent to the prin
24. quality or damage the printhead Cleaning the guides also prevents the media from skewing or improperly tracking as it travels through the media path which can result in smeared images and print off the side of the label Always clean the media guides immediately after a label jam in the printer To clean the media guides and media path Turn off the printer and remove the power cord 2 Remove the media cover 3 Remove the media and ribbon if necessary 4 Pull down on the lower media guide to open up the media path Upper media guide Lower media guide path 44XXU039 eps 36 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 3 Maintaining the Printer 5 Clean the lower media guide by using a lint free cloth moistened with isopropyl alcohol as shown in the following figure 14 Note The lower media guide is spring loaded You must hold it open to clean 6Use the cloth moistened with isopropyl alcohol to clean the upper media guide Be sure to remove all traces of debris 7 Remove all traces of dust paper and adhesive from the media path with a soft bristle brush or vacuum 8 Clean the flat surfaces of the media path including the edge guide with a lint free cloth and isopropyl alcohol 9 Release the lower media guide 10 If you are finished cleaning replace the media cover Cleaning the Label Sensors Two label sensors on the print
25. tear bar preserves print quality by ensuring close contact between the media and the printhead 34 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 3 Maintaining the Printer To clean the rollers and tear bar Turn off the printer and remove the power cord 2 Remove the media cover 3 Rotate the head lift lever clockwise to release the printhead 4 Remove media and ribbon if necessary 5 Clean the rollers by using a cloth moistened with isopropyl alcohol Move the cloth over the rollers in a side to side motion as shown Make sure to rotate the rollers so that you can clean all areas 14 Note Rotate the TTR assist roller toward you to clean the entire drive roller surface TTR assist roller m d lift lever 44XXU038 eps Drive roller Tear bar EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 35 Chapter 3 Maintaining the Printer 6 Clean both sides of the tear bar with a cloth dampened with isopropyl alcohol Remove all traces of dust paper and adhesive 7 Replace the media and ribbon 8 Engage the printhead by turning the head lift lever counterclockwise until the printhead locks 9 Ifyou are finished cleaning replace the media cover Cleaning the Media Guides and Media Path You should clean the media guides and media path regularly to keep debris off the media surface and printhead where irregularities can spoil print
26. the image band command is set too high the printer spends more time than necessary imaging and slows down label production What Is an Image Band Image bands are a section of memory where a picture of a label format is drawn This drawing process is known as imaging Once the picture is imaged the printer loads the picture from the image bands to the printhead for printing Each image band is equal to 1 inch of length of the label format The number of image bands you use may be less than the length of the label you are printing The number of image bands in inches does not have to equal the length of the label since the printer recycles the image bands Once the contents of an image band have been printed it may be reused to image the next section of the label Keep in mind that the more complex the label the longer it will take to image each section thus requiring a slower print speed To use a higher print speed use more image bands to allow more of the imaging process to complete before printing begins How the Image Bands Command Works The image bands command controls the amount of memory allotted to the imaging process When you increase the image band adjustment to a higher number you add more buffers to the imaging memory By doing this more of the label format is imaged before printing begins The minimum number of required image bands is dependent upon the print speed and the complexity of the label Labels that contain n
27. the printer safely and effectively use these items e Cleaning card P N 1 110501 00 e Cotton swabs e Isopropyl alcohol e Clean lint free cloth e Soft bristle brush or vacuum cleaner e Soapy water or mild detergent The following procedures explain how to access the printer parts and clean them without causing any harm to the printer or yourself EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 31 Chapter 3 Maintaining the Printer Warning A Warning 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 Avertissement L ouverture du couvercle du boXRier des composants fl ectroniques entra amp iera l annulation de la garantie et peut endommager les composants internes L ouverture du couvercle du bo Rier des composants Hectroniques expose l utilisateur des risques d FHectrocution qui peuvent r julter par les blessures ou la mort Switch off the printer power and remove the power cord before cleaning any part of the printer Avertissement Mettez l imprimante hors tension et dPjranchez le cfle d alimentation avant de nettoyer une parte de l imprimante Cleaning the Printhead 32 Caution In order for the printhead to provide good print quality it must maintain close contact with the media Therefore cleaning media debris from the
28. trademark of Dupont Speedo Dutch and Swiss are registered trademarks of Bitstream Inc The name Windows is a registered trademark of Microsoft Corporation IBM is a registered trademark of International Business Machines Corporation ii EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Manual Change Record This page records the changes to this manual The manual was originally released as version 001 Version Date Description of Change 002 10 2001 Updated the user s guide to support latest hardware version of the 4420 and 4440 printers 003 03 2003 Updated the user s manual to include the EasyLAN 1012 adapter accessory and the EasyLAN wireless option 004 09 2006 Updated this manual to include new front matter a warning about opening the electronics cover and troubleshooting tip on uneven print quality and ribbon wrinkling EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual iii iv EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Contents Contents Before YOu Be ta ix Safety Inforrmiatiori cec tee e e ty e dte e d e ep e ee deen EXER ade Ix Global Services and Support erinit ia ti EA nennen nnne nnne Ix Warranty Information sessi Ix Web Supports utet ita dee he ade AES ix Telephone SUppoOtt nem e D la X Who Should Read This Document essere X Related Doc tdents erre deed Pa RE I e tae ean xi 1 Getting A ee DR a 1 Learning About the Printer ir
29. turn on DIP switch 4 and turn off DIP switch 5 e To enable 15 mil emulation turn on DIP switches 4 and 5 e To enable 5 mil Advanced mode turn off DIP switches 4 and 5 e To enable 2 5 mil Advanced mode turn off DIP switch 4 and turn on DIP switch 5 T Press the Feed Pause button The printer prints out the software configuration label Verify that the label states the correct mode 8 Turn off the printer 9 Reset the DIP switches to the original settings and then turn on the printer 10 Download the 86XX formats fonts and graphics from the host to the 4420 or 4440 printer 70 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 6 Using Test and Service Mode Using Forms Adjust If the label prints too close to one edge you can reposition it by using the X forms adjust and Y forms adjust features The X forms adjust controls the position of the printing area along the length of the label The Y forms adjust controls the position of the printing area along the width of the label The following illustration shows the default X and Y origins Origin gt X x a FORMAT Y TY Leading edge Y 44XXU065 eps gt Direction of media from printer Default X and Y origins This illustration shows the default X and Y origins You can control the default X origin top of form with PrintSet or with the Test and Service DIP switches You can control the defau
30. type of media you are using For help see Loading Media Into the set Printer in Chapter 1 in the wrong position 5 Reduce the print speed You have exceeded the maximum recommended print speed Switch to approved media or clean the Media may be slipping against the platen printhead and platen roller as described in od Chapter 3 Maintaining the Printer roller causing the printing to compress The printer skips labels Edit the format to ensure that the text fits on randomly or sends an the label E The label format extends beyond the intermittent error label Gath Properly position the label gap sensor For help see Adjusting the Label Gap Sensor in Chapter 5 Use the top of form switch to adjust the top of form position For help see Fine Tuning the Top of Form Position in Chapter 5 The label gap sensor is not in the correct Label prints too close to BP position front or back edge of label The top of form position is not adjusted Continuous media fault Properly position the label mark sensor For light properly help see Adjusting the Label Mark Sensor in Chapter 5 The label mark sensor is not in the correct position EasyCod er 4420 and 4440 Bar Code Label Printer 5 User s Manual 43 Chapter 4 Troubleshooting the Printer Communication Problems If the printer is not receiving downloaded data try the solutions in the fol
31. width or tag width 19 mm 0 75 in C Gap between labels 2 54 mm 0 10 in D Label length self strip media 25 4 mm 1 0 in Label length butt cut media 12 7 mm 0 5 in E Media thickness including 0 08 mm 0 003 in backing F Reflective sensor mark length 2 54 mm 0 1 in G Notch length 2 54 mm 0 1 in H Notch height depth 6 4 mm 0 25 in Roll diameter Memory Base Optional MB of DRAM 8 or 16 MB DRAM SIMM modules Maximum 111 8 mm 4 4 in 114 3 mm 4 5 in 25 4 mm 1 0 in 609 6 mm 24 in 609 6 mm 24 in 0 30 mm 0 012 in 12 7 mm 0 5 in 3 2 mm 0 126 in 12 7 mm 0 5 in 213 mm 8 38 in 128K of flash 8 to 16 MB Kanji Katakana flash SIMM module EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 77 Appendix A Specifications Printhead 4420 Width 112 mm maximum 4 4 in Printed dot size 0 127 mm 0 00492 in square Resolution 8 dots per mm 203 dots per in Number of elements 896 per printhead X dimensions 10 mil to 500 mil 0 25 mm to 12 7 mm 5 mil 0 13 mm in drag mode only specified media only 4440 Width 112 mm maximum 4 4 in Printed dot size 0 065 mm 0 00246 in square Resolution 16 dots per mm 406 dots per in Number of elements 1792 per printhead X dimensions 5 mil to 500 mil 0 127 mm to 12 7 mm specified media only 2 5 mil 0 06 mm in drag mode only specified media only Printing Method The printers are capable of dir
32. 232 schematics 101 RS 422 schematic 102 changing core locking brackets 11 character sets Advanced mode 86 87 Code Page 850 88 definition 104 extended 89 international 86 list of 76 cleaning label sensors 37 media guides 36 media path 36 printer 31 printer covers 34 printhead 32 rollers 35 tear bar 35 cloning definition 104 coax interface option 80 Codabar 81 Code 11 81 Code 128 81 Code 16K 82 Code 2 of 5 81 Code 39 81 Code 49 82 Code 93 81 Code Page 850 character table 88 communicating with the printer 27 using PrintSet 27 using third party software 27 communications boundaries 98 configuring the serial port 25 problems 44 protocols 94 hardware 96 Multi Drop 96 Polling Mode D 96 Standard 94 user defined 97 XON XOFF 95 reference communication boundaries 98 communication protocols 94 host requirements 98 See also protocols testing by printing a test label 28 troubleshooting 45 64 communications interfaces 79 99 configuration commands changing from Test and Service mode 66 Emulation mode 66 label rest point 66 X forms adjust 66 Y forms adjust 66 DIP switch settings 66 112 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual configuration test labels hardware 14 software 15 troubleshooting 41 configuration printing test label 64 configuring the serial port 25 connecting printer toa mainframe 24 printer to a network 23 printer
33. 485 The following sections describe these interfaces See the Data Communications Reference Manual P N 044737 for more detailed information RS 232 Serial Interface Use the RS 232 serial interface in all asynchronous point to point full or half duplex direct data communications or modem control The printer cable must have the pin assignments for an RS 232 serial interface shown in the next table RS 422 Serial Interface Use the RS 422 interface in long line point to point direct connect installations The printer cable must have the pin assignments for an RS 422 serial interface shown in the next table RS 485 Serial Interface Use the RS 485 serial interface for Multi Drop installations only The printer cable must have the pin assignments for an RS 485 serial interface shown in the next table RS 232 RS 422 and RS 485 Serial Interface Pin Assignments Interface RS 232 422 485 RS 232 RS 232 3 RS 232 422 485 RS 232 422 485 Pin 1 Name Operation Chassis Ground Connect to pin 1 chassis ground of connected device GND Transmit Data Output Connect to receive data pin of connected device TD Receive Data Input Connect to transmit data pin of connected device RD Request to Send Output When you use a modem connect to modem RTS pin RTS The connection sets RTS to true before transmission The printer sets RTS to false after transmission Clear to Send CTS Input When you use a modem
34. 5 characters including the start of text and end of text characters The printer auto discriminates between Standard Polling Mode D and Multi Drop protocols The printer returns its highest priority status when it receives a valid block lt STX gt data lt ETX gt or when it receives the status request command lt ENQ gt When the printer receives the status dump command lt VT gt the printer returns all active status The printer status response time ranges from 30 to 100 ms depending on the complexity of the received message block In the case of a transmission error the printer responds with a lt NAK gt and discards the entire message block This table shows printer status conditions in descending order of priority Intermec Standard Protocol Printer Status Conditions Printer Status Character Buffer already full GS Ribbon fault US No label stock EM Buffer now full DC3 Printhead hot SI Offline paused DC3 Label at strip pin FS Skipping DCI Printing DC1 Ready Online DCI EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Appendix C Communications Reference Note Do not confuse the Buffer now full lt DC3 gt status with the XON XOFF characters lt DC1 gt and lt DC3 gt When the printer returns Buffer now full lt DC3 gt status it accepts the currently received message block At this time the printer can accept short messages to allow parsing of immediate commands such as Reset lt DLE gt
35. 7 user defined protocol 97 using the Feed Pause button 5 V variable data field definition 110 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual x X forms adjust setting with DIP switches 72 See also top of form XON XOFF definition 110 protocol 95 Y Y forms adjust setting with DIP switches 72 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Index 117 Index 118 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Intermec Worldwide Headquarters 6001 36th Avenue West Everett Washington 98203 U S A tel 425 348 2600 fax 425 355 9551 www intermec com EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 066392 004 P N 066392 004
36. Coder 4420 and 4440 Bar Code Label Printer User s Manual 23 Chapter 2 Installing the Printer Connecting the Printer to an AS 400 e To connect the printer directly to an AS 400 or midrange computer you need e a twinax adapter card P N 067879 e a twinax cable equivalent to IBM part number 7362267 or 7362062 The maximum cable length for the twinax interface is 1 525 meters 5 000 feet If you did not order the twinax card to be installed at the factory contact your local Intermec representative to have one installed in the optional 1 O board port of the printer For help on cabling and communications see the manual that comes with the twinax adapter card Note If you are using a midrange computer other than the AS 400 refer to your system documentation for information on cabling and setting up communications Connecting the Printer to a Mainframe To connect the printer directly to an IBM mainframe you need e a coax adapter card P N 067880 e a coax cable equivalent to IBM part number 2577672 or 1833108 If you did not order the coax card to be installed at the factory contact your local Intermec representative to have one installed in the optional I O board port of the printer The maximum cable length allowed is 1 500 meters 4 920 feet See the IBM specification Installation and Assembly of Coaxial Cable and Accessories part number GA27 2805 4 for further information For help on cabling and commun
