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I've printed images over 500kb. Can you print a small image? If not, perhaps the driver is the problem.
If you're trying to send a text file of IPL commands to the printer, set up a Generic Text printer driver, to to send the file as ascii characters instead of as a graphic image. You can set this up in addition to your Intermec driver.
Go to Printers and Faxes, Add Printer, Next, Select the Port, Select "Generic" Manufacturer, "Generic / Text Only" Printer, and give it a name like "Text". Cycle the printer power to clear previous attempts, then print the file to this printer name.
I am using Smartforms with Intermec printer 3400-e and it works in the correct way.
What is the software that you use to build the layout of the label? In my case Loftware.
What is the code to print the Barcodes.
In my case Code 39