Zebra P520i User's Manual

User’s Manual

P520i

Part Number.980477-001 Rev. B

© 2004 ZIH Corp.

FOREWORD

This manual contains installation and operation information for the P520i Series card
printers manufactured by Zebra Technologies Corporation.

RETURN MATERIALS AUTHORIZATION

Before returning any equipment to Zebra Technologies Corporation for in-warranty or
out-of-warranty repair, contact Repair Administration for a Return Materials
Authorization (RMA) number. Repack the equipment in the original packing material
and mark the RMA number clearly on the outside. Ship the equipment, freight prepaid,
to the address listed below:

For USA and Latin America:

Zebra Technologies Corporation

Card Imaging Division

1001 Flynn Road

Camarillo, CA. 93021-8706.USA

Phone: [phone]

FAX: [phone]

For Europe, Asia and Pacific:

EMEA Technical Support

Gordon Road

High Wycombe Bucks

HP13-6EQ UK

Phone: + 44 (0) 870 241 1527

FAX: + 44 (0) 870 241 0765

COPYRIGHT NOTICE

This document contains information proprietary to Zebra Technologies Corporation.
This document and the information contained within are Copyrighted by Zebra
Technologies Corporation and may not be duplicated in full or in part by any person
without written approval from Zebra. While every effort has been made to keep the
information contained within current and accurate as of the date of publication, no
guarantee is given that the document is error-free or that it is accurate with regard to
any specification. Zebra reserves the right to make changes, for the purpose of
product improvement, at any time.

TRADEMARKS

P520i is a service mark and Zebra is a registered trademark of Zebra Technologies
Corporation. Windows and MS.DOS are registered trademarks of Microsoft Corp. All
other trademarks or registered trademarks are marks of their respective holders.

iii

iii

iv

PRODUCT WARRANTY STATEMENT

Printers

All Zebra Card Printers are warranted against defects in material or workmanship for
twelve (12) months from the purchase date.

Proof of purchase or shipment date is required to validate the warranty period. The
warranty becomes void if the equipment is modified, improperly installed or used,
damaged by accident or neglect, or if any parts are improperly installed or replaced by
the user.

Note: Products returned must be packaged in the original or comparable packing and
shipping container. In the event equipment is not so packaged, or if shipping dama­ge is evident, it will not be accepted for service under warranty. Surface transporta­tion charges for return to customers in the continental United States is paid by Zebra.
Otherwise, Zebra pays CPT (carriage paid to) nearest airport, customer pays custo­mers, duties, taxes, and freight from airport to destination. If Zebra determines that
the product returned for warranty service or replacement is not defective as herein
defined, the customer will pay all handling and transportation costs.

Printheads

Since printhead wear is part of normal operation, the original printhead is covered by
a twelve (12) month warranty. Warranty period begins on purchase date.

To qualify for this warranty, the printhead must be returned to the factory or to an
authorized service center. Customers are not required to purchase Zebra supplies
(media and/or ribbons) for warranty qualification. However, if it is determined that the
use of other manufacturer supplies has caused any defect in the printhead for which
a warranty claim is made, the user is responsible for Zebra's labor and material
charges required to repair the defect. The warranty becomes void if the printhead is
physically worn or damaged, also if it is determined that failure to follow the preven­tive maintenance schedule listed in the User's Guide has caused defect in the thermal
printhead for which a warranty claim is made.

Spare Parts

All parts, maintenance kits, options kits, and print head accessories are warranted to
be free of defects in material and workmanship for 90 days (except where otherwise
denoted) from date of purchase. This warranty becomes void if the item is modified,
improperly installed or used, or damaged by accident or neglect.

v

DECLARATIONS OF CONFORMITY

This equipment has been tested and found to comply with the limits for a
Class B digital device, pursuant to part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against harmful interference in a
residential installation. This equipment generates, uses ans can radiate radio
frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular
installation. If this equipment does cause harmful interference to radio or tel­evision reception, which can be determined by turning the equipment off and
on, the user is encouraged to try to correct the interference’s by one or more
of the following measures:
Reorient or relocate the receiving antenna.
Increase the separation between the equipment and the receiver.
Connect the equipment into an outlet on a circuit different from that to which
the receiver is connected.
Consult the dealer or an experienced radio/TV technician for help.

The user may find the following booklet, prepared by the Federal
Communications Commission, helpful:
How to identify and resolve Radio/TV Interference Problems. This booklet is
available from the U.S. Government printing Office, Washington, D.C. 20402,
Stock No. 004-000-00345-4.
Use of a shielded cable is required to comply within Class B limits of Part 15
of FCC Rules.
Pursuant to Part 15.21 of the FCC Rules, any changes or modifications to this
equipment not expressly approved by Zebra may cause, harmful interferen­ce and void the FCC authorization to operate this equipment.

INDUSTRY CANADA NOTICE

This device complies with Industry Canada ICS-003 class B requirements.

Model: P520i conforms to the following specification:
FCC Part 15, Subpart A, Section 15.107(a) and Section 15.109(a)
Class B digital device

73/23/EEC

modified

by 93/68/EEC

1999/5/CE

EMC Directive

EN 55024 (2001)

EN 60950 (1992) and

Amendments A1 to

A11 (1997)

Immunity to Electromagnetic
Disturbances

Radio frequency interferences

89/336/EEC

modified by

92/31/EEC

and

93/68/EEC

RF Emissions control

RF Emissions and immunity
for radio equipment

Low voltage

Directive

R&TTE Directive

EN300330-2 V1.1.1

EN 55022 (1998)

EN 301489-3 V1.4.1

Product safety

For a formal Certificate, please contact Compliance Engineering at the
Camarillo facility.

vi

v

INTRODUCTION

Thank you for choosing the Zebra P520i Plastic Card Printer.

Zebra’s P520i card printers offer a low cost, high quality solution to those requiring
computer-controlled printing and encoding of credit card style plastic cards, Card
applications include personalized identification, access control, visitor, membership,
badges and tags.

This manual guides you to efficient start up and operation of your new Card Printer.

P520i printer models

The Zebra Product Number tells a story:

Here is a quick review of the Zebra Card Printer Series numbering and lettering
system to help you.

The P520i Plastic Card Printer employs Dye Sublimation and Resin Thermal Transfer
technologies. Model numbers include identifiers that specify options are shown using
the following lettering conventions:

P520i - X X X X X - X DO

Smart Card:

O = No
E = Yes

Magnetic Encoder:

O = No Windows Driver
M = Yes & User Documentation

Magnetic Encoder Options:

O = No
1 = Stripe down HICO
2 = Stripe Down LOCO
3 = Stripe Up HICO
4 = Stripe Up LOCO

Memory:
O = Standard Power Cord:
Interface: I = 120 Vac (US) and

U = Parallel & USB 220 Vac (Europe)
C = Ethernet & USB U = 240Vac (UK)

}

Ship-away kit

vii

vi

ICONS

Throughout this manual, different icons highlight important information, as follows:

Important general information.