37. E EEN DI D2 D3 D4 D5 D6 D D8 D9 T YT Y ow X ug de 2 x E y YT TEO E E2 E3 E4 E5 E6 E9 EA EB EC ED EE EF 3 To Fl Roa i or rs rm nm l Jp FF FO KES FA F5 F6 FB FC FD 48 1m 6C X 7B 29 9B AB 4C 7C 9C AC 4D 7D 9D AD 88 928 0 1xu 44XXU068 eps gt a 7 XI4l0luMcul xidigufes J EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Extended Character Sets Each internal font in the printer has a different character set associated with it as shown in the following tables The hex codes accompany each character Characters in Fonts c0 7x9 Standard Appendix B Character Sets c 7x11 OCR c2 10x 14 Standard a m Dig AAA mm m m rm wn m mia mia n sol EH S E P z mw 2 o cmo ca uU nous ca HI kalea died k o gt gt gt gt gt gt gt gt 4 MAA AA uds RE FIR ELLIS S 2 T 1 7 3 sia lh it 19 A 1B PABEDEFGHIJELMENO BU E Ej bs 1 2 3 F m g or 23 GIR SIT OV Alyx 2 iT S T AS sey Bhd BEB E Do ek A Lo ii f 2 h 36 k 38 39 ri 3B 3 a gt whe p regtiuwvuxuztil y ep oH ho 4 42 43 44 45 46 47 48 49 4A 4B 4D 4E 4F A SRR RPO RPO b 51 52 53 54 55 56 57 58 59 5A 5B i JE EY m BRB ROKK eo 61 62 63 64 65 66 67 68 69 6A d 6D 6E 6F on C i J ft E BES RPI ke k
38. Intermec 24947 ENV NLA Be RIAR 400 1166 021 Intermec Val User s Manual ho EasyCoder 4420 and 4440 Bar Code Label Printer 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 2001 2006 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 i gistics Intellitag Intellitag Gen2 JANUS LabelShop MobileLAN Picolink Ready to Work RoutePower Sabre ScanPlus ShopScan Smart Mobile Computing 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 patent applications pending Novell is a registered trademark of Novell Inc Kimdura is a registered trademark of Kimberly Clark Kapton is a registered
39. Print mode 3 In the top bank of the Test and Service mode DIP switches turn on switches 1 2 3 and 4 To move the X origin forward turn off switch 5 To move the X origin backward turn on switch 5 Top Bank Top Bank OFF OFF ee a y E ES EI 1 ON ON 1 2 3 4 5 1 2 3 4 5 Switch settings Switch settings for moving the for moving the X origin forward X origin backward 44XXU066 eps 4In the bottom bank of the Test and Service mode DIP switches set the DIP switches to the desired setting See the Dot increments DIP switch settings illustration earlier in this chapter to see how to set the X forms adjust forward or backward a given number of increments 5 Press the Feed Pause button The printer prints out the software configuration label using the new X forms adjust setting 6 Verify the X forms adjust number on the software configuration label matches the number you set in Step 4 Y Forms Adjust Use the Y forms adjust feature to control the position of the image in the direction parallel to the printhead See the Dot increments DIP switch settings illustration earlier in this chapter for information on how to move the image forward a number of dot increments If the label is too close to one edge of the printhead you can adjust it using this feature EasyCoder 4420 and 4440 Bar C
40. PrintSet 50 print quality correcting uneven 48 maintaining 48 optimizing 48 printing test label 64 problems 42 understanding 48 print speed adjusting for use with image bands 59 definition 108 printer cleaning 31 communication problems 44 communications 27 components back view 3 front view 2 connecting to a mainframe 24 connecting to a network 23 connecting to a PC through the parallel port 23 connecting to a PC through the serial port 23 connecting to an AS400 24 connecting to power 6 connecting to your system 22 cover cleaning 34 removing 7 dimensions 76 features 2 inspecting 30 installing 5 maintenance 30 memory using efficiently 57 opening 7 operation testing 64 troubleshooting 40 64 options 79 coax interface 80 cutter 80 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Index EasyLAN 101 interface 79 EasyLAN 10i2 adapter accessory 80 EasyLAN Wireless 80 Kanji Katakana 81 memory expansion 81 self strip batch takeup 80 twinax interface 80 plugging in 6 RAM allocation 57 storage limitations 57 understanding 57 serial port 100 specifications 76 to 78 printhead cleaning 32 definition 108 elements definition 108 specifications 78 printing hardware configuration test label 14 increasing speed 58 method 78 software configuration label 15 speed specifications 78 test label 28 PrintSet using to communicate with the pr
41. 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 A warning alerts you of an operating procedure practice condition or statement that must be strictly observed to avoid death or serious Warning 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 Caution ES 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 amp Support gt Warranty 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 wa
42. a bar code with the Code 39 symbology your printer prints out a label similar to this one 0123456789 0123456789 oN oo O un t en N o co e i M N Iz 44XXU033 eps 28 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 3 Maintaining the Printer This chapter explains how to clean and maintain the printer Even though the printers can withstand harsh environments you must clean them on a regular basis to maximize performance It is very important to perform the maintenance procedures if you expose the printer to dirt or debris This chapter covers these topics e Inspecting the printer e Maintenance schedule e Cleaning the printhead e Cleaning the printer covers e Cleaning the rollers and tear bar e Cleaning the media guides and media path e Cleaning the label sensors EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 29 Chapter 3 Maintaining the Printer Inspecting the Printer Inspect the printer and the rest of your data collection system equipment on a regular basis Your inspection should include these tasks e Make sure you have properly grounded the printer e Inspect the work environment Large electric motors welders and switching equipment can affect printer performance e Check the data collection network regularly for loose wires or poorly installed connections Be sure to replace corroded wires Maintenan
43. as 44 5 Optimizing Printer Performance 1 sse 47 Optimizing and Maintaining Print Quality essere 48 Correcting Uneven Print Quality essere 48 Adjusting the Print Darkness sees ener nnns 49 Fine Tuning the Top of Form Position sese 51 Adjusting the Label Gap Sensor sese 54 Adjusting the Label Mark Sensor essere enn 56 Using the Printer Memory Efficiently sess 57 How Is the Printer Storage Memory Used sessssssssss 57 Making the Most of the Memory 57 Increasing Throughput inicio 58 What Is an Image Band doncconnccniccniccconcconoconaconncnnnonn conocio no conn cnn nnnnrannconnos 58 How the Image Bands Command Works sss 58 Optimizing Print Speed and Image Band Setting susse 59 vi EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Contents 6 Using Test and Service Mode 7 1st 61 Using Test and Service Mode Procedures sesssssssseeeeeenee eene 62 Printing Test Labels 2 tate eset e oie edet iaa 64 Using Data Line Print Mode sse enne 64 Performing Selective Transfer sss enne 64 Using Memory Reset eer ree erre re rk rte EP e Eee eias 65 Setting Configuration Commands in Test and Service Mode sss 66 Setting the Number of Dot Increments sse 67 Adjusting the Lab
44. as Maxicode use both the horizontal and vertical axes to encode data even more efficiently than stacked symbologies 2D matrix codes are created as a matrix of square elements with each element being either white or black to encode data in a binary code Extensive error detection and correction codes are appended to 2D matrix symbologies often automatically 2D matrix symbologies generally cannot be read with a laser scanner Instead they are read by a digital imager that captures the entire symbol at once instead of scanning each component individually Since the components of 2D matrix symbologies are decoded after the image is captured they permit very fast data collection Supported 2D Matrix Symbologies Symbology Description Data Matrix Data Matrix is a 2D matrix symbology which is made up of square modules arranged within a perimeter finder pattern The finder pattern is a perimeter to the data region and is one module wide Two adjacent sides are solid dark lines These lines are used to define physical size orientation and symbol distortion EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 83 Appendix A Specifications 84 Supported 2D Matrix Symbologies continued Symbology Maxicode QR Code Description Maxicode is a fixed size symbology that is made up of offset rows of hexagonal elements arranged around a bullseye finder pattern Each hexagon represents one bit of information and is eith
45. asing throughput EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 47 Chapter 5 Optimizing Printer Performance Optimizing and Maintaining Print Quality Intermec designed and configured the printer to provide the best possible print quality for both direct thermal and thermal transfer media If necessary you can manually adjust the printer to perform registration tasks such as correcting uneven print quality Correcting Uneven Print Quality You may experience problems in print quality ribbon wrinkling or light print on one side of the label if the printhead is not making even contact with the label stock This condition can happen with any size label stock but is most common when using narrow label stock To achieve the best print quality adjust the bias adjust screw each time you use media of a different width 14 Note You must properly adjust the bias adjust screw to prevent premature printhead failure and excessive platen wear To adjust the bias adjust screw 1 Remove the media cover and locate the bias adjust screw Bias adjust SCrew 44XXU043 eps 48 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 5 Optimizing Printer Performance 2 To compensate for uneven print quality use a straight slot screwdriver to turn the bias adjust screw as shown Adjusting the bias adjust causes the printhead to rest evenly on the drive roller and results in even print q
46. asyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 6 Using Test and Service Mode Using the selective transfer command you can download the following label design attributes from one 4420 or 4440 printer to another e Any specified page or all pages e Any specified format or all formats e Any specified font or all fonts e Any specified user defined character UDC or all UDCs Set the serial port DIP switch settings to 115 200 baud even parity 1 stop bit and 8 data bits If you are transferring pages or fonts the destination and source numbers can be different If you are transferring formats or UDCs the destination and source number must be the same To perform selective transfer 1 Turn off the sending and receiving printers 2 Set the serial port on both the sending printer and the receiving printer to 115 200 baud even parity 1 stop bit and 8 data bits 3 Turn on the receiving printer 4 Press down and hold the Feed Pause button while turning on the printer The hardware configuration test label prints 5 Connect the serial ports of the sender and receiver ports together with an RS 232 null modem cable For help refer to Connecting the Printer to Your System in Chapter 2 and Communications Interfaces in Appendix C 6 Set the DIP switches on the sending printer and receiving printer for selective transfer as shown in the Test and Service mode DIP switch settings illustration
47. c Standard protocol 94 international character sets 86 interpretive field definition ips definition ISO definition K 106 106 106 Kanji Katakana option 81 L label definition 106 detecting the start 54 format definition 106 positioning along the length of label 72 positioning parallel along width of label 72 gap definition 106 sensor adjusting 54 mark sensor adjusting 56 printing a test 28 rest point adjusting 68 sensors cleaning 37 label format position adjusting with TOF switch 51 languages international character sets 86 LEDs Alert 4 Empty Pause 4 front panel 3 media or system faults 4 over temperature condition 4 Power Data 4 understanding 3 using to troubleshoot the printer 4 loading M fanfold media 9 roll media 8 thermal transfer ribbon 11 12 mainframe connecting to the printer 24 maintenance 30 114 location of parts to be maintained 31 schedule 30 tools for cleaning 31 margin definition 106 matrix symbologies See 2D symbologies Maxicode 84 media definition 107 fault troubleshooting guides cleaning 36 loading into printer 7 media sensitivity number description 15 direct thermal media settings table 18 setting for Intermec media and ribbon 16 setting for other media and ribbon 17 setting with PrintSet 16 thermal transfer settings table 18 or system faults 4 path cleaning 36 specifications 77 memory addi
48. ce Schedule Clean the printer regularly to maintain the quality of the labels and extend the life of the printer This table contains suggestions for cleaning the printer Use the following illustration to locate the parts you need to clean Printer Maintenance Schedule Printer Component Maintenance Period Thermal printhead Inspect after every roll of media Clean after every roll of media 6 000 in or 152 m or ribbon 18 000 in or 457 m Clean more often if necessary Printer Cover not shown Clean as necessary Drive roller and tear bar Clean after every six rolls of media If you are using Media path not shown hi tack adhesive you must clean after every roll of media Clean more often in environments that are Edge guide harsh or dusty Upper media guide Lower media guide Thermal transfer ribbon TTR assist roller Label gap sensor not shown Label mark sensor not shown 30 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 3 Maintaining the Printer EL roller Tear bar Drive roller o media guide Lower media P d guide Edge guide Thermal printhead 44XXU035 eps Printer parts This illustration shows the printer parts that need to be cleaned For a maintenance schedule of each part see the Printer Maintenance Schedule table earlier in this chapter Tools for Cleaning the Printer To clean
49. character sets 89 F factory default settings 78 fanfold media loading 9 faults media or system 4 Feed Pause button using 5 field definition 105 fixed data field definition 105 fixed format definition 105 flash SIMM additional storage memory 57 font copying to another printer See selective transfer definition 105 extended character sets 89 file definition 105 specifications 76 tables extended character sets 89 format copying to another printer See selective transfer file definition 105 positioning with DIP switches 71 forms adjust positioning the label format 71 setting from DIP switches 71 front panel LEDs 3 understanding 3 G graphic copying to another printer See selective transfer definition 105 specifications 76 H hardware configuration test label printing 14 hardware protocol 96 HIBC definition 105 host requirements communications 98 human readable definition 105 I image bands definition 106 description 58 function 58 optimizing with print speed 59 imaging definition 106 increasing printer throughput 58 increment decrement field definition 106 index definition 106 113 Index indicator LEDs front panel 3 inspecting the printer 30 interfaces coax 80 communications EasyLAN 101 79 EasyLAN 10i2 adapter accessory 80 EasyLAN Wireless 80 79 99 RS 232 99 RS 422 99 RS 485 99 twinax 80 Interleaved 2 of 5 81 Interme
50. cially designed to complement Code 39 With the correct reading equipment the two alphanumeric codes may be interchanged throughout a system without making any changes to software Code 128 was introduced in 1981 as a very high density alphanumeric symbology It is a variable length continuous code that employs multiple element widths The European Article Numbering system abbreviated as EAN is a numeric superset of UPC EAN has both a version that uses 8 digits and a version that uses 13 digits The version with 13 digits encodes the same number of bars as 12 digit UPC Version A but the 13th digit is encoded into a parity pattern at the left of the center guard bar Interleaved 2 of 5 is a high density self checking continuous numeric symbology which has mainly been used in the distribution industry Interleaved 2 of 5 actually encodes two digits one in the bars and one in the spaces EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 81 Appendix A Specifications 2D Symbologies 82 Supported Bar Code Symbologies continued Symbology Description POSTNET The Postal Numeric Encoding Technique POSTNET uses binary digits represented as full bars and half bars to provide a numeric bar code symbology that is easily read and decoded by optical reading systems POSTNET provides both error detection and correction capabilities UPC Universal Product Code UPC is a subset of EAN It is a fixed length num
