4004PD45S Industrial Plus

Honeywell PD45S Industrial Plus error 4004: Gap/Mark

The Honeywell PD45S Industrial Plus error 4004 is a media registration fault occurring when the printer's sensors cannot identify the gap between individual labels or the registration mark on a continuous web. This leads to printing over the gaps or stopping mid-page. Fixing the Honeywell PD45S Industrial Plus error 4004 requires verifying that the printer's media sensor aligns properly with the media's registration feature.

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Common causes

  • 1Sensor incorrectly aligned with the label gap.
  • 2Incorrect media type setting (Gap vs. Black Mark).
  • 3Optical sensor blockage due to adhesive glue residue.
  • 4Faulty led sensor light source.

Solutions

Quick Diagnosis

If the printer feeds labels continuously without stopping, or stops randomly regardless of label length, it is failing to detect the media edges (gaps).

Steps to follow

  1. 1

    Align labels

    Ensure the label gap or black mark is aligned exactly under the sensor eye.

  2. 2

    Calibrate media

    Trigger the media calibration routine from the device menu.

  3. 3

    Check media type

    Verify your label settings in the printer menu (Gap vs. Black mark).

Frequently asked questions

The error triggers because the printer fails to identify the gap between labels or the registration black mark.

Use the sensor adjustment dial to move the detection gate into line with your specific media format.

Standard thermal transfer labels compatible with the detection method you have enabled.

Cleaning the sensor after changing media rolls is critical for error-free performance.