Mechanical hazard, such as one associated with moving parts,
capable of resulting in equipment damage or personal injury.

Electrical hazard, such as an exposed voltage point, capable of
causing electrical shock and personal injury.

An area where electrostatic discharge (ESD) can cause
component damage. Use a grounding wrist band.

Elevated temperature hazard, capable of producing a burn.

Keep Card Printer clean by minimizing cover open time.

viii

vii

1
2

3
4

5

6

TABLE OF CONTENTS

GETTING STARTED • • • • • • • • • • 1

1•1 Unpacking your • • • • • • • • • • • • • • • • • • • • • • • • • • 1
1•2 Indicators and control • • • • • • • • • • • • • • • • • • • • • • 3

1•3 Printer installation • • • • • • • • • • • • • • • • • • • • • • • • 4

OPERATION • • • • • • • • • • • • • • 7

2•1 Printer Features • • • • • • • • • • • • • • • • • • • • • • • • • • 7
2•2 Loading Printing Ribbons • • • • • • • • • • • • • • • • • • • 8

2•3 Loading Lamination Patch • • • • • • • • • • • • • • • • • • • 10
2•4 Loading cards • • • • • • • • • • • • • • • • • • • • • • • • • • • 11

A- Card Feeder • • • • • • • • • • • • • • • • • • • • • • • • • • • 11
B- Card Cleaning Cartridge • • • • • • • • • • • • • • • • • • 12
C- Card Thickness Control Lever • • • • • • • • • • • • • • 13

D- Card Output Hopper • • • • • • • • • • • • • • • • • • • • • 13

2•5 Reject Card Box • • • • • • • • • • • • • • • • • • • • • • • • • • 14
2•6 Feeding one card at a time • • • • • • • • • • • • • • • • • • 16
2•7 Printing a test card • • • • • • • • • • • • • • • • • • • • • • • • 17
2•8 Printer menu information • • • • • • • • • • • • • • • • • • • 18

PRINTING A SAMPLE CARD • • • • • • 23

3•1 Install P520i Printer Driver • • • • • • • • • • • • • • • • • • • 24
3•2 printing a sample card • • • • • • • • • • • • • • • • • • • • • 25

CLEANING • • • • • • • • • • • • • • • 27

4•1 Cleaning system • • • • • • • • • • • • • • • • • • • • • • • • • • 28
4•2 Cleaning the print head • • • • • • • • • • • • • • • • • • • • • 29

4•3 Cleaning the Laminator rollers • • • • • • • • • • • • • • • • 30
4•4 Card Cleaning cartridge • • • • • • • • • • • • • • • • • • • • 31

TROUBLESHOOTING • • • • • • • • • 33

5•1 Interpreting LCD Display messages • • • • • • • • • • • • 33

A- Printing Station Status Messages • • • • • • • • • • • • 33

B- Laminator Station Status Messages • • • • • • • • • • 34

C- Print Station Alert Messages • • • • • • • • • • • • • • • 34

D- Laminator Station Alert Messages • • • • • • • • • • • 34

5•2 Print Quality Issues • • • • • • • • • • • • • • • • • • • • • • • • 37

TECHNICAL SPECIFICATIONS • • • • • 41

ix

viii

APPENDIX A • • • • • • • • • • • • • • 45

Introduction • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 45

A- Media Loading orientation • • • • • • • • • • • • • • • • 46
B- Magnetic Encoder Cleaning • • • • • • • • • • • • • • • • 47

APPENDIX B • • • • • • • • • • • • • • 49

Introduction • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 49

A- Media Loading orientation • • • • • • • • • • • • • • • • 50
B- Smart Card Contact Station Interface • • • • • • • • • 50

APPENDIX C • • • • • • • • • • • • • • 51

Available Full-Color Ribbons • • • • • • • • • • • • • • • • • 51
Available Monochrome Ribbons • • • • • • • • • • • • • • • 52
Print Ribbons vs Laminator Compatibility • • • • • • • • 52
Available Patch Ribbons • • • • • • • • • • • • • • • • • • • • 53
Cards for Printing and Lamination • • • • • • • • • • • • • 53
Cards Suitable for Printing Only • • • • • • • • • • • • • • • 53
Accessories • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 54

x

1

GETTING STARTED

1

GETTING STARTED

1 • 1 Unpacking your card printer

Your P520i printer ships in a carton and protective anti-static bag. Keep all packaging
material in case you need to move or re-ship the printer.
While unpacking, inspect the carton to ensure that no damage occured during
shipping.
Please ensure that you have a clean and nearly dust free environment for proper
operation and storage of the printer.

2

GETTING STARTED

In addition to user documentation, make sure the following items are included with
your P520i printer:

If any items are missing, please contact your dealer.
To reorder, please refer to Appendix C of this
manual.

CLEANING KIT

POWER CABLE(5)

PRINTER DRIVER CD

(Printer Documentation CD)

CARD HOPPER

CLEANING CARTRIDGE

Parallel CABLE

(for “U” Interface Option only)

GETTING STARTED

3

1 • 2 Indicators and Control

Your P520i printer has an LCD Display, two LED’s and two Panel Buttons.

The 16 character LCD 2-Line Display is used
for:

• Showing the printer’s current status

• Providing operator and service messages
(chapter 5)

The two LEDs are used for:

• Green: Power LED

• Amber: Alert LED (with Beeper)

The Menu Button (left) is a push button used
for:

• Bringing printer into Menu Mode when pressed
with the printer showing READY on the LCD Display.

• Using in Menu Mode to scroll through Menu
Options.

The Clear Button (right) is a push button used
for:

• Clearing an error status (when LCD Display shows
an error and Alert LED is on).

• Invoking automatic retry of the operation which
gave the error.

• Selecting a Menu Option when in Menu Mode.

Note: The buttons beep when pressed.

P520

LCD Display

Menu Button “Next”

Clear Button “Select”

Power LED

Alert LED

LCD

Display:

LEDs:

Panel

Buttons:

1 • 3 Printer Installation

The following will guide you through the installation of your P520i printer.

CAUTION: Limit AC power supplied to the P520i

Printer to 110 - 230 V AC, 60 - 50 Hz for an associa­ted 1,40A - 0,80A. Limit excess current draw to 16
amps or less, using an associated circuit breaker or
other such device. Never operate the printer in a
location where operator, computer, or printer can
get wet. Personal injury could result. The
printer must be connected to an earthed electrical
power supply and properly protected against
electrical surges and grounding faults.

1 • Place the printer in a location that allows easy

access to all sides. The printer should never be
operated while resting on its side or upside down.

2 • Place the printer’s power switch in the OFF (O)

position.

3 • Insert the power cable to the printer power

socket and attach to grounded electrical socket of
the proper voltage and type.

CAUTION: Intermittent or unpredictable operation

may occur from unsecured connectors. If
damaged, the power cable must be replaced by an
exact equivalent.
Use only Parallel Cable under 3 Meters in length.