51. crements farthest forward Use a negative number if you want the printer to retract the label a number of dot increments after it prints the label Use a positive number if you want the printer to feed the label a number of dot increments after it prints the label There are three ways to adjust the label rest point e You can use the Test and Service DIP switch bank Follow the procedure below to use the DIP switch settings to adjust the label rest point e You can set it by using the PrintSet application software See the Paper Handling portion of PrintSet for more information e You can use the IPL command See the IPL Programming Reference Manual P N 066396 for more information To adjust the label rest point Turn off the printer 2 Press and hold the Feed Pause button while turning on the printer The printer prints out a hardware configuration label and then enters Data Line Print mode 68 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 6 Using Test and Service Mode 3 In the top bank of the Test and Service mode DIP switches turn off switch 1 and turn on switches 2 and 3 To adjust the label rest point forward feed more label turn off DIP switch 4 To adjust the label rest point backward retract label turn on DIP switch 4 Top Bank Top Bank OFF DE OFF E Ej iz BU P on
52. ctly loaded the media Printer is out of media One of the sensors is incorrectly located Media type is set incorrectly You have incorrectly loaded the media Media fault You have configured the printer for self strip media Corrupt or incorrect information in the printer memory EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 4 Troubleshooting the Printer Solution Use PrintSet to change the image bands or print speed settings Use PrintSet to change the image bands or print speed settings Leave printer alone until 1t has time to cool down It will resume printing on its own Make sure the printhead is down The head lift lever should be almost straight up and down in the 1 o clock position Press the Feed Pause button to resume printing Configure the printer for the correct sensor either label gap or label mark sensor Use PrintSet to configure the correct sensor Try reloading the media For help see Loading Media Into the Printer in Chapter 1 Load new media For help see Loading Media Into the Printer in Chapter 1 Adjust the label gap sensor or the label mark sensor to the correct location for the label stock you are using For help see Adjusting the Label Gap Sensor or Adjusting the Label Mark Sensor in Chapter 5 Make sure the DIP switch for media type is set correctly For help see Configuring the Serial Port for Communicatio
53. cture network in your data collection network For more information see the EasyLAN Wireless documentation Coax Interface This option lets you connect the printer to an IBM 3270 Type A coax cable computer system operating in the VTAM CICS IMS TSO or 8100 DPPX environment The printer will emulate an IBM 3287 printer and you can connect it to an IBM 3174 76 99 system controller multiplexer Twinax Interface This option lets you connect the printer to an IBM twinax cable system with a twinax interface The printer will emulate an IBM 5256 Model 1 printer and can operate with an IBM System 34 System 36 System 38 or AS 400 host computer Cutter The cutter option lets you cut continuous media into individual labels ready for use You can also order two different trays that will catch the labels as they are cut Self Strip Full Roll Batch Takeup The self strip option allows labels to be peeled from the liner as they print and presented for immediate application to a surface such as a shipping box The batch takeup enables you to run the printer in batch mode and is capable of taking up a full roll of media This option is factory installed only EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Kanji Katakana Appendix A Specifications This option allows the printer to print Japanese characters in two Kanji fonts and three Katakana fonts This option also provides increased storage capacity Memory Ex
54. dustry UDC User Defined Character See graphic UDF User Defined Font See soft font variable data field Bar code and text fields that change from one label to the next XON XOFF A protocol that stops the host from sending data when the printer buffer fills up and starts it again when the buffer empties EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual I Index EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 111 Index Numbers 2D symbologies 82 Code 16K 82 Code 49 82 Data Matrix 83 Maxicode 84 MicroPDF417 83 PDF417 83 QR Code 84 A AC power receptacle 6 adjustments bias adjust screw 48 darkness adjust control 49 label gap sensor 55 label mark sensor 56 label rest point 68 X forms adjust 72 Y forms adjust 72 Advanced mode international character sets 86 87 Alert LED described 4 troubleshooting 41 AS400 connecting to the printer 24 B backing definition 104 bands image 58 bar code symbologies Codabar 81 Code 11 81 Code 128 81 Code 2 of 5 81 Code 39 81 Code 93 81 EAN 81 Interleaved 2 of 5 81 list of 81 POSTNET 82 UPC 82 batch takeup definition 104 described 80 BEL definition 104 bias adjust screw adjusting 48 using for optimal print quality 48 bi directional parallel port 98 boundaries communication 98 C cables considerations in noisy electrical environments 25 null modem schematics 101 RS
55. e The host computer must use the American Standard Code for Information Exchange ASCII for data communications e A serial port or a parallel port must be available on the host if you are connecting directly to the printer e The host must support at least one of the following data communications interfaces RS 232 RS 422 RS 485 115K or IEEE compliant 1284 bi directional parallel For information on configuring the host computer port concentrator or network controller see the reference manual for the controlling device Communications Boundaries The information below applies to all protocols that the printer supports Maximum Capacity Communications Boundaries Parameter Maximum Capacity Message delay 9999 milliseconds Character delay 9999 milliseconds Message block size 255 characters including STX and ETX characters Unlimited block size for XON XOFF Device address number A to Z 0 to 5 Multi Drop only Communications Interfaces The 4420 and 4440 printers come standard with both a serial port and a bi directional parallel port 98 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Appendix C Communications Reference The parallel port conforms to the IEEE 1284 standard and it supports Initialization Compatibility Mode Negotiation Nibble and Byte Mode for reverse data transfer The serial port supports serial communications with the following interfaces e RS 232 e RS 422 e RS
56. e following e Increase the amount of available memory by using the Memory Reset portion of the Test and Service menu See Using Memory Reset in Chapter 6 for more information e Delete any unneeded user defined fonts graphics pages or formats For help see the PrintSet software or the JPL Programming Reference Manual EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 57 Chapter 5 Optimizing Printer Performance e Purchase additional memory Contact your local Intermec representative for information on purchasing additional memory for the printer Increasing Throughput 58 To print labels as quickly as possible you must adjust the print speed in conjunction with the number of image bands one image band equals 1 inch of label The print speed and image band settings determine the rate at which the printer processes the images of the labels This rate in turn affects the throughput of the entire printing process The printer begins imaging the label as soon as it receives the command to select a format Since the printer starts imaging the label so early the chance that the imaging process will be unable to keep up with the print speed decreases and throughput improves However if the number of image bands is too low the imaging process is unable to keep up with the print speed In this case the printer stops printing and starts again at the lowest print speed with the maximum number of image bands If
57. e print quality for Intermec media and ribbon combinations on Intermec printers You can achieve the best print quality on the 4420 or 4440 printer by using only Intermec ribbon and media products This table lists the default MSN Default MSNs Media Type Default Direct thermal media 2 to 5 ips 470 Direct thermal media 6 to 8 ips 720 Thermal transfer media 2 to 10 ips 567 If you need to determine an MSN obtain the part number of your media and call 1 800 755 5505 press 1 and then 1 The part number may be printed on the outside of the box carton Use the PrintSet software your third party software or the Intermec Printer Language IPL command set to change the MSN If you do not know the sensitivity numbers for your media or ribbon use the PrintSet Print Quality Assistant to help you choose the correct MSN If you want to see the current sensitivity setting of your printer print out a software configuration label To print a software configuration label Turn off the printer 2 Press and hold the Feed Pause button while turning the printer on The printer prints out a hardware configuration label 3 Setthe DIP switches to print out the software test label Top Bank Turn off switches 1 through 6 and 8 Turn on switch 7 Bottom Bank Turn off switches 1 through 8 4Hold the Feed Pause button down for 1 second The printer prints out the software configuration label 5 Return the DIP switches to their original s
58. ect thermal DT printing or thermal transfer TTR printing using a thermal transfer ribbon Printing Speed Maximum 254 mm per second 10 inches per second on specified media only Minimum 51 mm per second 2 inches per second The print speed can be changed in 1 ips increments only Note that the printer cannot print at 228 6 mps 9 ips Ribbon Specifications Length 450 m 18 000 linear inches Widths 54 mm 2 1 in 76 mm 3 0 in 104 mm 4 1 in 114 mm 4 5 in Diameter 81 mm 3 2 in maximum Factory Default Settings The following table lists the factory default settings for the 4420 and 4440 printer Use PrintSet to set these parameters The printer s default serial port settings are described in Chapter 2 Installing the Printer 78 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Factory Default Settings Configuration Preamble Character Postamble Character Auto Transmit 1 Auto Transmit 2 Auto Transmit 3 Message Delay Power Up Mode Cutter End of Print Skip Distance Top of Form Media Sensitivity Number of Image Bands Maximum Label Length Printer Character Set Label Retract Label Retract Distance Print Speed Label Stock Type Intercharacter Delay s Storage Memory standard Printer Options Appendix A Specifications Default Setting Disabled Disabled Disabled Disabled Disabled 0 milliseconds 5 mil Advanced mode 4420 2 5 mil Advanced mode 4440 D
59. ection explains the function of the front panel LEDs and the Feed Pause button Using the Front Panel LEDs You use the front panel LEDs to monitor the status of the printer Chapter 1 Getting Started e Feed Pause D E HF Power Data Alert 3 Empty Pause 000 44XXU026 eps Front panel LEDs This illustration shows the LEDs that are on the front panel of the printers For help understanding these LEDs see the next LED Descriptions table LED Descriptions Number LED State Indication 1 Power Data Off Power off On Power on Flashing Receiving data 2 Alert Off Printing or idle Flashing Over temperature On System fault 3 Empty Pause Off Printing or idle Flashing Paused On Media fault Using the Front Panel LEDs for Troubleshooting You can use the front panel LEDs to troubleshoot the printer LED States for Problems Problem LED State Over Temperature If the printer overheats the Alert LED flashes and the printer stops Do not try to troubleshoot or adjust the printer just allow it enough time to cool down and it will resume operation on its own You should only encounter this problem after extended print jobs Media or Ifthe Empty Pause or the Alert LED remains on the printer is System experiencing a media or system fault See Chapter 4 Faults Troubleshooting the Printer for help in correcting the problem 4 EasyCoder 4420 and 4440 Bar Code Label Prin
60. el Rest Point eren 68 Setting Emulation Mode sss nennen nnns 69 Using Forms Adjust ecce ete ct tree tee eive NT a dee arde 71 X F rms AUS eere Eines 72 Y Forms A US diia 72 A hoy 02311 Clr 10101 1 eee anne ee ne fester O Deo t EE 75 4420 and 4440 Printer Specifications ccccccecscceseceseceseeeeeeeseeeseceseceseceseeeseeeseeesecneeeaeens 76 A A tte recte arca ees etit dere esae od euo ted eee tee 78 Printer Options 5 eee eterne nee esee tede Ee nope a Eaa E etate eaae E sene Een d 79 Communications Interfaces coonoocnnnconocononconnnonnconn cnn ncnnccon con nn coronaria nennen enne nnne en 79 EasyLAN 101 Interface nennen 79 EasyLAN 1012 Adapter sess 80 EasyLAN Wireless Option ener 80 Coax Itterface miii HER RIDE Da etia 80 Twinax Interface al 80 lunch RE 80 ur EE 80 Self Strip Full Roll Batch Takeup seen 80 ISI CLE PEE 81 Memory Expansion esssesseeseeeee eene enne enne nennen nennen innen enne nennen 81 Bar Code Symbologies Supported sse 81 2D Symbologles tret ete terere tete estre esit liceos eee tese tete baii 82 2D Stacked Symbologies essere 82 2D Matrix Symbologies ssssssseseseeeeeeeeenen enne 83 B Character Sets ooo dns LR DURER Riad 85 International Character Sets eee enne nnne nennen 86 Advanced Character Table sss enne 86 Emulation Mode Characte
61. elene Premium 627 Duratran 10 ips Kimdura Premium 7 623 European Kimdura Premium 6 ips 500 Series 567 Duratran II 1 Premium 7 10 ips Medium Sensitivity Paper 565 European Premium 7 ips Paper Premium 563 Duratran VG Standard 4 ips 533 European Tag Premium 6 ips 527 Duratran II Tag 7 6 ips mil Premium 7 513 European Coated Premium 6 ips 300 Series Low 369 Super Premium 5 ips Sensitivity Polyester Super Premium 3 Plastic 366 Super Premium 5 ips Polyester Super Premium 7 200 Series Low 238 Gloss Polyimide 3 ips Sensitivity Kapton Gloss Super Kapton Premium 236 Gloss Polyimide 3 ips Kapton Super Premium 7 226 Matte Polyimide 3 ips Kapton Super Premium 7 222 Matte Polyimide 3 ips Kapton Matte Super Premium EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 19 Chapter 1 Getting Started 20 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 2 Installing the Printer This chapter explains how to connect the printer to your PC or network and configure the serial port for communications This chapter covers these topics e Connecting the printer to your system e Configuring the serial port for communications e Communicating with the printer e Using PrintSet to test communications 21 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 2 Installing the Printer Connecting the Printer to Your System You can connect the printer to a PC a local area ne
62. er You must use an RS 485 which is automatically enabled when you enable Multi Drop Be sure to specify a unique address for the printer and verify that the baud rate is between 2400 and 19200 The printer uses Ready Busy and DTR data terminal ready of the RS 232C interface to indicate the printer s status You can configure Ready Busy and DTR independent of each other and independent of the software protocol you select for the serial port You can set each pin to one of these three settings default high and Ready Busy When you set the pin to high the printer will be ready to accept data anytime When you set the pin to Ready Busy the pin is high when the printer status is ready The pin is held low when the printer is in one of these conditions e Offline e Buffer full e No label stock e Ribbon fault e Label at strip pin If you set the printer to XON XOFF protocol the XON and XOFF characters will not be transmitted back to the host EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Appendix C Communications Reference When you set the pin to default 1t uses flow control if the serial port is set for XON XOFF protocol If you are using Intermec Standard protocol the printer uses Ready Busy User Defined Protocol The 4420 and 4440 printers provide the capability to change protocol characters However you cannot define your own protocol You can substitute characters to use as protocol cha
