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User’s Guide EasyCoder PD4 Bar Code Label Printer...
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The information contained herein is proprietary and 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.
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EN50081-1 (EN55022 CLASS A) and EN61000-4-2/-3/-4/-5/-6/-8/-11 (IEC Teil 2,3,4). The equipment also tested and passed in accordance with the European Standard EN55022 for the both Radiated and Conducted emissions limits. Intermec EasyCoder PD4—User’s Guide...
Global Services and Support ............x Warranty Information ............x Web Support ..............x Telephone Support ............x Related Documents ............x Introduction Description of EasyCoder PD4 ............2 Safety Warnings ................3 Product Identification ..............3 Installation Unpacking the Printer ..............6 Front View ..................7 Rear View ..................8...
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Printhead Pressure Adjustment .............59 Printhead Dot Line Position Adjustment ........60 Label Gap Sensor Position Adjustment ........62 Label Gap Sensor Calibration ............63 Ribbon Tension Adjustment ............64 Ribbon Shield Adjustment ............65 Switching Edge Guide ..............66 Intermec EasyCoder PD4—User’s Guide...
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Self-Adhesive Strip ............76 Self-Adhesive Labels ............77 Tickets with Gaps ............79 Tickets with Black Mark ..........81 Interfaces RS-232 Interface ................84 Protocol .................84 Interface Cable ..............84 USB Interface ................85 Parallel Interface ................86 Firmware Upgrading Requirements ................88 Instructions ..................88 Intermec EasyCoder PD4—User’s Guide...
Safety Summary 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.
(ESD). When you see this icon, you must follow standard ESD guidelines to avoid damaging the equipment you are servicing. Note: Notes either provide extra information about a topic or contain special instructions for handling a particular condition or set of circumstances. Intermec EasyCoder PD4—User’s Guide...
To understand the warranty for your Intermec product, visit the Intermec web site at http://www.intermec.com and click Service & Support. The Intermec Global Sales & Service page appears. From the Service & Support menu, move your pointer over Support, and then click Warranty. Web Support Visit the Intermec web site at http://www.intermec.com...
Introduction This chapter introduces the EasyCoder PD4 printer. The chapter covers the following topics: • Description of EasyCoder PD4 • Safety summary • Product identification Intermec EasyCoder PD4—User’s Guide...
The EasyCoder PD4 is a basic-performance thermal transfer/direct ther- mal label printer suitable for medium-duty industrial applications. With robust metal outer casing and inner mechanics, the EasyCoder PD4 provides durability, even in industrial environments. The EasyCoder PD4 comes in three main versions:...
• Carefully read the warning text on the envelope before using a clean- ing card. Product Identification The machine label is attached to the printer’s rear plate and contains information on type, model, and serial number as well as AC voltage. It also contains various signs of approval. Intermec EasyCoder PD4—User’s Guide...
Installation This chapter explains how to unpack and install the EasyCoder PD4 printer and also describes the printer’s various parts in detail. It covers the following topics: • Unpacking the printer • Parts on the printer’s front • Parts on the printer’s rear plate •...
• Check that any options you ordered are included. • Check that all the accessories are included. As standard, the box con- tains: - Intermec EasyCoder PD4 printer - Power cord - Parallel cable - High edge guide...
The front cover can be removed for loading of labels at peel- off (self-strip) operation and for installation of a cutter (options). Control lamps LCD display (some models only) Control keys Front cover Side door with inspection window Intermec EasyCoder PD4—User’s Guide...
The rear plate contains the On/Off switch, the AC power cord socket, and various interface connectors and slots. Serial port USB port Parallel port On/Off Switch AC Power cord socket Intake slot for external fan-fold supply Intermec EasyCoder PD4—User’s Guide...
The media can be supplied from a supply post, or from an external supply of fan folds behind the printer. Side door (opened) Ink position lever Supply post Edge guide Ribbon supply shaft Ribbon rewind shaft Ribbon rod Printhead lever Intermec EasyCoder PD4—User’s Guide...
In front of the print mechanism is a fold-out label taken sensor, which can hold the printing of next label until the previous one has been removed. Label taken sensor Label feed guide Printhead pressure Printhead adjusters lever Thermal printhead Tear bar Intermec EasyCoder PD4—User’s Guide...