GETTING STARTED

4

5

OPERATION

4 • Attach and secure the interface cable to printer and

computer. Note: In printers with two-connectors, use
the USB or the Parallel/Ethernet, never both.

5 • Switch power on.

Parallel Computer
Connector Option

USB Computer
Connection

Ethernet Computer
Connector Option

OPERATION

6

The following shows the function of the switch and indicators found on P520i
Printers that use Ethernet Computer Interfaces.

Press the Ethernet Push button with the printer ON to to get a Test Card.

Press and hold the Switch while turning ON the Printer to perform a RESET.

LED Action Status Being Signaled

Red Flashing Power-On Self Testing
Red Solid > 30 sec Failure of Power-On Tests
Red/Green Flashing Alternately Firmware Download mode
Green Solid > 30 sec Proper Hardware Operation; Network Found
Green Rapid Flashing (9/sec) Network not Found
Green Slowly Flashing (1/sec) Print Job in Progress

Ethernet Test Card

LEDs

Ethernet Push
Button

Ethernet Indicators

Ethernet Push Button

ENABLED STATUS

TCP/IP

101.2.228 ADDRESS

255.225.25.0 SUBNET MASK

10.1.2.1 DEFAULT GATEWAY

Enabled TIMEOUT GATEWAY

ENABLED STATUS

Unknown FRAME FORMAT

Unknown MODE

2159748 SERIAL NUMBER

00074D20F484 HARDWARE ADDRESS

8.00 (3133A FIRMWARE (DATE CODE)

GENERAL

None GENERAL

ERROR

NETWARE

None TCP/IP

None NETWARE

ENABLED STATUS

JET ADMIN

PORT NAME

PORT CONFIGURATION

CONNECTED TO

Online PRINTER STATUS

Enabled BIDIRECTIONAL

None ERROR

FIRMWARE IS COPYRIGHTED

ZebraNet Print Server Confiruration

7

OPERATION

2

OPERATION

2 • 1 Printer Features

The following shows the features found on your P520i Printer:

Standard Features: Optional Features:

1 • Print Head Unlock Lever A • Smart Card Contact Station
2 • Print Head B • Magnetic Encoder Station
3 • Card Thickness Control Lever
4 • Card Feeder
5 • LCD Display and two panel Buttons
6 • Card Cleaning Cartridge
7 • Laminator
8 • Laminator Unlock Lever
9 • Card Output Hopper
10 • Rejected Card Box
11 • Cleaning Roller

OPERATION

8

2 • 2 Loading Printing Ribbons

The P520i Printer requires approved ribbons (see Appendix C). The Resin Thermal
Transfer and Dye Sublimation ribbons and Lamination are specifically designed for
your P520i Printer. For optimum performance and printer life (Print Head), always use
approved ribbons.

DO NOT TOUCH the print head or the electronic

components on the print head carriage.
Discharges ofelectrostatic charge from the human
body or other surfaces can damage the print head
or other electronic components used in this devi­ce.

1 • Remove ribbon from packaging.

2 • With printer power ON and Printer Ready status,

open cover and press down on the Print Head
Unlock Lever to open the print head carriage. The
print head carriage will pop open.

OPERATION

9

3 • Load ribbon onto the supply spindle “1”

(under print head carriage) and empty core ( with
tape attached) onto the take-up spindle “2”. Make
sure the ribbon comes off the top of the supply
spindle and feeds to the top of the take-up spindle.

4 • Push down on the Print Head Lock Lever until an

audible “click” signals the locked-down position.

5 • Close Cover

Please note that the ribbon automatically
synchronises whenever the print head lock down
occurs.

The card flipper will not operate and an error will
be indicated if you try to flip a card when the cover
is open.

2

1

OPERATION

10

2 • 3 Loading Lamination Patch

The P520i Printer requires approved patches (see Appendix C).
Clear patches, hologram patches or Overlay varnishes are specifically designed for
your P520i Printer. For optimum performance and printer life (Laminator), always use
approved patches.

1 • Remove patch from packaging.

2 • With printer power ON and printer Ready status,

open cover.

3 • Press down on the Laminator Unlock Lever to

open the laminator bracket. The laminator bracket
will pop open.

4 • Load patch onto the supply spindle “1”

(under laminator bracket) and align the notch of the
empty core with the spindle screw ( with tape
attached) onto the take-up spindle “2” .
Make sure the patch comes off the top of the supply
spindle and feeds to the top of the take-up spindle.

5 • Push down on the Laminator Lock Lever until an

audible “click” signals the locked-down position.

6 • Close Cover

.Please note that the ribbon automatically
synchronises whenever the laminator head
lock down occurs.

2

1

OPERATION

11

2 • 4 Loading Cards

To help you load, print, and collect cards, the P520i has the following items:

A - CARD FEEDER

This items is used for loading cards.

1 • Open Card Feeder Cover by putting your fingers

on both sides and rotating the cover in a clockwise
direction to the open position.

2 • Install cards into Feeder* as shown.

3 • Close Card Feeder Cover.

DO NOT bend cards or touch print surfaces as this

can reduce print quality. The surface of the cards
must remain clean and dust free. Always store
cards in an enclosed container. Ideally, use cards
as soon as possible. If cards stick together,
carefully shuffle them.

* See Chapter 6, Technical Specifications, for card requirements and capacities.

12

OPERATION

B - INSTALL CARD CLEANING CARTRIDGE

This items is used to clean the cards entering the printer.
It must installed before using the printer.

1 • Remove Card Cleaning Cartridge from

plastic bag and peel off protective wrapper from
adhesive cleaning roller.

2 • Open printer cover and remove the yellow

reminder tape from the location for the Cleaning
Cartridge.

3 • Make sure the arrow on top of the assembly is

facing towards the rear of the printer.
Hook assembly into slot on printer and rotate down.
Ensure the assembly locks in place.

13

OPERATION

C - CARD THICKNESS CONTROL LEVER

This items is operated by the user to prevent more than one card feeding into the
printer at the same time and causing a jam.

Open cover, and adjust lever to the correct
position for the card thickness you are using. Repeat
for different card thickness. (Factory setting is for 30
mil (0,762 mm) card thickness). See diagram below:

Card thickness:

A - 60mil (1.524mm) to 50mil (1.27mm)
B - 40mil (1.016mm)
C - 30mil (0.762mm)
D - 20mil (0.508mm)
E* - Less than 20mil (0.508mm)
*Start at lowest position and move lever up
to match card thickness.

For other card thickness, start lever at lowest
position and move up until cards feed.

Note: For Lamination cards should only be 30 mil cards, and composite PVC is prefered

for optimum performance.

D - CARD OUTPUT HOPPER

This items is used for printing cards.

Install card Output hopper onto printer by hooking
over bottom edge of card exit aperture.