63. er black or white depending on the state of the encoded data bit United Parcel Service UPS Research and Development developed Maxicode for the specific purpose of encoding information about a parcel This symbology only encodes very specific data that is divided into the following fields a 5 digit zip code a 4 digit zip code extension a 3 digit country code a 3 digit class of service and a string of uppercase letters numbers or limited punctuation marks QR Quick Response Code is a matrix 2D symbology that encodes data into patterns consisting of black and white dots or modules A three position detection pattern enables omni directional reading and ultra high speed reading QR Code can handle a wide range of data including numerical alphabetical Kanji Hiragana Katakana graphics and control codes A built in error correction function enables the QR Code to repair errors in the code EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual B Character Sets This chapter contains tables for the character sets that the 4420 and 4440 printers support To select a character set use PrintSet your third party software application or the IPL command set This chapter contains these character sets e International character sets e Extended character sets EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 85 Appendix B Character Sets International Character Sets The following tables show wh
64. er media and change the media type setting For help loading the media see Loading Media Into the Printer earlier in this chapter To change the media type setting see Configuring the Serial Port for Communications in Chapter 2 1 Note Save the packaging that your ribbon came in Attached to the ribbon packaging is a small label with a three digit sensitivity number printed on it You need this information to set the correct media sensitivity number For help see Setting the Media Sensitivity Number later in this chapter The core of your thermal transfer ribbon is either made of cardboard or plastic You need to use the correct core locking brackets for your ribbon core The printer ships from the factory with the cardboard core locking brackets already attached 1 Note If you do not use the correct core locking brackets you may experience printing problems or possible damage to the printer To change the cardboard core locking brackets to plastic core locking brackets Pull up on the middle of the cardboard core locking bracket P N 065375 while pushing down on one end with your index finger until the end of the bracket is free of the ribbon hub 2 Remove the other end of the bracket from the ribbon hub 3 Slide one end of the plastic core locking bracket P N 066792 into a bracket slot on the ribbon hub EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 11 Chapter 1 Getting Started 4 Lift
65. er require regular cleaning e Label mark e Label gap To clean the label sensors Turn off the printer and remove the power cord 2 Remove the media cover 3 Disengage the printhead by rotating the head lift lever clockwise until the printhead releases 4 Remove the media and ribbon if necessary EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 37 Chapter 3 Maintaining the Printer 5 Clean the label mark sensor with a cotton swab moistened with isopropyl alcohol Label mark sensor Ipper media Cleaning guide brush underside Label gap sensor 44XXU040 eps 6Pull down on the lower media guide to expose the label gap sensor Using a cleaning brush or vacuum remove all debris and dust from the label gap sensor 7 Clean the upper and lower label gap sensor with a cotton swab and alcohol 8 Replace the media and ribbon 9 Engage the printhead by rotating the head lift lever counterclockwise until it locks in place 10 If you are finished cleaning replace the media cover 38 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 4 Troubleshooting the Printer This chapter provides some hints for troubleshooting error messages that the printer sends to the host and problems you may experience with the printer This chapter covers these topics e Troubleshooting checklist e Printer operation problems e Printer q
66. eric continuous symbology employing four element widths Two common types of UPC are Version A which encodes 12 digits and Version E which encodes 6 digits UPC has been used in the supermarket industry since 1973 UPC supplemental code is intended for only periodical issue numbers 2D symbologies provide a more efficient way of encoding data than standard bar code symbologies 2D symbologies use two dimensions to hold data instead of one allowing much more information to be stored in a smaller amount of space The printer can print both stacked and matrix 2D symbologies 2D Stacked Symbologies 2D stacked symbologies consist of short linear segments stacked on top of each other In addition to being able to condense a large amount of information into the stacked format PDF417 provides an extensive error detection and correction option Up to 510 characters can be recovered if they are lost due to an error in scanning or if the label is damaged 2D stacked symbologies can be scanned with a laser scanner or imaging device that features 2D code scanning capability Supported 2D Stacked Symbologies Symbology Description Code 16K Introduced in 1988 Code 16K is an alphanumeric symbology similar to Code 49 in that it employs multiple rows from 2 to 16 Each row is fixed length and uses a mirror image of the Code 128 coding patterns Code 49 Code 49 is an alphanumeric symbology developed in 1987 as a means of labeling very small objects
67. est 3 Release the Feed Pause button when the media starts moving The printer feeds out one or two blank labels and then prints the hardware configuration test label 4 Turn the printer power off and then on again 4440 Hardware Configuration Memory Installed Flash Storage 128 kilobytes Image RAM 805 kilobytes Flash SIMM OKB Mileage Inches Processed Inches Burned 2376 Labels Cut i70 Printhead Width 1792 Dot Size 22 5 Burn Pot Setting 128 Hardware Options 1 0 Option none Internal Option none External Option none 2664 Program 067197 Version 0 8 14 Note The hardware configuration label defines the above parameters Individual values vary between printers If you are unable to print a hardware configuration test label see Printer Operation Problems in Chapter 4 14 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 1 Getting Started Setting the Media Sensitivity Number The media sensitivity number MSN is important because you use it to optimize print quality and print speed The three digit MSN specifies the amount of heat required by the printhead to image a label The amount of heat that each roll of media or ribbon requires is unique due to different chemistries and manufacturing processes Intermec has developed heating schedules the amount of heat required to image a label to produce the highest possibl
68. ettings 6 Turn the printer off and then on again EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 15 Chapter 1 Getting Started Setting the MSN for Intermec Media and Ribbon 16 The sensitivity number on each roll of thermal transfer media or ribbon has an asterisk in place of one of the digits To optimize the sensitivity number for thermal transfer media you combine the digits as in this example Example Setting the Sensitivity Number Sensitivity Media or Ribbon Number Description Thermal transfer media 56 The asterisk reserves the third digit to identify the ribbon s sensitivity number Thermal transfer ribbon Se The asterisk reserves the second digit to identify the media s sensitivity number 567 Optimized media sensitivity number To set the sensitivity number for direct thermal media use the three digit sensitivity number located on the roll of media or listed in the Direct Thermal Media Sensitivity Settings table later in this chapter To set the MSN with PrintSet 1 Start PrintSet on your PC 2 Click the Media Type button nn The Media Type dialog box appears 3 On the Print Quality Setup tab enter your three digit number in the Media Sensitivity Number field EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 1 Getting Started Media Type xj Print Quality Media Setup Print Quality Setup m Enter data if known Media Sensitivi
69. etween the Enables the printer to work with either direct thermal or thermal Top Bank Switch Number Bottom Bank Switch Number o OPETE Mza O OFF Iz aia O OFF Ly A VACA NCAA NDA YA ZA PA 1 0N ON 1 2 3 4 s 6 7 1 ON ON 3 5 6 7 Baud Rate Selection E Multi Drop Address Selection 19 200 9 0 0 ok A 9 600 oo o B 1 000 4 800 10 0 c 01 00 2 400 01 O D 11 O00 1 200 11 0 E O 01 0 38 400 00 1 F weer 0 1 O0 57 600 10 1 G 01 1 O0 115 200 O1 1 H e 1 1 0 ep y 4 I 0 0 01 Parity Selection J 1 O O 1 Even K eae de Orel Oda oo L eet E co None 10 M 001 I None O 1 N 1 O 1 I 1 o ex O 1 1 1 Number of Data Bits P 1 1 1 1 7 Bic 9 O 0 9 8 Bit o R 0 0 0 S 01 0 O Reserved T e 1 00 o 0 01 O BatchTakeup V erry O1 O Eu id Enabled o x DO a O t Y 0 O O 1 efault settings are noted with Z 1 0 O 1 0 0 1 O 1 an 1 rT 1 O I 2 so 01 I1 3 O1 1 4 1 1 5 1 1 Be Ree 0000000000000000 Protocol Selection XON XOFF Industry Standard XON XOFF Intermec Standard Intermec auto Discriminate Intermec Multi Drop oo O 1 10 1 1 Media Type Direct Thermal Thermal Transfer an efault settings are noted with 44XXU020 eps DIP switch settings These charts illustrate the settings for the DIP switches on the top and bottom banks For a descr
70. fer ribbon Ribbon supply hub Upper media guide ZF Ribbon rewind 9 d Head hub po lift lever Printhead 44XXU028 eps TTR assist roller 8 Engage the printhead by rotating the head lift lever counterclockwise until it locks 9 Enable thermal transfer printing by setting DIP switch 8 on the bottom bank of switches to the on position Refer to Configuring the Serial Port for Communications in Chapter 2 for DIP switch settings 10 Press the Feed Pause button to advance the ribbon through the printer The printer is now ready to print the hardware configuration test label Note When replacing the thermal transfer ribbon roll in the future use the empty ribbon supply core as the new rewinder core EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 13 Chapter 1 Getting Started Printing the Hardware Configuration Test Label You can print the hardware configuration test label to test the printer and make sure it is operating correctly The hardware configuration test label lists the printer s configuration and provides information on the status of the printer hardware Use this label for reference when connecting the printer to your system To print the hardware configuration test label Turn off the printer 2 Press and hold the Feed Pause button while you turn the printer on The Alert and Empty Pause LEDs blink during the printer self t
71. he printer command set to tell the printer what kind of media you are using 14 Press the Feed Pause button to advance several inches of media through the printer and out the label opening in the front cover The yellow Empty Pause LED goes out Note If the yellow Empty Pause LED does not go out reload the media and try again Note In the future you may want to refer to the label located on the inside of the media cover for directions on loading media Loading Fanfold Media In fanfold printing you place a stack of fanfold media at the rear of the printer and feed it into the printer through a slot in the rear cover To load fanfold media 1Open the printer 2 Rotate the head lift lever clockwise to release the printhead 3 Turn the supply roll retainer counterclockwise and slide it to the outer end of the supply roll post See the next illustration EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 9 Chapter 1 Getting Started Media access slot Head lift L lever Edge Na guide Lower a Fanfold media guide Supply al f roll T e post roll retainer 44XXU008 eps 4Place the fanfold media slightly lower than the slot in the printer back cover Align the fanfold media with the label path through the printer Insert media through the slot at the rear of the printer and thread it over the supply roll post 5 Unscrew the edge guide and slide i
72. he printer that presents each label after it is printed with the backing removed so it may be applied immediately sensitivity The responsiveness of thermal media or of thermal transfer ribbon to heat it is determined by the time required for a unit measure of heat to affect the media or ribbon serial A communication scheme in which the bits of a byte are transferred one at a time Often serial transmission is used to link host computers to terminals and PCs to printers skip To move the paper to the next label soft font A file stored in the printer to provide the ability to print text using fonts that are not resident in the printer EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 109 Glossary 110 Standard protocol A communications protocol capable of controlling communications between two devices connected by a single data communication line symbology A scheme for encoding data as bar code Code 39 Interleaved 2 of 5 and Codabar are examples of different symbologies thermal transfer A method of printing by which heat from the printhead melts ink from the ribbon onto media The ink adheres to the media as it cools and the ribbon is removed top of form The point where printing can start on a label The top of form is separated from the edge of the label by the margin UPC Universal Product Code A numeric 12 digit bar code symbology used extensively in retail particularly the grocery in
73. ia steep UNI na tee Wes Rese ee we tav 2 Understanding the Front Panel essere 3 Using the Front Panel LEDs sess 3 Using the Front Panel LEDs for Troubleshooting seen 4 Using the Feed Pause Button 3 Preparing the Printer for Installation eese 5 Connecting the Printer to a Power Source sese 6 Opening th Pt e RR teet ab n ee PER al 7 Loading Media Into the Printer eesssssssssseseeeeereeeeneeenenes 7 Loading Roll Media esses 8 Loading Fanfold Media sse 9 Loading Thermal Transfer Ribbon sss 11 Printing the Hardware Configuration Test Label ses 14 Setting the Media Sensitivity Number cccccccesseeseeseeseeseeseeseeeeeeecaeeeeesecaeeeenseeeeneenaees 15 Setting the MSN for Intermec Media and Ribbon sssssssss 16 Setting the MSN for Other Media and Ribbon esses 17 2 Installing the PM dne toties etd eoe RE ae 21 Connecting the Printer to Your System seessseseseeseeeeeenr enne 22 Connecting the Printer to a PC enne 22 Connecting the Printer to a PC Serial Port sess 23 Connecting the Printer to a PC Parallel Port esses 23 Connecting the Printer to a Network 23 Connecting the Printer to an AS 400 sse 24 Connecting the Printer to a Mainframe
74. ications see the manual that comes with the coax adapter card Cabling in Noisy Electrical Environments 24 The items listed below create noisy electrical environments that can disrupt data communications between your host computer and the printer e Large power transformers e Large electrical motors e Arc welders e Motor controllers e Switch gears EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 2 Installing the Printer If any of these items are near the printer you may want to try any of the following suggestions to reduce the effects of electrical noise If you need help eliminating noise ask your Intermec representative for assistance e Always use shielded cable Connect the cable and shield to the metal backshells on the cable connectors and fasten the connectors to the serial ports using screws e Install ferrite cable clamps e Connect the printer chassis ground to the building ground You will find the chassis ground on the ground pin of the printer power cord Configuring the Serial Port for Communications You need to configure the serial port of the printer to match the configuration of your PC or network controlling device If the printer s default settings do not match use the DIP switch settings table to configure the serial port 14 Note You need to configure the printer serial port for 8 data bits if you want to print code pages or 8 bit ASCII character sets Also
75. ich hex codes to download for international characters not available in the U S character set To use the tables find the hex code for the U S character that corresponds with the character in your language Advanced Character Table If you are running the printer in Advanced mode you are not using 86XX Emulation use this table to find the right hex codes for the international character sets Advanced Mode Hex Codes Tusce 3 24 40 5B 5C 5D 5E 60 7B 7C 7D TE U S ASCII U K ASCII Germany France Spain Switzerland Italy Emulation Mode Character Table This table shows the hex codes for the character sets that print if the printer is running under Emulation mode Emulation Mode Hex Codes WORKER OR A 40 5B 5C 5D SE 60 7B 7C 7D TE USC LA AC O O O O eee U K ASCII Germany France Spain Switzerland Italy 86 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Appendix B Character Sets IBM Translation Character Table If you are running the printer with IBM Translation enabled use this table to find the right hex codes for the international character sets IBM Translation Hex Codes FEE IE 8 26 HE HE FE 7K FY 23 24 40 5B 5C 5D 5E 60 7B7 7D U S ASCII U K ASCII Germany France Spain Switzerland EN Italy 9 292 22 A 22 22 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 87 Appendix B Character Sets Code Page 850 Character Table