(100 to 240 VAC). Computer The EasyCoder PD4 is fitted with one 36-pin Centronics socket for the parallel interface, one 9-pin D-style subminiature (DB9) socket for the RS-232 serial interface port and one class B connector for the USB inter- face port (see Appendix C).
Chapter 2—Installation Controls and Indicators The EasyCoder PD4 has several ways of communicating directly with its operator: • Three control lamps, • a graphic display window with background illumination, • three control keys, • and a beeper. Control Lamps The LED (Light Emitting Diode) control lamps are labelled “Power”, “Ready”, and “Error.”...
In Dump Mode Enter Direct Mode Reset printer to default (press >3 sec.) In paused Direct Enter Direct Mode Mode In paused Print Continue printing Cancel printing Mode (press >1 sec.) In Autosensing Cancel autosensing Mode Intermec EasyCoder PD4—User’s Guide...
Starting Up This chapter explains how to start up the printer after installation or after having been switched off. It covers the following topics: • Switching on the printer • Direct Mode • Printing a test label Intermec EasyCoder PD4—User’s Guide...
Download Mode by sending a Reset command (^@) or rebooting the printer. If you take none of the actions described above, the printer will enter the Direct Mode, which is indicated in the display window: Intermec EasyCoder PD4—User’s Guide...
• Pause the Direct Mode by pressing the Pause key. When the Direct Mode is paused, this message is displayed: • Enter the Setup Mode by simultaneously pressing the Feed and Pause keys (see Chapter 5). Intermec EasyCoder PD4—User’s Guide...
LSS (liner+label – detection level – liner) Date Time Example of a test label from an 203.2 dpi (8 dots/mm) EasyCoder PD4. For the meaning of the various commands, refer to the ESim v5.xx for EasyCoder PD4, Programmer's Reference Manual.
Chapter 4— Loading Media Tear-Off (Straight-through) The EasyCoder PD4 can print on labels, tickets, tags, and continuous stock in various forms. This section describes the case when the media is torn off manually against the printer’s tear bar. This method is also known as “straight-through printing.”...
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Pull out the printhead lever and flip it Open the side door. counterclockwise a quarter of a turn. Place the media roll onto the media supply roll post and align the media to Flip the label feed guide upward. the printer's center section. Intermec EasyCoder PD4—User’s Guide...
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This diagram shows the media path This diagram shows the media path when using an external supply of, for when using and internal supply. example, fan-folded tickets. Intermec EasyCoder PD4—User’s Guide...
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Optionally, press the lower part of the feed rod and close the printhead. label taken sensor to flip it open. When in use, the label taken sensor should be in a horizontal position. Close the side door. Intermec EasyCoder PD4—User’s Guide...
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Chapter 4—Loading Media Tear-Off, cont. Press the Feed key to advance the media and adjust the media feed. Intermec EasyCoder PD4—User’s Guide...
Chapter 4—Loading Media Peel-Off (Self-strip) The EasyCoder PD4 can print on labels, tickets, tags, and continuous stock in various forms. This section describes the case when self-adhesive labels are separated from the liner immediately after printing. The liner is then wound up on an optional integral liner takeup hub (see Chapter 6 “Options”).
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(16 in) of the liner and route the liner around the tear bar, then back under Wrap the liner counterclockwise around the print mechanism and label feed rods the takeup hub and secure it with the to the takeup hub. U-shaped clip. Intermec EasyCoder PD4—User’s Guide...
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Optionally, press the lower part of the When in use, the label taken sensor label taken sensor to flip it open. should be in a horizontal position. Intermec EasyCoder PD4—User’s Guide...
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Chapter 4—Loading Media Peel-Off, cont. Press the Feed key to advance the media Close the side door. and adjust the media feed. Intermec EasyCoder PD4—User’s Guide...
The EasyCoder PD4 can use transfer ribbon rolls wound with the ink- coated side facing either outward or inward. Illustrations in this manual generally show the ink-coated side facing outward.
Ink facing outward on ribbon roll: Load a fresh ribbon roll onto the ribbon supply shaft (A) and an empty ribbon Route the ribbon as illustrated and stick core onto the ribbon rewind shaft (B). it to the take-up core. Intermec EasyCoder PD4—User’s Guide...