REJECT BOX FULL

14

OPERATION

2 • 5 Rejected Card Box

The P520i Printer is equipped with a Rejected card Box. When an encoding can not be
completed, the card is ejected into the Rejected Card Box. The P520i Printer counts the
number of cards which go into the Reject Card Box. After 10 cards the printer stops,
the Amber LED Flashes and a LCD Message is displayed indicating the need to empty
the reject box.

WHEN TO MAINTAIN

When the LCD screen reports message

HOW TO MAINTAIN

1 • Press the top of the Rejected Card Box Door as

shown. Allow the door to swing down and open.

2 • Remove all cards from the Rejected Card Box.

OPERATION

15

3 • Swing the Rejected Card Box Door and press the

top. An audible “click” signals the locked position.

4 • Press the Clear Button on the front panel to

re-start the current printer job and to clear the
rejected cards counter.

16

OPERATION

2 • 6 Feeding one card at a time

A Manual Feed Slot is avalable on the side of the Card Feeder cover for feeding single
cards. Cleaning Cards are fed manually through this slot.
The Feeder must be empty

for manual card feeding to work properly.

For one-at-a-time printing, feed cards through slot
on side of Feeder.

Do not feed more than one card at a time.

2 • 7 Printing a Test Card

With ribbon and cards loaded, your P520i printer is ready to print. To check the
operation of the printer and the laminator you should print a test card.

NOTE: Test cards are not laminated.

1 • When the printer displays READY, press the

“Next” button (left) on your Control Panel to MENU
PRINTER, then the “Select”button (right) to PRIN­TER INFO.

2 • Press twice the “Next” button to SELF TEST

MENU and then “Select” to TEST PATTERN.

3 • A test card will print after a few seconds. LCD

display will show printing status. Test Card is
printed on both sides of the card.

This is an example of the test card.

17

OPERATION

Front Side: Printer Operation

Back Side: Laminator Operation

18

OPERATION

2 • 8 Printer Menu Information

The printer is equipped with an LCD Display and two key buttons which gives access
to printer menus.
When the printer status shows READY, press the Menu button to enter the Menu Mode

Menu Button “NEXT”(left)

Clear Button “SELECT”(right)

When you are in Menu Mode the top line display shows
menu information and the second line of
display clarifies the function of the two “NEXT” and
“SELECT” key buttons relative to the current menu item.
The printer will return to READY Mode if either of
the two key Buttons is not pressed within ten
seconds of entering Menu mode.

P520i LCD Menu Trees:

19

OPERATION

Menu Tree: Printer station

MAIN MENU

READY

READY

PRINTER MODULE

MENU

After 10 seconds of
selection inactivity,
READY returns
automatically.

PRINTER

INFORMATION

PRINTER

PARAMETERS

RIBBON

INFORMATION

Model Number of

xxxx

V3.21

COUNTER

xxxx

xxxx

xxxx

xxxx

Printer

Firmware Version
Installed

Number of Cards
Printed

Number of Cards in
Reject Box

Image Centering
Offset (Pixels)

x = YMC Contrast
Settings

Mag Stripe Type
HICO, LOCO, NONE

Printer Ribbon
(Driver Selection)

Remaining
Ribbon

MODEL NAME

FIRMWARE VER

REJECT BOX

OFFSET X/Y
X:xx Y:yy

COLOR PARAMETERS

Y:xx-M:xx-C:xx

MAG OPTION

[NEXT]

RIBBON TYPE

800015-xxx

PRINTS REMAINING

Hold

Hold

Hold

Hold

Hold

Hold

Hold

Hold

Hold

LAMINATOR

MENU

SELF TEST CARD

MENU

CLEANING

MENU

PRINTER

EJECT CARD

See Laminator
Group

See Following Pages

}

EJECT CARD
PROCESSING

xxxxxxxxxxxx

Sends Card to
Output Hopper

Appears only when
option is installed

xxxxxxx

OPERATION

20

Menu Tree: Laminating station

READY
READY

After 10 seconds of
selection inactivity,
READY returns
automatically.

See Menu Mode
Printer Group

LAMINATOR

INFORMATION

LAMINATOR

PARAMETERS

MAIN

MENU

PRINTER MODULE

MENU

LAMINATOR

MENU

MODEL NAME

xxxx

FIRMWARE VER

Vx.xx

COUNTER

xxxx

MODEL NAME

xxxx

OFFSET FIRST

xxxx

OFFSET SYNCH

xxxx

PEEL OFFSET

xxxx

TEMPERATURE

xxxx

SPEED

[NEXT]

xxxx

Model Number of
Laminator

Hold

Firmware Version
Installed

Hold

Laminations
Performed

Hold

Laminator Model
Name

Hold

First Ribbon
Mark Offset

Hold

Ribbon Sync Mark
Offset

Hold

Patch Centering
Offset

Hold

Heat Roller
Temperature

Hold

Lamination and
Cooling Times

Hold

SELF TEST CARD

MENU

CLEANING

MENU

LAMINATOR
SELF TEST

See Next Page

}

LAMINATE

SINGLE SIDE

LAMINATE

[NEXT]

DUAL SIDE

Action Complete

SINGLE SIDE

PROCESSING

Action Complete

DUAL SIDE

PROCESSING

OPERATION

Menu Tree: Test Cards and Cleaning

21

READY
READY

PRINTER MODULE

MENU

LAMINATOR

MENU

SELF TEST CARD

MENU

After 10 seconds of
selection inactivity,
READY returns
automatically.

See Menu Mode
Printer Group

See Menu Mode
Laminator Group

SELF TEST CARD

TEST PATTERN

SELF TEST CARD

PRINT PARAMETERS

SELF TEST CARD
MAG PARAMETERS

SELF TEST CARD

LAMINATOR

First, remove both Ribbons and
Plastic Cards, then insert Cleaning
Card into Card Feeder

Te st Card Menu

Action Complete

TEST PATTERN

PROCESSING

Action Complete

PARAMETERS
PROCESSING

Action Complete

PROCESSING

Action Complete

LAMINATOR

[NEXT][NEXT]

PROCESSING

In-process
Status

MAG

CLEANING

MENU

CLEANING

PRINTER

CLEANING

MAGNETIC HEAD

In-process
Status

Action Complete

PRINTER

CLEANING

Action Complete

MAGNETIC HEAD

CLEAN MAG HEAD

xxxxxxxxxxxx

Appears only when
option is installed

xxxxxxx

OPERATION

22

PRINTING A SAMPLE CARD

3

PRINTING A SAMPLE CARD

Printing with the P520i Printer requires the Windows Printer Driver, your card desi­gn/issuing software or printer command level programming through the printer inter­face.

The P520i Card Printer can be used with any Windows 98 SE/ME, NT 4.0, 2000. or XP
software application program, using the drivers provided with the printer.

This section contains information on the printing of a dual-sided card in color
(using the 5-Panel color ribbon YMCKK) and the Windows Printer Driver.