76. inter 27 using to set the media sensitivity number 16 problems communication 44 print quality 42 printer operation 40 protocols 94 hardware protocol 96 Multi Drop 96 Polling Mode D 96 Standard 94 user defined 97 XON XOFF 95 Q QR Code 84 quality correcting uneven print 48 optimizing and maintaining print 48 problems troubleshooting 42 R RAM using efficiently 57 ready definition 108 Ready Busy line definition 108 removing the printer cover 7 requirements electrical 76 host 98 rest point label 68 ribbon specifications 78 roll media loading 8 115 Index rollers cleaning 35 RS 232 99 definition 108 null modem cable schematics 101 RS 422 99 cable schematics 102 definition 109 RS 485 definition 109 described 99 S scan definition 109 scannable definition 109 schedule of maintenance 30 selective transfer definition 109 described 64 self strip definition 109 described 80 sensitivity definition 109 sensor adjusting the label gap 54 adjusting the label mark 56 cleaning label 37 serial interface 98 RS 232 99 RS 422 99 RS 485 99 serial port configuration 25 description 100 using to connect a PC to the printer 23 serial definition 109 setting the media sensitivity number 15 16 17 settings factory default 78 skip definition 109 skipping labels adjusting the printer to stop 55 soft font definition 109 software configuration
77. iption of each setting see the DIP Switch Settings Descriptions table earlier in this chapter EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 2 Installing the Printer Communicating With the Printer Now that your printer is connected to your system you are ready to print labels by downloading data from the host to the printer Downloading is the universal term used to describe the transfer of information from the host to any connected peripheral device such as the printer When you transfer data from your printer to the host you are performing a process called uploading You can use several methods to download information in your data collection system This section describes three different ways to communicate with the printer 1 Using the PrintSet software 2 Using third party software 3 Using Intermec Printer Language IPL commands Using the PrintSet Software You can install the PrintSet application software from the Printer Companion CD that shipped with the printer Use PrintSet to easily configure your printer from your PC You can also use PrintSet to e download graphics and fonts including TrueType e print test labels e modify and download configuration files Refer to the online help for information on using PrintSet Using Third Party Software You can use third party software to set many of the printer parameters You can configure the parameters that your software does n
78. isabled 100 dots 0 5 in 20 dots 0 1 in 470 Direct Thermal 567 Thermal Transfer 3 1000 dots 5 in US ASCII Disabled 0 3 inches per second ips Die cut 0 ms 128K flash This section contains a list of all the options you can use with the 4420 and 4440 printer along with a brief description Consult your local Intermec representative to order any option Communications Interfaces You can order any of these field or factory installable communications interfaces for the printer EasyLAN 10i Interface This option lets you connect the printer to a 10BaseT Ethernet network Various network printing protocols are available For more information see the EasyLAN 101 documentation EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 79 Appendix A Specifications Finishers 80 EasyLAN 10i2 Adapter The external EasyLAN 10i2 Ethernet adapter P N 072885 and the internal EasyLAN 1012 Ethernet adapter P N 072884 allow you to share your available printer resources with everyone on your Ethernet network With the EasyLAN 1012 adapter installed the parallel port on the printer is not available for use For more information see the EasyLAN 1012 documentation EasyLAN Wireless Option The EasyLAN Wireless is an 802 11b radio option that lets the printer communicate wirelessly with a PC that contains an 802 11b radio card ad hoc network It can also communicate with other devices via an access point infrastru
79. k APR OKO ANY 9 71 72 78 74 75 76 7 78 79 TA 7B Ki TE TF a Lu B aora E a g l Be Be oo la ls D E F Pus A L3 na B AA e ree eoo 91 92 9 94 95 96 9 9 99 94 9E 9D 9E 9F x Xa Al A2 A3 M AB AG AT A8 A9 AA AB AD AE AF x kpo Bl B2 3 B4 B5 B6 B7 B8 B9 BA BB BD BE BF x xc Cl c c3 C4 C5 C6 c7 C8 C9 CA CB CD CE CF ok xp DI p23 D D5 D6 D D8 D9 DA DB Aj 2C 3C 5C 6C 8C 9C BC CC DC EasyCod er 4420 and 4440 Bar Code Label Printer User s Manual 89 Appendix B Character Sets Characters in Fonts c20 c21 22 c25 c26 c28 c30 c41 8 point 12 point 20 point outline fonts monospace fonts 6 point to 36 point tulo A yok ape RAK o 2 o 2 2 wala le HL 3 12 apa 13 14 15 16 17 18 19 14 1B ic 1D far far l 4 y aora e Tf 06 amp 7 gt 2 aia TS e St a a EA 22 23 24 25 26 27 28 29 2A 2B 2C PRIN RATA d LI 2 3 l 4 15 6 7 18 9 i Ez 3 31 32 33 34 35 36 37 38 39 34 3B 3c 35 3E 3F a I cee A BEB 6H HH E M N 4 4 42 43 44 45 46 47 48 49 4 4B 4C 4D 4E 4F sss Q R 1S LT LU viw xyz N 1 5 51 52 53 54 55 56 57 58 a 5a 5B 8C 8D 5E 5F PA NA c dle f gl hli i
80. l Printer User s Manual C Communications Reference This chapter provides communications reference information This chapter covers these topics e Communications protocols e Communications interfaces e Serial port communications EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 93 Appendix C Communications Reference Communications Protocols Communications protocols are important because they determine the transmission standards for communications between the printer and the host The printer and the host must use the same protocol and parameters to communicate properly The printer supports the flow control and block transfer protocols described in the next sections All of these protocols are point to point except Multi Drop Application programs and or ROM BIOS determine which protocols your computer can support For more detailed information refer to the Data Communications Reference Manual P N 044737 Intermec Standard Protocol 94 Intermec Standard protocol is a proprietary block transfer status response protocol For each block sent the host must wait for the appropriate response before sending the next block lt DC1 gt Except for single character status commands lt ENQ gt and lt VT gt Standard protocol transmits characters in message blocks beginning with the start of text lt STX gt character and ending with the end of text lt ETX gt character Message blocks can be up to 25
81. label or ribbon stock Dirty printhead Printing not aligned on Printer is misfeeding media label Labels are not stopping at Incorrect label rest point setting the right point for removal Print quality is poor Incorrect media sensitivity setting Incorrect darkness control setting Print speed exceeds the capability of the media Printhead platen roller or label path are dirty quality For help see Adjusting the Print Darkness in Chapter 5 Change sensitivity setting to match the type of media you are using for help see Setting the Media Sensitivity Number in Chapter 1 If you set the sensitivity setting correctly try changing the dark adjust Use only Intermec label and ribbon stock to ensure superior print quality and product performance Clean the printhead For help see Cleaning the Printhead in Chapter 3 Make sure you have correctly installed the media For help see Loading Media Into the Printer in Chapter 1 Adjust the label rest point For help see the PrintSet online help or the PL Programming Reference Manual Change sensitivity setting to match the type of media you are using If you set the sensitivity setting correctly try changing the print darkness For help see the PrintSet online help or the ZPL Programming Reference Manual Adjust the darkness adjust control For help see Adjusting the Print Darkness in Chapter 5 Lower the print speed or use
82. lk l mn 6 61 62 63 64 65 66 67 68 69 6A eB d 6b 6E 6F rs Lt ou vow x Z poo TRAE 71 72 73 74 75 76 77 78 7970 7p 78 7F TA 7B 82 81 82 83 84 85 86 87 88 89 8A 8B 8C 8b 8 8F 9 91 92 93 94 95 96 97 98 99 94 9B 9c 9D 9E OF o 9 2 lolo la fe e 1 UI f T A a Ja 43 m as as Sa as ol aa a ac Xda ar 2 9 EJIL 3 9 9 3 2 fe 1 09 abla al B BI B2 B3 B4 ps po Kp B8 B9 BA BB BC BD BE BF 42 2 92 KKP ETA peepes 212192 c ci c2 ez c4 cs co Pez cs co CA em cc cp ce c D 2 2 x229 9 y I D p pn p3 p4 ps w pz ps og pa os DC DD oe pe P kk P kekk 2 12 2 xx RE E El E2 E3 4 E5 E6 E7 E8 E9 EA EB EC ED EE EF 2 09 9 9 KP KP 9 Jo Fl F2 F3 F4 F5 F6 F7 F8 F9 FA FB FC FD FE FF O gt 2F there is white space surrounding the characters that prevents the image from reaching the maximum graphic size Note You cannot print these characters as 4 x 4 inch graphics because EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Appendix B Character Sets Characters in Fonts c23 OCRA Anl fik i L7 at ii m Tu n 2A 2B 2C 2D 2E gt mu 3 PO 3 t S U DT 5a d col ee S E eo co
83. lowing table Communications Problems Symptom Printer does not communicate with the host Possible Causes Solution Serial port is incorrectly configured Make sure the printer s serial port settings match those of the host Print a software test configuration label as explained in Using Test and Service Mode Procedures in Chapter 6 to check the serial port settings Damaged or incorrect I O cable Check the connections at both ends or replace the cable See Appendix C for cable information Preventing Data Loss 44 Several problems can cause data loss or communications problems on the printer Data loss can result in printing errors or missing field data The printer is a serial ASCII device It communicates with the host through an ASCII serial communications I O port Hardware handshaking involves the use of a hardware wire Software handshaking involves a two way datalink between the devices The two devices communicate with each other without losing data through the use of handshaking The printer sends both forms of handshaking simultaneously when the printer s input buffer is full Any loss of data can cause printing errors or missing data Hardware handshaking uses pins 11 or 20 of the RS 232 interface to control data flow When the printer is using Intermec Standard protocol it holds pins 11 and 20 high when it is ready to receive data The printer holds the pins low when it is in one of the following conditi
84. lt Y origin with the DIP switches only 14 Note An image printed on direct thermal media may have an X origin position which is slightly different than the same image printed on thermal transfer media Always use X forms adjust and Y forms adjust with the same media type that you plan to use for printing labels The default X origin is 0 10 inch 20 dot increments from the leading edge of the label You can move the X origin forward or backward 30 increments where each increment is 5 mil The default Y origin is 0 00 inch from the edge of the label You can move the Y origin down 30 increments where each increment is 5 mil EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 71 Chapter 6 Using Test and Service Mode 72 X Forms Adjust Use the X forms adjust to control the position of the label format along the length of the label When you move the X origin forward the printer moves the format away from the leading edge of the label When you move the X origin backward the printer moves the format closer to the leading edge of the label It is easier to use the TOF switch to move the origin forward or backward but the printer will reset itself to the default position if you lift the printhead or cycle printer power To set the X forms adjust Turn off the printer 2 Press and hold the Feed Pause button while turning on the printer The printer prints out a hardware configuration label and then enters Data Line
85. n this position for most labels wider than 2 5 cm 1 0 in To adjust the label gap sensor Remove the media cover 2 Turn the label gap sensor knob approximately 1 2 turn counterclockwise to free the sensor for adjustment 3 Slide the label gap sensor knob to the position where the label gap sensor is optimized for the label stock Here are some guidelines for you to follow e f the labels are less than 2 5 cm 1 0 in wide position the label gap sensor in the middle of the label e f the labels are greater than 2 5 cm 1 0 in wide position the label gap sensor over the straight edge of the label not over the label radius Label radius Label gap sensor Gas Label gap sensor knob Lower 44XXU050 eps media guide 4 Turn the label gap sensor knob clockwise to secure it in the new position 5 Try printing a label to see if the printer is detecting the start of the label top of form 6 Ifthe printer is still not detecting the top of form slide the label gap sensor a little further toward the outer edge of the lower media guide 7 Replace the media cover EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 55 Chapter 5 Optimizing Printer Performance Adjusting the Label Mark Sensor 56 The label mark sensor detects the black mark on the back of continuous media stock The printer uses the output to determine the start of pri
86. ning card forward until you have pulled the entire card through the media path 9 Repeat Steps 6 through 8 10 Dispose of the cleaning card properly 11 Ifyou are finished cleaning replace the media cover To clean the printhead using a cotton swab and isopropyl alcohol Turn off the printer and remove the power cord 2 Remove the media cover 3 Disengage the printhead by rotating the head lift lever clockwise until the printhead releases This raises the printhead so that you can clean it 4 Remove the media and ribbon if necessary EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 33 Chapter 3 Maintaining the Printer 5 Use a cotton swab moistened with alcohol to remove any dirt adhesive or debris from the print surface on the bottom of the printhead 44XXU037 eps Printhead 6 Wait 5 to 10 seconds for the print surface to dry Replace the media and ribbon 7 Engage the printhead by rotating the head lift lever counterclockwise until it locks in place 8 If you are finished cleaning replace the media cover Cleaning the Printer Covers Clean the printer covers with a general purpose cleaner soapy water or mild detergent Do not use abrasive cleansers or solvents Be sure to clean the transparent panel on the media cover so that the media supply inside the printer is visible when you close the cover Cleaning the Rollers and the Tear Bar Cleaning the rollers and the
87. ns in Chapter 2 Try reloading the media For help see Loading Media Into the Printer in Chapter 1 See possible media fault causes and solutions above Set the printer to the default configuration using the DIP switches For help see Connecting the Printer to a Power Source in Chapter 1 Reset the memory to return the printer to its default configuration For help see Using Memory Reset in Chapter 6 After you reset the memory power off the printer and return the DIP switches to the required setting For help see Configuring the Serial Port for Communications in Chapter 2 41 Chapter 4 Troubleshooting the Printer Print Quality Problems If the labels are not being printed properly check the following table to locate the symptom and correct the problem Print Quality Problems Symptom Possible Causes Blotches printing on labels Dirty printhead Dirty media path or rollers Poor quality label or ribbon stock Solution Clean the printhead For help see Cleaning the Printhead in Chapter 3 Clean the media path For help see Cleaning the Media Guides and Media Path in Chapter 3 Use only Intermec label and ribbon stock to ensure superior print quality and product performance Printing is too light or too Incorrect darkness adjust control setting Adjust the control to achieve the best print dark Incorrect media sensitivity setting Poor quality