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Check that the ink position lever above Route the ribbon as illustrated and stick the ribbon supply hub is in correct it to the take-up core. position. Flip the printhead lever back to its original position and close the side door. Intermec EasyCoder PD4—User’s Guide...
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Chapter 4— Loading Media Intermec EasyCoder PD4—User’s Guide...
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All these parameters and several others can also be set using ESim commands. The chapter covers the following topics: • Controlling the printer • Setup methods • Navigating in the Setup Mode • Setup options table Intermec EasyCoder PD4—User’s Guide...
This is indicated in the display like this: The operator can also cancel the printing of the remainder of a batch print job by pressing the Cancel key for more than 2 seconds. When the printing is completed, the display shows: Intermec EasyCoder PD4—User’s Guide...
Chapter 5—Printing Setup Methods The EasyCoder PD4 can be set up using two methods: • Using ESim Commands This method support all setup parameters and uses various ESim com- mands transmitted from the host computer to the printer. Please refer to ESim v5.xx for EasyCoder PD4, Programmer’s Reference Manual.
Default 2 bits English Default LCD Language Simplified Chinese Chinese characters Traditional Chinese Chinese characters Setting review Review setting items without any changes (scroll by pressing Pause) Exit & Save Default Exit Exit & No save Intermec EasyCoder PD4—User’s Guide...
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Chapter 5—Printing Note: Do not use a higher density setting than required for your media and application. Lower density setting saves your printhead and extends its life. Intermec EasyCoder PD4—User’s Guide...
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Options This chapter describes the options available for the EasyCoder PD4 printer. The options can be factory installed, field-installed by an authorized service tech- nician, or installed by a trained operator. The options are: • Stripper and Internal Rewinder • Cutter...
1 Remove the screw that holds the front cover. Remove the front cover. Front cover Screw 2 Open the side door and remove the rewinder option cover plate, which is held by two Phillips screws. Cover plate Intermec EasyCoder PD4—User’s Guide...
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4 Plug in the cable from the rewinder switch into the front one of the two connectors in the center section. Switch Rewinder cable 5 Install the media as described in Chapter 4 “Media Load”, section “Peel-off (Self-strip).” Intermec EasyCoder PD4—User’s Guide...
1 Remove the screw that holds the front cover. Remove the front cover. Front cover Screw 2 Open the side door and remove the tear bar, which is held by two Phillips screws. Screws Tear bar Intermec EasyCoder PD4—User’s Guide...
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4 Plug in the cable from the cutter into the rear one of the two con- nectors in the center section and fasten the cable to the bottom plate using the two cable clips included in the kit. Cutter connector Cutter cable Cable clips Intermec EasyCoder PD4—User’s Guide...
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Note: Make sure that the printer is set to use the cutter, either in the Setup Mode (see Chapter 7) or using an O command, see ESim v5.xx for EasyCoder PD4, Programmer’s Reference Manual. The label taken sensor cannot be used with the cutter.
Troubleshooting This chapter lists various possible cases of inferior printout quality, describes possible causes, and sug- gests remedies. Intermec EasyCoder PD4—User’s Guide...
72: Flashing not completed (RESET) Switch power off/on or send ^@ cmd 73: Download error (RESET) Switch power off/on or send ^@ cmd 81: Cutter jammed or not installed Clear media from cutter or disable cutter Intermec EasyCoder PD4—User’s Guide...
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Check if thermal printhead needs cleaning was not printed along the feed direction Check if application software has errors Check ribbon for creases and wrinkles. See Ribbon Tension Adjustment and Ribbon Shield Adjustment in chapter 9. Intermec EasyCoder PD4—User’s Guide...
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When using stripper, abnormal function Check if stripper full sensor is working occurs Check if media is loaded properly Note: If further problems should occur, please contact your distributor for more information. Intermec EasyCoder PD4—User’s Guide...
3 After the media jam is cleared, switch on the power to the printer, and the cutter blade will go back to its original position. Note: It is recommended to use labels with a length of 30 mm (1.18 in) or more. Intermec EasyCoder PD4—User’s Guide...
In the Dump Mode, you can reset the printer to its default setup values by pressing the Cancel key for 3 seconds or more. To exit the Dump Mode and enter the Direct Mode, tap the Feed key. Intermec EasyCoder PD4—User’s Guide...