BEFORE installing updated printer driver versions,
always delete the existing printer driver version
from your computer using Add/Remove from the
Windows Control Panel.

23

PRINTING A SAMPLE CARD

24

3 • 1 To install the P520i Printer Driver proceed

as follows:

IMPORTANT NOTE: Ensure that your PC printer

port is set to ECP mode and also ensure that you
have deleted any previous versions ot this printer
driver. If you have any doubts please contact your
IT department.

❐ Start your computer and then Windows.

❐ Insert your “Zebra Driver” CD into an available drive.

❐ Wait for the Driver Install Wizard to self-launch, and follow the instrutions.

25

PRINTING A SAMPLE CARD

3 • 2 Printing a sample card:

You can either follow the steps below to print your first card or choose the sample card
available during driver installation.

❐ Go to the Microsoft Word Software.

❐ If the printer was not selected as the default printer, go to the file menu

and Select Printer and choose Zebra P520i Card Printer in the printer names
list. Then Close the print dialog box.

❐ Come back to file menu and choose Page Setup.

❐ Select Paper Size tab and in Paper Size choose Card. Then select the

orientation: “landscape”.

❐ Go to Margins tab, Set the Top, Bottom, left and right margins to O (zero)

values.

❐ Press OK to close Page Setup window.

❐ The card appears on the screen.

❐ Design a card with 2 sides similar to the following:

❐ Once you are ready to print, go to File and point Print

❐ The printer will feed in a card and start printing (the data download time will

vary depending on the complexity of the card design and the processing speed
of the computer).

❐ Once the printing job is achieved the card is ejected from the printer.

Build the World with us!
http://cards.zebra.com

Front Side:

Back Side:

PRINTING A SAMPLE CARD

26

27

CLEANING

4

CLEANING

PROTECT YOUR FACTORY WARRANTY!

The recommended maintenance procedures must
be performed to maintain your factory warranty.
Other than the recommanded cleaning procedures
described in this manual, allow only Zebra
authorised technicians to service the P520i Printer.

NEVER loosen, tighten, adjust, or bend, etc. a part

or cable inside the printer.

NEVER use a high pressure air compressor to

remove particles in the printer.

4 • 1 Cleaning System

Your P520i Printer includes a simple cleaning system using the Pre-Satured Cleaning
Cards provided. The regular use of these cards will clean and maintain important parts
of your printer that cannot be reached: including the Print Head, the Lamination
station and Transport Rollers.

WHEN TO CLEAN

When the LCD screen reports messages.

HOW TO CLEAN

1 • Leave power on.

Open Cover and release Print Head Bracket.
Remove ribbon.
Close Print Head Bracket
Close Cover. Remove cards from Card Feeder.

2 • Insert one Pre-Saturated Cleaning Card

(provided) through slot on the side of the Card

feeder Cover.

3 • Press the right panel button for a few seconds.

The card will feed into printer and carry out the
cleaning process. repeat the process with a new
Cleaning card if necessary.

Note: For a printer cleaning prior to the WHEN TO CLEAN signal, press the Left Panel

button until the LCD screen shows “CLEANING MENU”. Press the right Panel button
to select and one more time again to run the cleaning process (Repeat first steps 1 &
2 above).

28

CLEAN PRINTER

Although the CLEAN PRINTER message is
displayed until the cleaning process has been
performed, the printer will continue to operate.

CLEANING

29

CLEANING

4 • 2 Cleaning the Print Head

A cleaning using the cleaning system with cards usually suffices. However, a
separate Print head cleaning using swabs can remove more stubborn deposits when
print anomalies persist. To avoid deposits, only use foam-tipped swabs.

1 • Switch power Off, open cover, raise Print Head

and remove the Ribbon.

2 • Clean Print Head by moving alcohol-moistened

swab tip side-to-side across Print Head elements.
Only use moderate force.
Make sure the elements are dry before switching on.
(To reorder swabs see Appendix C).

Never use a sharp object to scrape deposits from
the print head. Permanent damage will result.

30

CLEANING

4 • 3 Cleaning the Laminator Rollers

A cleaning using the Cleaning System with cards usually suffices, moreover your
printer is equipped with two cleaning rollers situated before the card enter the
Laminator. The upper roller has a coating that collects any loose particles on the
surface of cards. However, a separate Laminator Station cleaning can remove more
stubborn deposits.

To avoid deposits, only use foam-tipped swabs.
Never touch the rollers with fingers.

WHEN TO MAINTAIN

Cleaning frequency varies with different
environments. Clean when lamination anomalies
persist.

HOW TO MAINTAIN

1 • Switch OFF your printer and open cover. Make

sure the Laminator rollers cool down.

2 • Press down on the unlock lever to open the

Laminator braquet.

3 • Clean the two Laminator rollers and the

two transport rollers gently with a swab.
(The above transport roller “1” can be temporary
removed for an easy clean)

4 • Make sure the rollers are dry before Pushing

down the bracket and switching on your printer.

1

31

CLEANING

4 • 4 Card Cleaning Cartridge

Your P520i Printer also has a Card Cleaning Cartridge. This item cleans the cards
entering the printer. To ensure print quality, the cleaning roller requires periodic
replacements.

WHEN TO MAINTAIN

When LCD screen reports message or at ribbon
replacements.
Run a printer cleaning first.
(see 4.1 Cleaning System for more instructions).

HOW TO MAINTAIN

1 • Open Cover and locate Cleaning Cartridge

2 • Gently remove Cleaning Cartridge by rotating up

and away from printer.

CLEAN PRINTER

32

CLEANING

3 • Remove Cleaning Roller from Cartridge and dis-

card.

4 • Install new Cleaning Roller into Cartridge*. To

avoid contamination, always hold the Cleaning
Roller assembly by the ends.

5 • Carefully peel off wrapper from new Cleaning

Roller while in Cartridge.

6 • Replace Cartridge into printer. Make sure the

arrow on top of the assembly is facing towards the
rear of the printer. Hook assembly into slot on prin­ter and rotate down. Ensure the assembly locks in
place.

DO NOT touch the roller surface that contacts the

cards.

7 • Close Cover

¨See Appendix C for replacement Cleaning Rollers.

Although the CLEANING PRINTER message is
displayed until maintenance has been performed,
the printer will cotinue to operate.

33

5

TROUBLESHOOTING

This section offers solutions to potential problems you may experience with your
P520i printer. The table below lists the screen messages that will be displayed on the
printer’s LCD, both during normal operation and to alert operator of any error
conditions. There is also some additional information dealing with quality issues
concerning printing onto cards.

5 • 1 Interpreting LCD Display messages

A • Printing Station Status Messages

SCREEN MESSAGE

INITIALIZING

READY

WAIT TEMPERATURE

DOWNLOADING DATA

PRINTING YELLOW

PRINTING MAGENTA

PRINTING CYAN

PRINTING MONO

PRINTING VARNISH

PRINTING UV

PRINT HOLOGRAM

MEANING

Power-ON Initialization is
occuring.