88. nt The label mark sensor is behind the platen roller and near the inboard edge of the printer You can position the label mark sensor no more than 6 35 cm 2 5 in from the inboard edge of the printer To adjust the label mark sensor 1 Remove the media cover and locate the label mark sensor 2 Use your index finger to slide the label mark sensor to the correct position for the media You can position the label mark sensor anywhere from the inboard edge of the printer to the center of the paper path OO L m roller Locate the label mark sensor behind the platen roller near the inboard edge of the printer Use your finger to adjust the label mark sensor a ll Inboard edge of printer The platen roller is not shown for clarity only Label mark sensor 44XXU052 eps 3 Print a few labels to make sure that the label mark sensor is detecting the black mark on the media 4 Replace the media cover EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 5 Optimizing Printer Performance Using the Printer Memory Efficiently To receive the best performance from the printer you must understand how to use the printer memory The following sections can help you determine the most efficient way to use the printer memory How Is the Printer Storage Memory Used There is enough storage memory
89. nter 6 Resetthe DIP switches to their original setting and then turn on the printer Note You can also use the Test and Service command D to reset all printer RAM Setting Configuration Commands in Test and Service Mode 66 Test and Service mode gives you with another way to change configuration commands besides sending them down from the host You can change these commands by setting the Test and Service mode DIP switches e Label rest point e Emulation mode e X forms adjust e Y forms adjust Top Ban Bottom Ban OFF N O OFF amm he pum nc o pu uu 1 ON E ZIV ZIV ZZV Z JIZ JZ Z Z ON 1 2 3 4 5 61 2 4 6 El 8 8 Label Rest Point Adjust Forward 01 1 NN N N N Adjust Backward sN N N N N Emulation 10 1 5 0 mil Advanced mode 00 10 mil 86XX mode 10 15 mil 86XX mode 1 1 X Forms Adjust 1 1 1 1 Adjust Forward O Adjust Backward 1 N N N N N N UN NN Y Forms Adjust 1 1 10 N N N N N Number Least significant bit first 44XXU062 eps Configuration DIP switch settings This illustration shows the Test and Service mode DIP switch settings for changing the configuration commands EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 6 Using Test and Service Mode Se
90. o connect the printer to a PC serial port Turn off the printer 2 Plug the 25 pin connector into the serial communications port on the rear of the printer 3 Plug the other end of the cable into a serial port on the PC 4 Ifnecessary change the PC serial port configuration to match the printer See Configuring the Serial Port for Communications later in this chapter for more information Connecting the Printer to a PC Parallel Port If you are using a parallel port to communicate with the printer you need a parallel cable to run between the printer and the PC You can purchase the Intermec IEEE 1284 parallel cable P N 590124 or purchase a compatible cable from your local computer store To connect the printer to a PC parallel port Turn off the printer 2 Plug the parallel interface connector into the parallel communications port on the rear of the printer 3 Plug the other end of the cable into a parallel port on the PC Connecting the Printer to a Network You can connect the printer to Novell NetWare networks Ethernet networks token ring networks or other TCP IP networks To connect the printer to a network you must have an interface card for example EasyLAN 1012 installed Ethernet coax and twinax cards are field or factory installed If you need to change the printer s communications parameters follow the procedures in Configuring the Serial Port for Communications later in this chapter Easy
91. ode Label Printer User s Manual Chapter 6 Using Test and Service Mode To set the Y forms adjust Turn off the printer 2 Enter Test and Service mode by pressing down and holding the Feed Pause button while turning on the printer The printer prints out the hardware configuration label and then enters Data Line Print mode 3 In the top bank of the Test and Service mode DIP switches turn on switches 1 2 and 3 4 In the bottom bank of the Test and Service mode DIP switches turn on or off the appropriate DIP switches Refer to the Dot increments DIP switch settings illustration earlier in this chapter to see how to set the Y forms adjust forward or backward a given number of increments 5 Press the Feed Pause button The printer prints out the software configuration label using the new Y forms adjust setting 6 Verify the Y forms adjust number on the software configuration label matches the number you set in Step 4 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 73 Chapter 6 Using Test and Service Mode 74 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual A Specifications This chapter contains the following reference information e Specifications e Factory default settings e Printer options e Supported bar code symbologies EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 75 Appendix A Specifications 4420 and 4440 Printer Specifications This
92. odified version of Code 39 that has 43 characters utilizes the Modulus 43 check character and reserves some character combinations for special usage human readable A character number or symbol printed in a font that a human can read as opposed to bar code symbology which only a machine can read EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 105 Glossary 106 image bands A portion of an image in the shape of a strip of the image A certain number of image bands are stored in memory before printing begins This method allows printing and imaging to take place simultaneously imaging The process of generating a picture of the label in printer memory increment decrement field Bar code or text fields the printer automatically changes from one label to the next For example a batch of labels with serial number text or bar code fields that change from 001 to 002 to 003 and so on index To move from the start of the label to the start of print With continuous media to advance the media over the label gap to the edge of the next label interpretive field A text field that describes the data in the associated bar code field ips Inches per second A measurement of print speed that measures the number of inches of media that is printed each second ISO International Organization for Standardization An internationally accepted 7 bit character code The U S version is ASCII label The
93. on DIP switch settings illustration earlier in this chapter for the appropriate DIP switch settings EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 67 Chapter 6 Using Test and Service Mode 2 See the previous illustration of the Dot increments DIP switch settings Scan down the of Dot Increments column until you reach the number of dot increments you want to adjust the command forward or backward 3 In the bottom bank turn on the switches that have a 1 in their column Turn off all other switches 4 Press the Feed Pause button and the printer prints out the software configuration label and stops at the new location For example you print a label and discover that it does not extend far enough from the tear bar You need to move the label rest point forward 10 dot increments 0 05 inch so that the printer feeds more label out when it finishes printing Find 10 in the of Dot Increments column It shows a in the columns of DIP switches 2 and 4 and a O in the columns of 1 3 and 5 The 1 tells you to turn on the switch The O tells you to turn off the switch Turn on switches 2 and 4 Turn off all other switches Adjusting the Label Rest Point The Label Rest Point configuration command adjusts the point at which the printer presents each label for removal Use this command in conjunction with self strip applications The label rest point adjust range is from 30 5 mil increments farthest back to 30 5 mil in
94. ons e Buffer full e Ribbon fault e No label stock e Label at strip pin The printer uses XON XOFF protocol for software handshaking When the input buffer is full the printer transmits an XOFF character This character alerts the host to the fact that the printer buffer is full and cannot receive any more data When the printer is ready to receive more data it sends the XON character EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 4 Troubleshooting the Printer To check for communications problems 1Check the cabling from the printer to the host system 2 Check the communications interfacing of the devices connected to the printer 3 Check the printer for proper electrical operation of the I O port 4 Ensure the host system is not overrunning the printer input buffers 5 Ensure the data string being sent to the printer contains the correct information EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 45 Chapter 4 Troubleshooting the Printer 46 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Optimizing Printer Performance This chapter explains how to optimize and maintain print quality This chapter covers these topics e Correcting uneven print quality e Adjusting the print darkness e Fine tuning the top of form position e Adjusting the label gap sensor e Adjusting the label mark sensor e Using the printer memory efficiently e Incre
95. ont Ne N NN N T All Fonts 1 1 1 1 1 1 Data Line Print 10 0 00 9 o_o Selective Transfer 110 Send Pages 1 oo Single Page S S S S S p D D D AIL Pages 1 1 1 D L Send Format o 10 ee I 1 Single Format S S S SS 1 D All Formats 1 1 1 1 1 1 Send UDC 1 10 D D D Single UDC S S S S All UDCs 1 1 1 1 1 D EST 1 1 1 SS 11 1 Send Font O00 1 Single Font S S S S S D DD D D All Fonts 1 1 1 1 1 1 1 1 1 1 Send Configuration 1 O 1 Send Tables O 1 1 Send All 1 1 1 Memory Reset 00 1 Page Format O OO UDC Font 1 O00 Configuration O 1 O Tables 1 1 O All 1 1 1 Q OFF Batch of 1 ON Batch of 100 N Page Format UDC Font number Least significant bit is switch 8 S Source Page Format UDC Font number Least significant bit D Destination Page Format UDC Font number Least significant bit f N 44XXU061 eps Default settings are noted with an Test and Service mode DIP switch settings This illustration shows DIP switch settings for Test and Service mode functions EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 63 Chapter 6 Using Test and Service Mode Printing Test Labels The 4420 or 4440 printer can print a variety of test print labels that provide you with information about the printer configuration and the quality of the printing To print a test label Turn off the printer 2 Press and hold the Feed Pause button while turning on the printer The printer prints out a hard
96. ot set by using the printer command set or the configuration DIP switches Use your third party software to create label formats and convert graphics into a user defined character UDC format that the printer can interpret Refer to your third party documentation and the JPL Programming Reference Manual P N 066396 for more information Using Intermec Printer Language IPL Commands You can create labels by downloading formats designs and data with IPL commands You can use the IPL commands to perform any function or activate any feature of the printer except for those features or functions that you set with the DIP switches For help using IPL commands see the JPL Programming Reference Manual EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 27 Chapter 2 Installing the Printer Using PrintSet to Test Communications If you would like to test communications between your host and the printer you can use PrintSet to download a test label To print the test label 1 Start PrintSet on your PC 2 Click the Test Print button 3 Select the Test Label option button 4 Select either the Text or the Bar Code option button If you select to print text you can choose a font in the Select Printer Font list box If you select to print a bar code you can choose a symbology in the Select Symbologies list box 5 Click the Print button Your printer prints out a test label For example if you chose to print
97. pansion You can install a flash SIMM module into the SIMM socket on the main PCB to hold more fonts or bitmap graphics You can also install a DRAM SIMM to increase the image buffering capabilities of the printer You can purchase either module in 8 or 16 MB sizes only Bar Code Symbologies Supported The 4420 and 4440 printers support the following bar code symbologies Supported Bar Code Symbologies Symbology Codabar Code 2 of 5 Code 11 Code 39 Code 93 Code 128 EAN Interleaved 2 of 5 Description Originally developed in 1972 Codabar is a numeric symbology most commonly used in libraries blood banks and air parcel express applications Code 2 of 5 is a straightforward numeric symbology developed in the late 1960s It has been used for warehouse sorting systems photofinishing envelope identification and for tracking sequentially numbered airline tickets All information is contained in the width of the bars the spaces do not contain information Code 11 was developed in early 1977 to satisfy requirements for a very high density discrete numeric bar code The most extensive application of Code 11 has been for labeling telecommunications equipment Code 39 is the first alphanumeric symbology ever developed and is the standard non retail bar code It is a discrete self checking symbology of variable length and is used mostly by the automobile and medical industries Introduced in 1983 Code 93 was spe
98. ptimizing Printer Performance 1 Remove the media cover 14 Note Do not raise the printhead while adjusting the TOF position 2Press on the back part of the TOF switch Each time you press the TOF switch you move the label format backward 0 127 mm 0 005 in 44XXU059 eps 3 Press the TOF switch repeatedly until the format moves backward to the correct position on the label Ww Q amp Q Q amp ba Q Q a gt S 3 Y i S Of SS fe o e es OS OT o 2 0 o a s A a sf SE nds sf Sm nsf 2 o 2 Sli 2 Si 2 o Sa E gt oe gt 90 0 1 4 gt 6 T pr s C o o o X Q Q NA x o carm uM AN A ES Ks EE E ES S m o o E a EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 53 Chapter 5 Optimizing Printer Performance To move a label format forward with the TOF switch You notice that the format is printing toward the back part of the label Label direction from printer oo m y y Y A TF pe TE a T Ake o R or or 0 PT
99. r Table sse 86 IBM Translation Character Table sese 87 Code Page 850 Character Table essere 88 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual vii Contents C Communications Reference viii Extended Character Sets n i sondesouseaetetuees 89 pP 93 Communications Protocols ooonooccnnonoccnonanonanannncnananonananaconnnccnnnnononnnncccnnnnncnnnnccnananncc n 94 Intermec Standard Protocol eese eene nennen nnne 94 XON XOFF Protocol Software and Hardware Flow Control 95 Polling Mode Dit Rete tdi tete bites 96 Multi Drop Protocol teet ee b ud te bie tiic iedete 96 Hardware Proton NOIRS VESTE 96 User Defined Protocol ooononcccconocccinonanononnncnononnccnananonnnoconnnnncconnnoronnnnccnannacnnnos 97 Host Requirements iere rore ret eee edd ede pats 98 Communications Boundaries cccccccecsccesssccesssecesssssessesessssecessscessseceeseees 98 Communications Interfaces cccccccccsccsccessssesssceccsssccccsscsccssseccsssecssssecessesecsssscessesseees 98 RS 232 Serial Intetface aaa 99 RS2422 Serial tera etre er er Eee ete ea ede 99 RS 485 Serial Interface ooonocononocccononncnonnncnnnnanononancnnnanancnn N es a Ea 99 Printer Serial POrt ee date ten A tttm ae Re dvtuet 100 EE 103 ne 111 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Before You Begin Before
100. racters but the rules for the chosen protocol do not change The printer does not use any protocol characters that you replace with the NUL character One table of protocol characters exists You may redefine these characters to create a table that all of the protocols can use One possibility for you to redefine protocol characters may be the replacement of control characters with printable characters 14 Note Please use caution when replacing control characters with printable characters One control character can be replaced with only one printable character The next table lists the protocol characters that you can redefine and the protocols they affect Protocols Affected by Redefining Characters Character STDPOL Mode D Multi Drop XON XOFF SELECT IN X POLL IN RES IN REQ IN SOM IN X EOM IN X AFF IN NEG IN DLE IN X XON IN XOFF IN X SELECT OUT POLL OUT RES OUT REQ OUT SOM OUT EOM OUT AFF OUT NEG OUT X DLE OUT X gt PA PA KM mK KM KM OX PA pA KM mK KM KM OX gt K pA KM KM KK X P P4 KK KM KK MX X EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 97 Appendix C Communications Reference Protocols Affected by Redefining Characters continued Character STDPOL Mode D Multi Drop XON XOFF XON OUT X XOFF OUT X X X PROTO CMD 1 X X PROTO CMD 2 X X TIMEOUT ON EOM X X Host Requirements The 4420 and 4440 printers have the following hardware and software requirements