This chapter describes how the operator can maintain the printer. Regular maintenance is important for the printout quality and for the life of the printhead. The chapter covers the following topics: • Printhead cleaning • External cleaning • Printhead replacement. • Media jams. Intermec EasyCoder PD4—User’s Guide...
Never use any hard or sharp tools to peel away stuck labels or similar. The printhead is delicate and can easily be dam- aged. 6 Allow the printhead to dry for a minute or so before loading a new supply of media and ribbon. Intermec EasyCoder PD4—User’s Guide...
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Chapter 8—Maintaining the Printer Clean the printhead dot line. Intermec EasyCoder PD4—User’s Guide...
Stuck labels should be peeled away using your fingers only. If necessary, dissolve the adhesive using isopropyl alcohol first. Isopropyl alcohol [(CH CHOH; CAS 67-63-0] is a highly flammable, moderately toxic, and mildly irritating sub- stance. Intermec EasyCoder PD4—User’s Guide...
5 Pull out the printhead straight forward. 6 Insert the replacement printhead so it engages the connectors on the printhead bracket. 7 Reload the transfer ribbon, close the printhead, close the side door and switch on the power. Intermec EasyCoder PD4—User’s Guide...
CHOH; CAS 67-63-0] is a highly flammable, moderately toxic, and mildly irritating sub- stance. • Reload the media as described in Chapter 4. • Switch on the power. • Readjust the media feed by pressing the Feed key. Intermec EasyCoder PD4—User’s Guide...
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• Printhead balance adjustment • Printhead pressure adjustment • Printhead dot line position adjustment • Label gap sensor position adjustment • Label gap sensor calibration • Ribbon tension adjustment • Ribbon shield Adjustment • Switching edge guide Intermec EasyCoder PD4—User’s Guide...
Balance box 5 Engage the printhead and load the ribbon. 6 Test and readjust if necessary. (Hint! If you use direct thermal media you will not have to load and remove the ribbon over and over again.) Intermec EasyCoder PD4—User’s Guide...
5 Engage the printhead and load the ribbon. 6 Test and readjust if necessary. (Hint! If you use direct thermal media you will not have to load and remove the ribbon over and over again.) Intermec EasyCoder PD4—User’s Guide...
3 Important step! Use a straight-slot screwdriver to turn the two screws at the top of the printhead bracket counterclockwise a single turn. 4 Lift the printhead by pulling out the printhead lever and flipping it counterclockwise a quarter of a turn. Intermec EasyCoder PD4—User’s Guide...
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7 Load the ribbon (only in case of thermal transfer printing). 8 Test and readjust if necessary. (Hint! If you use direct thermal media you will not have to load and remove the ribbon over and over again.) Intermec EasyCoder PD4—User’s Guide...
Use the lever at the rear side of the print mechanism to move the sensor inward or outward. The point of detection can be seen from the front when the printhead is lifted. Sensor lever Point of detection Intermec EasyCoder PD4—User’s Guide...
6 The printer switches automatically to the Direct Mode. To break the Autosensing Mode before it is finished and enter the Direct Mode, press the Cancel key. Intermec EasyCoder PD4—User’s Guide...
If the printer have problems pulling the labels (especially when using a ribbon less than 50 mm/2 in wide), push the knob at the end of the ribbon supply hub inwards (1) and rotate it counterclockwise to decrease the breaking force (2). Intermec EasyCoder PD4—User’s Guide...
Screw adjustment must not exceed two full turns. In such a case, paper feed may not be smooth and the screws need to be turned counterclockwise completely and readjusted from start. Test Label A Test Label B 1234567890 1234567890 Intermec EasyCoder PD4—User’s Guide...
Chapter 9—Adjustments Switching Edge Guide As standard, the EasyCoder PD4 is fitted with a low edge guide on the media supply roll post. The low edge guide makes it simple to fit a media supply roll on the post, but it only guides the core of the roll. Therefore, the EasyCoder PD4 is delivered with an enclosed high edge guide which the user can fit quite easily when the application so requires, for example...
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Washer Coil spring Post Adjust for width Fold down of media roll for media load Be careful to flip the high edge guide straight up before closing the side door, or the guide could be damaged. Intermec EasyCoder PD4—User’s Guide...
Technical Data This appendix lists the technical data for the printer. Please note that Intermec reserves the right to change without prior notice and that this information does not represent a commitment on the part of Intermec. Intermec EasyCoder PD4—User’s Guide...