Ready for Print Data

A pause for a Print Head
cool down is occuring.
Printer data is being recei­ved.
The yellow bit map is
being printed.
The magenta panel is
being printed.
The cyan panel is being
printed.
A monochrome bit map is
being printed.
A varnish bit map is being
printed.
An ultra-violet bit map is
being printed.
A hologram bit map is
being printed.

ACTION

Wait for the ready message

TROUBLESHOOTING

34

SCREEN MESSAGE

INITIALYZING

READY

LAMINATING

STAND BY MODE

WARMING UP

MEANING

Power-ON Initialization is
occuring.
The Laminator can accept
cards.

Card lamination is occuring.

The Laminator is in Reduced­power Mode.
The Laminator is not yet at
the temperature needed for
lamination.

ACTION

Wait

TROUBLESHOOTING

SCREEN MESSAGE

ENCODING

CLEAN PRINTER

CLEANING

FLIPPING CARD

DOWNLOADING FW

MEANING

The printer is encoding the
Magnetic Stripe.

The printer is prompting for
operator maintenance.

The printer is performing an
internal cleaning routine.

A card-flip to the opposite side
is occuring.

Firmware is downloading to
the printer.

ACTION

Carry out the cleaning
procedure as detailed in
section 4 of this manual.

A • Printing Station Status Messages (Continued)

B • Laminating Station Status Messages

35

PRINTING A SAMPLE CARD

SCREEN MESSAGE

REMOVE RIBBON

OUT OF RIBBON

MECHANICAL ERROR

OUT OF CARD

ROTATION ERROR

COVER OPEN

HEAD OPEN

COMMAND ERROR

PARAMETERS ERROR

ENCODING ERROR

REJECT BOX FULL

CHECK RIBBON

PRINTER LOCKED

MEANING

The ribbon has not been
removed while the cleaning
operation is in progress.

The printer ribbon has run
out.

The printer has an error
moving the card internally

The card feeder is empty
The printer has an error

moving the card in the Card
Flip.

The cover is open
The print head is not locked

into position

The data being sent from the
host is not recognised.

The features of the card are
not recognised or the data for
the stripe is incorrect.

Data cannot be written or
read from the magnetic stripe
on the card.

The reject box is full.
Invalid ribbon or none detec-

ted.

Printer is locked

ACTION

Remove ribbon

Replace printer ribbon.
Remove the jamed card.

Ensure the card is not
out of specification

Add more cards or adjust the
card feeder to accept the cards.

Remove card

Close the cover
Lock the print head in its lower

position.
Check that the data is suitable

for printing. Try reprinting a card
from known “good” data.

Check the windows driver
options and printer type.
Check the data format.

Check that the cards are loaded
with the magnetic stripe in the
correct orientation. Check whe­ther high or low coercivity cards
have been specified. Check that
the data conforms to ISO speci­fications. See Appendix A of this
manual for further information.

Empty Reject Box.

Install proper ribbon.

Press the Select Button, and fol­low the Passcode Menu instruc­tions.

Ribbon Errors: Check that the print ribbon has not “run out”. Lock and then unlock the

print head assembly; this resynchronises the ribbon automatically. When using a color
ribbon, it should advance automatically so that the leading edge of the yellow panel is
beneath the print head. Ensure that the correct ribbon type has been specified in the
Windows driver.

Card Feed & Mechanical Errors: Ensure that the card thickness adjustment has been

set-up correctly to allow one card to feed.

Magnetic Encoding Errors: Check that the cards are inserted correctly in the printer.

Ensure that the cards are low or high coercivity as required, and are set-up correctly
in the printer driver.

Cleaning Alert: The printer has counted the number of cards printed and has

automatically flagged that a cleaning routine needs to be carried out. (See Chapter 4).

C • Print Station Alert Messages

PRINTING A SAMPLE CARD

36

SCREEN MESSAGE

COVER OPEN

HEAD OPEN

OUT OF RIBBON

OUT OF CARD

MECHANICAL ERROR

COMMAND ERROR

NO ACCESS

ROTATION ERROR

RIBBON FAILURE

TEMPERATURE ERR

FLASH ERROR

MEANING

The cover is open.

The Laminator Head is rai­sed.

The Laminator has run out
of ribbon.

There is no card in the
Laminator.

An error occured while
moving a card.

The Laminator has received
an invalid Command or
Parameter.

Laminator access is restric­ted.

A Laminator Flip-over error
occured.

The film is glued to the card
during the cool-down per­iod

Lamination Temperature fai­lure.

Laminator Flash Memory
produced an error,

ACTION

Close cover.

Latch down the Lamination
Head.

Load a new ribbon

Check for a jamed card.
Ensure the card is not out of
specification.

Produce an initialization by
switching Printer Off and On.

Check then resend
Command.

Check for Card Jam.

Open Laminator Bracket,
remove card, and close
Bracket. Check Lot Code of
the Lamination Ribbon roll.

TROUBLESHOOTING

D • Laminating Station Alert Messages

5 • 2 Print Quality Issues

This section will help you resolve print quality problems. The print quality is
dependent on several factors. The two most important factors that will increase your
print quality are cleanliness and card stock. To diagnose and fix print quality problems,
follow the troubleshooting procedure below:

• Small spots appear on the printed card with a non-printed area or a different color.

Possible Cause

A • Contamination on the card surface.
B • Dust inside the printer and/or dirty Cleaning Roller.

>> Solution

A1 • Check that cards are stored in a dust free environment
A2 • Use a different supply of cards.

B1 • Perform a Cleaning of the printer (see Cleaning section).
B2 • Replace Cleaning Roller (see Cleaning section)

• There are non-printing horizontal lines (white) on the card surfaces.

Possible Cause

A • Ribbon is not correctly positioned.
B • Print Head may be dirty.
C • Print Head elements may have been damaged

(e.g. scratched or burnt).

>> Solution

A1 • Open cover and press down the Print Head Unlock Lever to open the Print

Head carriage. The Print Head will move up.

A2 • Check that the ribbon is properly rolled onto the ribbon cores and there

are no wrinkles in the ribbon.

A3 • Push down on the Lock Lever until an audible “click” signals the locked-

down position.

A4 • Ribbon will automatically synchronize.
A5 • Print again.

B1 • Perform a Cleaning of the Print Head (see 4 • 2 Cleaning the Print Head).

C1 • Call service for Print Head replacement information.

37

TROUBLESHOOTING

38

TROUBLESHOOTING

• Printing shows very pale or inconsistent results.

Possible Cause

A • Ribbon have been stored improperly or is damaged.
B • Cards may not meet specifications.
C • Contrast and/or Intensity may be set to values

which are too high.

D • Dust or embedded contamination on elements of

the Print Head.

>> Solution

A1 • Change ribbon and print again.

B1 • Use a different supply of cards.

C1 • Adjust Contrast and/or Intensity values in software.