101. retainer counterclockwise and slide it lightly up against the media support Turn the supply roll retainer clockwise to secure 6 Loosen the edge guide and slide it all the way to the outer edge of the lower media guide Tighten it in place 7 Pull down on the lower media guide to allow easy access to the media path 8 Unroll several inches of media and insert it between the media guide plates as shown below Make sure the label passes between the upper and lower media guides and out the front of the printer Head lift Upper lever media guide Media roll Label gap Media sensor Edge Lower AAXXUO27 eps guide media guide 8 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual R R Chapter 1 Getting Started 9 Release the lower media guide and adjust the edge guide by loosening it and sliding it to position the media firmly against the inside wall of the printer 10 Adjust the label gap sensor position if necessary For help see Adjusting the Label Gap Sensor in Chapter 5 11 Ifyou are using thermal transfer media you need to load ribbon Follow the instructions for Loading Thermal Transfer Ribbon later in this chapter before you finish performing this procedure 12 Lower the printhead by rotating the head lift lever counterclockwise until it locks 13 Ifyou are loading continuous media or mark label stock use PrintSet your third party software or t
102. rollers may have different pin assignments 1 Note Connect pin 1 to shield at one end only 102 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual G Glossary EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 103 Glossary 104 backing Silicon release liner on media to which labels are attached until ready for use batch takeup A device that rewinds media useful for printing batches of labels BEL A command character that instructs the printer to return an error status code character sets The letters numerals and symbols that support particular languages such as French or U S ASCII or automatic identification technology such as Code 39 or Codabar cloning A procedure that copies the RAM contents configuration formats fonts pages and graphics from the memory of one printer to the memory of another data file The collection of data and printer commands that when sent to the printer is merged with a format file to print a label Data Line Print mode A mode of operation in which the printer prints each command accompanied by its ASCII code in hexadecimal format that it receives from the host density The number of data characters that can be represented in a linear unit of measure Often expressed in characters per inch direct thermal A method of thermal printing in which images are printed when heat from the thermal printhead produces a black mark on the media
103. rranties of merchantability and fitness for a particular purpose Web Support Visit the Intermec web site at www intermec com to download our current documents in PDF To order printed versions of the Intermec manuals contact your local Intermec representative or distributor Visit the Intermec support services knowledge base Knowledge Central at intermec custhelp com to review technical information or to request technical support for your Intermec product EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual ix Before You Begin Telephone Support These services are available from Intermec Service Order Intermec products Order Intermec media Order spare parts Technical Support Service Service contracts In the U S A and Canada call 1 800 755 5505 Description and choose this option e Place an order 1 and then choose 2 e Ask about an existing order Order printer labels and 1 and then choose 1 ribbons Order spare parts 1 or 2 and then choose 4 Talk to technical support 2 and then choose 2 about your Intermec product e Get a return authorization 2 and then choose 1 number for authorized service center repair e Request an on site repair technician e Ask about an existing 1 or 2 and then choose 3 contract e Renew a contract e Inquire about repair billing or other service invoicing questions Outside the U S A and Canada contact your local Intermec representati
104. s Solution No power or loss of power You have damaged or disconnected the Make sure you have plugged the power cable AC power cable into both the printer and an outlet or power strip Replace the cable if damaged Printer circuit breaker tripped Turn the printer off and back on again Labels stop feeding through Printer is out of media Load new media For help see Loading the printer Media Into the Printer in Chapter 1 You have loaded the label stock Check the media path For help see incorrectly Loading Media Into the Printer in Chapter 1 You have set the printer for continuous Use PrintSet to check the configuration label stock settings If the settings are incorrect use 40 PrintSet to change the settings Media is sticking to the paper path Clear any extraneous material from the paper path and clean it thoroughly Refer to Chapter 3 Maintaining the Printer EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Printer Operation Problems continued Symptom Printer slows down The Alert LED flashes and printing stops Media fault Test configuration label does not print Printer is not communicating not printing or not printing properly Possible Causes You have incorrectly set the image bands or print speed Printer has aborted and reset the print speed and image bands Printhead has overheated The printhead is up Sensor type set incorrectly You have incorre
105. section describes the specifications and performance parameters for the 4420 and 4440 printers Dimensions no options installed Height 41 9 cm 16 5 in Width 24 8 cm 9 75 in Length 43 8 cm 17 25 in Weight 19 35 kg 43 Ibs Electrical Requirements Input Voltage 100 115 200 or 230 VAC 10 Frequency 50 60 Hz Current 2or1lA Environment Operating 4 C to 40 C 407F to 104 F Storage 0 C to 70 C 32 F to 158 F Humidity 10 to 90 with maximum wet bulb 82 F 28 C and minimum dew point 36 F 2 C Character Sets US ASCII Norwegian Danish UK ASCII Swedish Finnish German Italian French Spanish Switzerland Code Page 850 Fonts and Graphics There are 21 resident bitmap fonts including OCR A and B and three outline fonts available on the printers You can use font ID 3 through 6 and 8 through 19 to download user defined fonts Maximum UDF 102 mm square 4 in square Maximum UDC 102 mm square 4 in square 76 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Appendix A Specifications Media Specificafions pu E E a 1 o V ee p i i 44XXU067 eps Media dimensions This illustration shows how to measure media dimensions See the next table Minimum and Maximum Media Dimensions for specific media dimensions Minimum and Maximum Media Dimensions Letter Description Minimum A Label width 16 5 mm 0 65 in B Backing
106. t is a 25 pin D style subminiature receptacle The port is wired as a data terminal equipment DTE device Hy DTR AoSs02PSSPSGS SE c E 4 P ALA LALA AS 3 a Q CTS RTS 8 S GND 44XXU073 eps Serial port pin assignments This illustration shows the serial port pin assignments EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Appendix C Communications Reference Shield 25 Pin Socket D Sub Metal Backshell 25 Pin Plug D Sub Metal Backshell Chassis Ground CHASSIS GROUND Transmitted Data Received Data Received Data Transmitted Data Request to Send Clear to Send Carrier Detect Data Set Ready Data Terminal Ready Ground Ground Data Terminal Ready Data Set Ready Carrier Detect Clear to Send PC AAXXUOT4 eps Printer 25 Pin PC Connector RS 232 null modem cable This illustration shows the pin assignments for the RS 232 null modem cable for the 25 pin PC connector P N 048668 14 Note The metal backshell is connected directly to the shield to achieve electrostatic discharge ESD immunity Shield 9 Pin Socket D Sub Metal Backshell 25 Pin Plug D Sub Metal Backshell Chassis Ground Received Data Transmitted Data Transmitted Data Received Data Clear to Send Carrier Detect Request to Send Data Terminal Ready Data Set Ready Data Set Ready Data Terminal Ready Carrier Detect Clear to Send Request to Send Ground Ground PC 44XXU075
107. t online help e Use the IPL command set to select Emulation mode For help see the IPL Programming Reference Manual EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 69 Chapter 6 Using Test and Service Mode To set the printer to Emulation mode using DIP switches 1 Upload label formats fonts and graphics from the 8636 or 8646 printer to the host computer 2 Turn off the printer 3 Disconnect the 86XX printer and install the 4420 or 4440 printer See Chapter 2 for information on installing the 4420 or 4440 printer 4 Press and hold the Feed Pause button while turning on the printer The printer prints out a hardware configuration label 5 In the top bank of the Test and Service mode DIP switches turn on switches 1 and 3 and turn off switch 2 6 Use the table below to help you choose the appropriate DIP switch settings Setting Description 86XX 10 mil The printer emulates an 8636 or 8646 printer printing multiples of 10 mil 0 01 inch drag and picket bar codes 86XX 15 mil The printer emulates an 8636 or 8646 printer printing multiples of 10 mil 0 01 inch drag and picket bar codes Advanced 5 mil The printer uses the 4420 command set and prints in multiples 4420 default of 5 mil 0 005 inch drag and picket bar codes Advanced 2 5 mil The printer uses the 4440 command set and prints in multiples 4440 default of 2 5 mil 0 0025 inch drag and picket bar codes e To enable 10 mil emulation
108. t to the outer edge of the lower media guide Screw it in place 6 Pull down on the lower media guide to allow easy access to the media path 7 Insert the fanfold media through the printer mechanism as shown in the previous illustration The fanfold media passes over the supply roll post and out the front opening of the printer 8 Release the lower media guide and adjust the edge guide to position the media firmly against the inside wall of the printer 9 Slide the supply roll retainer up to the edge of the fanfold media and turn the supply roll retainer clockwise until it locks firmly in place This action secures the media against the inside wall of the printer 10 Rotate the head lift lever counterclockwise until it locks to engage the printhead 10 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 1 Getting Started 11Replace the media cover 12 Press the Feed Pause button to advance one label through the printer The yellow Empty Pause LED goes out 14 Note If the yellow Empty Pause LED does not go out reload the media and try again 14 Note In the future you may want to refer to the label located on the inside of the media cover for directions on loading media Loading Thermal Transfer Ribbon If you plan to print in thermal transfer mode you must install thermal transfer ribbon TTR on the ribbon supply hub after you install the thermal transfer media You also must use thermal transf
109. tches to the test or service function you wish to perform See the following table for a list of the DIP switch settings 4 Press the Feed Pause button The test begins immediately 5 If you want to perform another function change the DIP switch settings and press the Feed Pause button The function the printer is currently executing terminates and the printer performs the new function To exit Test and Service mode Turn off the printer 2 Reset the DIP switches to their original settings 3 Turn on the printer Use the information in the following table to set the DIP switches for the appropriate Test and Service mode function you want to perform EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 6 Using Test and Service Mode Top Bank Bottom Ban O OFF OFF N Y Ex Y OE ROS OY SY DER ua E xS REIS A A A AVA AA ZA A TESTS ON 2 3 4 51 2 3 4 5 6 6 7 8 Test Prints Configurations 00 O Hardware 0 OO Q Software 00 Q Test Labels 1 0 Print Quality 10 O v Pitch o O Q Page 1 0 Single Page 0 1 Oo 0 NN NN N o All Pages 1 1 1 1 1 Q Format 1 1 O O o Single Format E N NN N N Q All Formats 1 1 1 1 1 1 10Q UDC 00 1 OO Single UDC N N NN UN N Q N All UDCs 1 1 1 1 1 1 1Q Fent 1 0 31 0 6 Single F
110. ter parallel A communication scheme in which the bits of a byte are transferred simultaneously over a multistrand cable picket A method of bar code printing in which the bars in the bar code print one at a time in a series The bar code appears along the length of the label EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 107 Glossary 108 pitch 1 The number of characters printed in one horizontal inch determined by the increment by which the printer platen moves 2 Rotation of a bar code symbol about an axis parallel to the direction of the bars point size A unit of measure for font height 72 points equals 1 inch as measured from slightly above the top of the uppercase letters to slightly below the bottom of the lowercase descenders Polling Mode D protocol Polling Mode D is a protocol that allows devices and controllers to exchange data in an ask and receive format Use Polling Mode D to connect multiple devices to a single multiport controller print speed Measured in inches per second ips the rate at which media travels past the printhead printhead The mechanism inside the printer that prints The printhead for the 4420 printer consists of 896 thermal elements The printhead for the 4440 printer consists of 1792 thermal elements printhead elements The parts of the printhead that print by placing a mark on the label when heated Each element on the 4420 printer is 0 005 inches sq
111. ter User s Manual Using the Feed Pause Button Chapter 1 Getting Started The Feed Pause button located on the front panel of the 4420 or 4440 printer performs several functions depending on the mode of the printer Feed Pause Button Functions Printer Mode You Want To Idle Feed out one label or a minimum specified amount of media What to Do Press and release the Feed Pause button feedContPress and hold the Feed Pause button inuously media Take the printer offline Printing Pause the printer Cancel the current print job Turned on for Print the hardware the first time configuration test label Preparing the Printer for Installation When you release the button the media stops feeding Press the Feed Pause button twice Press the button again to bring the printer online Press and release the Feed Pause button Press and release the button again to resume printing Press and hold the Feed Pause button until the printer stops printing Press and hold the Feed Pause button See Printing the Hardware Configuration Test Label later in this chapter EasyCo der 4420 and 4440 Bar Before connecting the printer to your data collection system you need Code to Label Printer connect the printer to a power source User s 2 open the printer 3 load media 4 load ribbon Manual 5 print a hardware configuration test label These steps are described
112. the top of form TOF switch The TOF switch controls the position of the format forward or backward along the length of the label Only use the TOF switch to fine tune the label format position after you design the label Use PrintSet or the IPL top of form command to control the default TOF setting For help on using the top of form command see the PrintSet online help or the PL Programming Reference Manual P N 066396 The printer returns to the default TOF setting when you e cycle printer power e lift the printhead EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 51 Chapter 5 Optimizing Printer Performance 52 44XXU045 eps TOF switch The TOF switch is a small rocker switch located on the lower outboard plate of the printer To move a label format backward with the TOF switch Note You will see the new format position on the second label you print after pressing the TOF switch You notice that the format is printing toward the front part of the label A Label direction from printer 2 z z n2 N e 4 0 0 0 co D oz ox ox 5 3 3 m m m m OO ok Qos O H cog 22 gg eg ES a a a o oc oc oe X 0 ae uoo o ck es a B a s o o o o QN A HAXXUOAT CDS EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 5 O
113. tional storage flash SIMM 57 expansion option 81 increasing amount available limitations 57 reset using 65 returning printer to default settings 65 specifications 77 usage limitations 57 problems 57 using efficiently 57 MicroPDF417 83 mnemonic code definition 107 modem DTE to DCE cable schematics MSN See media sensitivity number Multi Drop protocol definition 107 described 96 41 43 57 65 102 N network connecting to the printer 23 nibblized definition 107 O OCR font definition 107 offline definition 107 on off switch 6 online definition 107 opening the printer 7 operation problems troubleshooting 40 optimizing print speed and image band settings 59 options printer 79 over temperature condition 4 P page definition 107 pages copying to another printer See selective transfer parallel port bi directional communications interface 98 using to connect a PC to the printer 23 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual parallel definition 107 PDF417 83 picket definition 107 pitch test label printing 64 pitch definition 108 plugging in the printer 6 point size definition 108 Polling Mode D protocol definition 108 described 96 POSTNET 82 power loss troubleshooting 40 Power Data LED 4 preparing the printer for installation 5 preventing dataloss 44 print darkness adjusting with darkness adjust control 49 adjusting with