Inner Core Diameter 25.2 to 25.6 mm (1.00 inches) Modes of Operation Tear-Off (Straight- through) Peel-Off (Self-strip) Optional Cut-Off Optional Firmware Operating System ESim v5.xx Latin Fonts 5 resident alphanumeric fonts. Windows bitmap fonts can be down- loaded. Intermec EasyCoder PD4—User’s Guide...
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Moveable, left- Out of Media aligned Printhead Lifted Ribbon End Label taken Controls Control Lamps 3; Power, Ready, and Error Bi-color Display Graphic LCD with back- ground light Control Keys 3; Feed, Pause, and Cancel Beeper Intermec EasyCoder PD4—User’s Guide...
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Accessories and Options Integral Self-strip Unit Option For peel-off with Liner Takeup operation Cutter Option 2MB Flash Memory Option Expansion Module Keyboard/Display Unit Option EasyLAN 10 External Option Ethernet Adapter /. Versions with graphic display front panel only. Intermec EasyCoder PD4—User’s Guide...
Media rolls to be loaded inside the printer should be wound with the printable side facing outwards. The media supply must not be exposed to dust, sand, grit, etc. Any hard particles, however small, can damage the printhead. Intermec EasyCoder PD4—User’s Guide...
Appendix B—Media Specifications Media Non-Adhesive Strip ⇐ a ⇒ Media Width Maximum: 118.0 mm (4.65 inches) Minimum: 25.0 mm (1.00 inches) Paper Type Setup • Plain paper NON-ADHESIVE STRIP Intermec EasyCoder PD4—User’s Guide...
⇐ c ⇒ Media Width (excluding liner) Maximum: 116.4 mm (4.58 inches) Minimum: 23.8 mm (0.94 inches) Paper Type Setup • Plain paper SELF-ADHESIVE STRIP Intermec EasyCoder PD4—User’s Guide...
The Label gap sensor must be able to detect the extreme front edges of the labels. It can be moved 0 to 57 mm (0 to 2.24 inches) from the inner edge of the media (see Chapter 9). Paper Type Setup • Gap paper Intermec EasyCoder PD4—User’s Guide...
Minimum: 1.2 mm (0.05 inches) Paper Type Setup • Gap paper Note: Do not allow any perforation to break the edge of the media as this may cause the media to split and jam the printer. Intermec EasyCoder PD4—User’s Guide...
Note: The black mark should be non-reflective carbon black on a whitish background. Do not allow any perforations to break the edge of the media as this may cause the media to split and jam the printer. Intermec EasyCoder PD4—User’s Guide...
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Appendix B—Media Specifications TICKETS WITH MARKS FEED DIRECTION Intermec EasyCoder PD4—User’s Guide...
Interfaces This appendix describes the interface connectors found on the printer’s rear plate. It covers the follow- ing topics: • RS-232 interface • USB interface • Parallel Interface Intermec EasyCoder PD4—User’s Guide...
Signals on printer’s serial port: DB-9 Signal Meaning External +5V DC Max 500mA, permanently enabled Transmit data Receive data Ground Clear to send Request to send Interface Cable Computer end: Depends on computer model Printer end: DB-9pin plug Intermec EasyCoder PD4—User’s Guide...
USB port on the host, either directly or via a hub. Other devices, like a keyboard and a mouse, can be connected to the same hub. If you need to connect more than one Intermec USB printer to a host, you should use different USB ports.
Data 0-7 host /Acknowledge printer Busy printer /Paper empty printer /Select printer 14-16 Not connected Chassis ground External +5V DC Max 500mA, permanently enabled 19-30 Signal ground Not connected /ERROR printer Signal ground 34-36 Not connected Intermec EasyCoder PD4—User’s Guide...
To upgrade the printer’s firmware via a cable connection from a PC run- ning MS Windows, you will need the following: • The Intermec EasyCoder PD4 Config Tool. This is a free software running under Microsoft Windows . It makes it possible to download various firmware version either directly to the printer or to a memory...
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Intermec Technologies Corporation Corporate Headquarters 6001 36th Avenue West Everett, WA 98203 U.S.A. tel 425.348.2600 fax 425.355.9551 www.intermec.com EasyCoder PD4 User’s Guide *1-960614-01* *1-960614-01*...