D1 • Perform a Cleaning of the Print Head (see 4 • 2 Cleaning the Print Head).

• Printing shows blurry printed image.

Possible Cause

A • Ribbon may not be correctly positioned.
B • Ribbon may not synchronized on the correct color

panel position.

C • Cards may not meet specifications.
D • Dust inside the printer and/or dirty Cleaning Roller.

>> Solution

A1 • Open cover and press down the Print Head Unlock Lever to open the Print

Head carriage. The Print Head will move up.

A2 • Check that the ribbon is properly rolled onto the ribbon cores.
A3 • Push down on the Print Head Lock Lever until an audible “click” signals

the locked-down position.

A4 • Ribbon will automatically synchronize.
A5 • Print again.

B1 • Open cover and press down the Print Head Unlock Lever to open the Print

Head carriage. The Print Head will move up.

B2 • Push down on the Print Head Lock Lever until an audible “click” signals

the locked-down position.

B3 • Ribbon will automatically synchronize.
B4 •Print again.

C1 • Use a different supply of cards.

D1 • Perform a cleaning of the Print Head (See 4 • 2 Cleaning the Print Head).
D2 • Replace Cleaning Roller (See 4 • 3 Cleaning Cartridge).

39

• No printing on the card.

Possible Cause

A • Ribbon may not be installed in the printer.
B • Cards may not meet specifications.
C • Cable on Print Head may be disconnected.
D • Print Head elements may be scratched or burnt.

>> Solution

A1 • Check for ribbon in the printer.

B1 • Use a different supply of cards.

C1 • Power off the printer and check the Print Head cable connections.

D1 • Call Service for Print Head replacement information.

For optimum print quality, always keep cover of
the printer closed except during ribbon loading
and card thickness control procedures.

The card flipper will not operate and an error will
be indicated if you try to flip a card with the cover
open.

TROUBLESHOOTING

40

TROUBLESHOOTING

41

TECHNICAL SPECIFICATION

6

TECHNICAL SPECIFICATIONS

General • High speed printing & laminating

• Small footprint

• Windows Drivers for 98SE, ME, NT 4.0, 2000, and XP

• One year printer warranty

• One year print head warranty`

Color Printing • Color dye sublimation or monochrome thermal

transfer printing

• 300 dpi (11.8 dots/mm) print resolution

• Edge to edge printing standard

Bar Code • Code 39

• Code 128 B & C with & without check digit

• 2 of 5 & 2 of 5 industrial

• UPCA

• EAN8 &EAN13

• PDF 417 2D bar code

Fonts • Internal: Normal 100 point, Bold 100 point

• True Type fonts available via Windows Driver

Cards • Types PVC, Composite

• Card width/length: ISO CR-80 - ISO 7810,

2.125” (54mm) by 3.375” (86mm)

• Option: Magnetic Stripe - ISO 7811

• Option: Smart Card - ISO 7816-2

• Card thickness: 10mil (0,25mm) to 50mil (1,25mm)

for printing only and 0,8mm for printing and lamina
tion.

• Card Feeder capacity: up to 300 cards (10mil), up to

100 cards (30mil)

• Card Output Hopper capacity: 300 cards (10mil),

up to 100 cards (30mil)

CARD DIMENSIONS

ISO STANDARD DIMENSIONS FOR PLAIN CARD

ISO STANDARD DIMENSIONS FOR MAGNETIC STRIPE CARD

CHIP POSITION FOR SMART CARD

TECHNICAL SPECIFICATION

42

0.403 in (10.25 mm)

0.782 in (19.87 mm)

0.357 in (9.07 mm)

0.720 in (18.3 mm)

AFNOR Cards

0.403 in (10.25 mm)

0.782 in (19.87 mm)

0.757 in

(19.23 mm)

1.121 in

(28.46 mm)

ISO 7816 Cards

Ribbons • Monochrome: 1000/1500 cards/roll

• Monochrome colors: back, red, blue, green,

silver, gold, white.

• K-resin + O: 500 cards/roll

• K-dye + O: 500 cards/roll

• YMC: 300 cards/roll

• YMCK: 250/400 cards/roll

• YMCK-K: 200 cards/roll

• YMCKO: 200/330 cards/roll

• YMCKOK: 170 cards/roll

Patches • Clear Patch 1 or 0.6 mil

• Clear Patch for mag. stripe 1 mil

• Clear Patch for smart card 1 mil

• Hologram 1 mil

• Varnish full overlay

Overlay Varnish • Thermal transfer

• 4 microns thick

• Clear and holographic options:

- Clear

- Genuine/Secure Hologram

- Custom Hologram

Interfaces • Centronics Parallel or Ethernet

• USB port

Mechanical • Width: 31,69” (805mm*)

• Depth: 9,25” (235mm*)

• Height: 10,43” (265mm*)

• Weight: 47,28 Ibs (21,45 kg)

Electrical • 110 ~ 230 Volts AC, 60 ~ 50 Hz

• FCC Class B, CE, UL, and CUL approved

Environmental • Operating Temperature: 60 to 86°F (15 to 30°C)

• Operating Humidity: 20 to 65% non condensing

• Storage Temperature: 23 to 158°F (-5 to 70°C)

• Storage Humidity: 20 to 70% non condensing

• Ventilation: Free air

Dye sublimation printing requires dye sublimation ribbons,with either black or cyan,
magenta, and yellow (plus black resin) panels.

*Measured without card output hopper.

Options • Ethernet Port

• Smart Card Contact Station (0.76mm cards only)

• Magnetic Encoder (0.76mm cards only)

• Cleaning Supplies

43

TECHNICAL SPECIFICATION

CENTRONIC CABLE INTERFACE

The above drawing shows the required connections to use the printer centronic interface.

TECHNICAL SPECIFICATION

44

Printer Pin Lign Name

1 -STROBE

2DO

3D1

4D2

5D3

6D4

7D5

8D6

9D7

10 -ACK

11 -BUSY

12 PE

13 SLCT

14 -AUTO FEED

32 -ERROR

31 -INIT

36 SLCT IN

19-30-33 GND

Note: The printer pins number 15, 16, 18, 30, 34, 35 are not connected.

45

APPENDIX A

A

APPENDIX

Magnetic Card Stripe Encoder

This section contains information on the additional operations of the P520i Printers
with Magnetic Card Stripe Encoder.
(See Chapter 2 for location.)

INTRODUCTION

Operation and maintenance requirements for the P520i Printer with the optional
magnetic card stripe encoder.
(See Chapter 2 for location.)
The magnetic encoder can be set for either high or low coercivity.

A • MEDIA LOADING ORIENTATION

The magnetic encoder is a factory installed item
with the read/write head positioned below the card
path, available with HICO encoding or LOCO enco­ding.

When loading cards into the Card Cartridge, please
ensure that the magnetic stripe is facing down and
closest to the rear.

Also available are Printer models with the Magnetic
Read/Write head positioned above the card path,
with HICO encoding or LOCO encoding.