114. to a PC using the parallel port 23 using the serial port 23 printer to an AS400 24 printer to power source 6 printer to system 22 using the parallel port 22 using the serial port 22 core locking brackets changing 11 cutter option 80 D darkness adjust control setting 49 using for optimal print quality 49 data file definition 104 Data Line Print 64 definition 104 entering 64 using to test the operation of the printer 64 using to troubleshoot printer 64 data loss checking for communications problems 45 preventing 44 Data Matrix 83 default settings See factory default settings density definition 104 dimensions printer 76 DIP switch settings chart 26 configuration commands 66 descriptions 25 for dot increments 67 Test and Service mode 63 direct thermal definition 104 dot increments setting the number of 67 downloading definition 27 drag definition 104 E EAN definition 105 described 81 EasyLAN 101 interface option 79 EasyLAN 10i2 adapter accessory 80 EasyLAN Wireless interface option 80 electrical requirements 76 Empty Pause LED 4 Emulation mode 69 definition 105 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Index international character sets 86 setting with DIP switches 69 entering Test and Service mode 62 environment specifications 76 Ethernet interface option See EasyLAN 10i interface option exiting Test and Service mode 62 extended
115. trip pin FS Label skipping DC2 Printing DC2 Ready DC2 If the host ignores the printer sending an XOFF the printer resends an XOFF after receiving every 15 characters from the host In the case of transmission error the printer discards the characters with the error and keeps the rest of the message block 95 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Appendix C Communications Reference Polling Mode D Polling Mode D is a block transfer protocol that transmits data in blocks of up to 255 characters including protocol overhead For Polling Mode D the host concentrator is responsible for asking the printer for data it might have polling and requesting to send data to the printer selecting LRC characters frame the blocks for additional data integrity Use Polling Mode D for point to point networks that connect the printer to an Intermec port concentrator RS 232 or RS 422 are acceptable This protocol is the default setting for the 4420 and 4440 printer Return the protocol setting to Polling Mode D by setting the printer DIP switches to the factory default settings 9600 E 7 1 or by sending down the Test and Service mode command D Multi Drop Protocol Hardware Protocol 96 Use Multi Drop protocol to connect up to 32 devices to an Intermec controller on a four wire RS 485 two twisted pair This protocol is similar to Polling Mode D except each device has a unique address POL and SEL charact
116. tting the Number of Dot Increments You can move the label rest point and X forms adjust configuration commands forward or backward by setting the printer DIP switches Use the top bank of DIP switches to determine whether the movement is forward or backward Use the bottom bank of DIP switches to set the number of dot increments for label rest point X forms adjust and Y forms adjust The printer moves in 5 mil increments or 0 005 inch per dot Bottom Bank OFF 5 ln ls ele 0 OFF ON VA JS IIS DA gu 1 2 3 4 5 of Dot Increments 1 1 Oo oo O 2 O 1 o oO 10 3 1 1 10 o oO 4 o o 1 O O 5 1 o 1 o 10 6 10 1 1 o o 7 1 1 1 10 10 8 10 o o 1 o 9 1 o Oo 1 o 10 o 1 o 1 Oo 11 1 1 o 1 10 12 Oo 10 1 1 o 13 1 o 1 1 o 14 o 1 1 1 o 15 1 1 1 1 10 16 10 10 o o 1 17 1 o o oO 1 18 10 1 o o 1 19 1 1 o Oo 1 20 10 10 1 Oo 1 21 1 o 1 Oo 1 22 10 1 1 o 1 23 1 1 1 o 1 24 10 o 10 1 1 25 1 o o 1 1 26 o 1 10 1 1 27 1 1 10 1 1 28 o o 1 1 1 29 1 o 1 1 1 30 Oo 1 1 1 1 44X XU063 eps Dot increments DIP switch settings This illustration shows the dot increment settings for the bottom bank of switches See the previous illustration Configuration DIP switch settings for the top bank DIP switch settings To set the number of dot increments 1In the top bank turn the appropriate switches on or off for forward or backward movement See the Configurati
117. twork an AS 400 or other midrange or a mainframe This section explains how to connect the printer to any of these systems You can use any of these three ports on the rear of the printer e Serial communications port e Parallel port e Optional I O board port if you have an interface card installed Optional I O 44XXU012 eps Printer ports This illustration shows you where to connect your system to the printer Connecting the Printer to a PC You can connect the printer to either a serial COM port or a parallel port on your PC You must provide the correct cables for connecting the printer Contact your Intermec representative for ordering assistance if you do not have the appropriate cables 22 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 2 Installing the Printer Connecting the Printer to a PC Serial Port To comnect the 4420 or 4440 to your PC serial port you need a shielded EIA RS 232 RS 422 or RS 485 electrical interface with a 25 pin D style subminiature connector You can purchase the Intermec serial 9F 25M null modem cable P N 048693 or purchase a compatible cable from your local computer store Currently Intermec does not offer a cable for the RS 422 interface However you will find a schematic in Appendix C that you can use to purchase or make your own cable Also see Appendix C for the RS 232 RS 422 and RS 485 serial port assignments T
118. ty Number If you need help select the 567 Print Quality Wizard pushbutton Print Darkness e Print Lighter 0 Darker du Quality Cancel AClick OK 5 Download your change to the printer by pressing the button to send command updates to the attached printer E Setting the MSN for Other Media and Ribbon If you are not using Intermec media and ribbon or you misplaced your packaging with the three digit sensitivity number label on it you can set the approximate sensitivity rating The first column of the Direct Thermal and Thermal Transfer Media Sensitivity Settings tables list the approximate sensitivity settings To achieve acceptable print quality enter the three digit MSN for example 800 If you are unsure of how to set the media sensitivity rating start with the highest setting which provides the lowest energy 800 for thermal transfer and 700 for direct thermal and work your way down until you achieve the best print quality 14 Note The hardware configuration label defines the above parameters Individual values vary between printers Use the maximum recommended print speed only as a guideline Optimize your individual print speed based on your media and the format that you want to print If you exceed the maximum recommended print speed you may notice reduced print quality EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 17 Chapter 1 Getting Started 18 Direct
119. uality If printing is light on If printing is light on the the right side of label rur s 4 left side of label turn the T turn the bias adjust screw a ias adjust SCrew c 44XXU044 eps 3 Replace the media cover Adjusting the Print Darkness Use the darkness adjust control in combination with the Print Darkness adjustment in PrintSet to fine tune the darkness of print on the labels The fine adjustments compensate for variations in the media lot to lot the printhead or the printer Set the darkness adjust control after you enter the media sensitivity number For the best results in adjusting the print darkness energy to the printhead perform these procedures in order 1 Set the correct sensitivity number 2 Adjust the manual darkness adjust control on the back of the printer 3 Adjust the Print Darkness setting in PrintSet To adjust the manual darkness adjust control 1 Locate the darkness adjust control on the back of the printer 2 Use a small straight slot screwdriver to adjust the print darkness e To increase the print darkness turn the control clockwise e To decrease the print darkness turn the control counterclockwise EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 49 Chapter 5 Optimizing Printer Performance 50
120. uality problems e Communication problems e Preventing data loss EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 39 Chapter 4 Troubleshooting the Printer Troubleshooting Checklist You may have printer operation print quality or printer communications problems at some time during the life of the printer It is easy to fix most of the problems and consequently not delay operation of the printer for very long To troubleshoot the printer First try cleaning the printer components and checking all of the connections See Chapter 3 Maintaining the Printer for details 2 If cleaning the printer and checking the connections does not solve the problem use the following tables to locate the symptom Follow the solution in the table to fix the problem If you receive an error message refer to the IPL Programming Reference Manual P N 066396 for a complete list of error messages and their solutions An electronic copy of the IPL Programming Reference Manual is available on the Internet at www intermec com If the problem persists contact an Intermec customer service representative In the U S A call 1 800 755 5505 and in Canada call 1 800 668 7043 If you are an international customer contact your local Intermec representative Printer Operation Problems If the printer is not operating correctly try locating the problem in the table below Printer Operation Problems Symptom Possible Cause
121. uare in area Each element on the 4440 printer is 0 0025 inches square in area Each element is switched on and off separately in order to react with the media or thermal transfer ribbon to create a mark on the label ready The state in which the printer is able to print the normal operating state of the printer Ready Busy line Pin 11 20 of the rear panel connector Indicates whether the printer is ready or not ready busy RS 232 Widely recognized protocol standard for serial binary data interchange The standard covers the physical electrical and functional characteristics of the interface EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Glossary RS 422 Standard for the voltage and impedance levels for serial data transmission on balanced lines Similar to RS 232 but handles larger distances and faster communication RS 485 Standard for allowing multiple devices to share a common set of serial data communication lines The signaling is very similar to RS 422 The maximum number of devices allowed is 32 scan To read a bar code with a device known as a scanner that converts optical information into electrical signals scannable A symbol that can be successfully scanned and correctly decoded selective transfer A procedure that copies selected formats fonts graphics or pages stored in the memory of one printer to the memory of another self strip An optional factory installed device for t
122. umerous fields with different rotations graphics or combinations of these formatting options may require a higher number of image bands EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 5 Optimizing Printer Performance To set the number of image bands use PrintSet or the IPL command For help see the PrintSet online help or the JPL Programming Reference Manual Optimizing Print Speed and Image Band Setting The maximum number of image bands available for use is 20 bands The minimum number of image bands available is 2 To optimize the number of image bands for your print speed 1 Set the image band setting at the lowest number 2 2 Print a label at the desired speed If the label prints the image band setting is optimal You do not need to perform any more adjustments If the number of image bands is too low the printer aborts the label before printing is completed and attempts to reprint the label at the slowest speed 2 ips with the highest number of image bands 20 You need to continue with Step 3 3 Return to the original print speed and increase the original number of image bands one at a time Continue to increase the number of image bands until the printer prints a label correctly If the printer still aborts and reprints at the highest image band setting you may be trying to optimize at a print speed that is too high for the label format Try optimizing the number of image bands at
123. up on the middle of the bracket and use your index finger to slide the other end of the bracket into the remaining bracket slot on the ribbon hub Core locking bracket Bracket slot To load thermal transfer ribbon Make sure you have raised the printhead If not turn the head lift lever clockwise until it releases the printhead 2 Place the empty ribbon core that came with the printer onto the ribbon rewind hub 3 Detach the leader from the new thermal transfer ribbon roll and unwind the end of the ribbon approximately 20 32 cm 8 in The edge of the ribbon has a leader with an adhesive strip on the leader edge for guiding the ribbon through the printhead mechanism 4 Slide the roll of thermal transfer ribbon onto the ribbon supply hub with the ribbon roll winding clockwise 5 Route the ribbon leader through the printer mechanism as shown in the following illustration 6 Attach the leader from the new thermal transfer ribbon roll to the empty ribbon core using the adhesive strip on the leader edge 14 Note Make sure the ribbon runs above the upper media guide The shiny side of the ribbon must come in contact with the printhead 7 Wind the ribbon rewind hub clockwise until the ribbon runs smoothly through the printhead mechanism and the leader moves past the printhead 12 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Chapter 1 Getting Started Empty ribbon roll Thermal trans
124. ve To search for your local representative from the Intermec web site click Contact Who Should Read This Document Analysts and programmers should use this manual to learn how to operate program and connect the printer to a network or system The first part of this manual tells you how to install operate maintain and troubleshoot your printer The last part of the manual covers advanced features of the 4420 and 4440 printers A basic understanding of programming and data communications is necessary EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual Before You Begin Related Documents The Intermec web site contains Intermec documents in PDF that you can download for free To download documents 1 Visit the Intermec web site at www intermec com 2 Click Service amp Support gt 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 EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual xi Before You Begin xii EasyCoder 4420 and 4440 Bar Code Label Printer User s Manual 1 Getting Started This chapter introduces the 4420 and 4440 printer and explains how to get your new printer up and running This chapter covers these topics e Learning about the printer e Understanding the front panel e Preparing the printer for installation
125. ware configuration label and then enters Data Line Print mode 3 Set the DIP switches to print out the test label of your choice software print quality or pitch Refer to the Test and Service DIP Switch Settings table for the correct settings 4 Hold the Feed Pause button down until the printer starts printing The printer begins printing out the test label immediately 5 Exit Test and Service mode by turning the printer off and returning all DIP switches to their original settings Using Data Line Print Mode Use Data Line Print mode to troubleshoot communications between the printer and host and to test the operation of the printer When the printer is in Data Line Print mode it prints all downloaded data with the hexadecimal equivalent directly underneath it Hold the Feed Pause button down momentarily to suspend the test Press the Feed Pause button longer to transmit the firmware program and version number to the host To enter Data Line Print mode Turn off the printer 2 Press down and hold the Feed Pause button while turning on the printer The hardware configuration test label is printed You are now in Data Line Print mode Performing Selective Transfer 64 If you want to copy select formats pages fonts or graphics to another printer but you do not want to clone the entire RAM contents use the selective transfer command Use this command to set up different printers to print the same label formats E

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