When loading cards, please ensure that the
magnetic stripe is facing up and closest to the rear.

Note:

M1 = Stripe Down HICO M3 = Stripe up HICO

M2 = Stripe Down LOCO M4 = Stripe up LOCO

approved HICO & LOCO PVC cards are available. (See Appendix C).

ONLY USE cards that comply with ISO 7810 & 7811
standards for magnetic stripe cards. The magnetic
stripe must be flush to the surface of the card to
work properly. Never use cards which have
taped-on magnetic stripes.

APPENDIX A

46

B • MAGNETIC ENCODER CLEANING

There exists two different processes to clean the Magnetic stripe Encoder.
The first process consists of a standard cleaning of the printer. This cleans the most
important parts of the printer; including the print Head, Transport Roller and Magnetic
Stripe Encoder (refer to chapter 4 “Cleaning” for more instructions.)

The second process consist of a cleaning of the Magnetic Encoder using the Menu
Button from the LCD Display.
To access the Magnetic Cleaning Menu proceed as below:

1 • Leave power on.

2 • Remove cards from the card feeder.

3 • Insert one presaturated card (provided) through

slot on the side of the Card Cartridge.

4 • Press the Menu button until the LCD screen

shows CLEANING MENU.

5 • Press the Select button to select.

6 • Press the Menu button again until the LCD screen

shows CLEAN MAG HEAD.

7 • Run this operation by pressing the select button.

ISO STANDARD ENCODING

47

APPENDIX A

Track # Field Separator Track density Valid Characters # of characters

1^210BPI* Alphanumeric 79***

(ASCII 20 - 95**)

2=75BPI* Numeric 40***

(ASCII 48 - 62)

3=210BPI* Numeric 107***

(ASCII 48 - 62)

* Bit per inch

** Except the “?” character

*** Including Start, Stop and LRC characters. Also note that these 3 characters are
automatically managed by the magnetic encoder according to the ISO Standard norms.

NOTE: Refer to the Card Printer Programmer’s Manual for complete programming information.

APPENDIX A

48

49

APPENDIX B

B

APPENDIX

Smart Card Contact Station

This section contains information on the additional operations of the P520i Printers
with Smart Card Contact Stations.
(See Chapter 2 for location.)

INTRODUCTION

Your P520i may be equipped with an optional Smart Card contact station.
Smart Cards can store fingerprints, voice recognition patterns, medical records and
other such data.
This printer model basically responds to commands that position the cards to the
contact station, where the printer connects the pins to the contacts connector on the
Smart cards.
An external “encoder/reader” is necessary for programming Smart Cards (ISO 7816).
All other printer operations remain the same as the standard P520i model.

A • MEDIA LOADING ORIENTATION

Position the cards with the Smart Card Chip at the
top of the card and towards the printer.

B • SMART CARD CONTACT STATION INTERFACE

When a command to the parallel printer interface
sends a card to the Smart Card Contact Station, the
printer connects the Smart Card Contact Station to
the female DB-9 connector on the rear of the printer.
An attached external Smart Card Programmer can
be used to program Smart card chips

Refer to the Card printer programmer’s Manual for complete programming information.

DO NOT position printing over the Smart Card Chip.

APPENDIX B

50

DB - 9 SMART CARD DB - 9 SMART CARD

PINS CONTACT POINTS PINS CONTACT POINTS

1 CI (VCC) 6 C6 (Vpp)

2 C2 (Reset) 7 C7 (I/O)

3 C3 (Clock) 8 C8 (RFU)

4 C4 (RFU)

5 C5 (GND)

9 (GND when chip is at station)

51

APPENDIX C

C

Part Number Description Cards/roll

800015-440 YMCKO 200
800015-540 YMCKO 330
800015-448 YMCKOK 170
800015-480 YMCKK 200
800015-445 YMCK 250
800015-545 YMCK 400
800015-470 YMC 300
800015-450 Kdye-O 500
800015-460 KrO 500
800015-443 YMCUvK 200
800015-543 YMCUvK 300

APPENDIX

Accessories & Supplies

Please contact your Zebra authorised dealer to place an order for accessories and supplies.

AVAILABLE FULL-COLOR PRINTER RIBBONS

Use only Zebra-approved card, ribbon and
patches media. Using non-approved card or rib­bon media can void your warranty.

Refer to the Accessories section for more
information about Card and Ribbon Media

available from Zebra Technologies Corp.

APPENDIX C

52

AVAILBLE MONOCHROME RIBBONS:

Only 30 mil cards should be used when the card is
to be laminated.
Use 30 mil composite cards whenever possible to
ensure compliance of the finished card to ISO
flatness guidelines.

PRINT RIBBONS VS LAMINATIOR COMPAIBILITY:

NOTE: * These ribbons can possibly be used without using the “O”-Panel.

‡ These ribbons can only be used with the full overlay Part Number

800015-125 and not with the 800015-131.

Part Numbers Description Patch 1 mil Patch 0.6 mil Full Overlay

-012 to -017 -135 to -138 -125 & -131

800015-101 to -109 Monochrome Ribbon no yes yes ‡
800015-440 & -540 YMCKO no* no* yes
800015-445 & -545 YMCK yes yes no
800015-448 YMCKOK no* no* yes
800015-450 Kdye-O no* no* yes
800015-460 KO no* no* yes
800015-470 YMC yes yes no
800015-480 YMCKK yes yes no
800015-443 & 543 YMCUvK no* no* yes

PRINTING STATION LAMINATOR COMPATIBILITY

Part Number Description Cards/roll

800015-101 Black 1000
800015-102 Red 1000
800015-103 Green 1000
800015-104 Blue 1000
800015-106 Gold 1000
800015-107 Silver 1000
800015-109 White 1000
800015-185 Scratch-off Gray 840
800015-301 Black 1500

AVAILABLE PATCH RIBBONS:

CARDS FOR PRINTING AND LAMINATION:

CARDS SUITABLE FOR PRINTING ONLY:

53

APPENDIX C

Part Number Description Cards/roll

Patch 1 mil Carrier-Based Rolls

800015-012 clear patch for cards w/mag. stripe 100
800015-013 clear patch for smart cards 100
800015-014 clear full coverage patches 100
800015-031 clear full coverage alternating wWITH mag. stripe 100 (50 cards)
800015-032 Genuine Secure Hologram Image Patches 100
800015-033 World Globe Hologram Image Patches 100

Zebra TrueSecure Varnish Overlays

800015-131 Clear 350

Zebra TrueSecure 0.6 mil Carrier-Based Rolls

800015-135 clear full coverage patches 170

Part Number Description Card/pack thickness

104523-111 Premier grade PVC 100 30mil
104523-112 Premier grade PVC LoCo 100 30mil
104523-113 Premier grade PVC HiCo 100 30mil
104524-101 Premier plus grade composite 100 30mil
104524-102 Premier plus grade composite LoCo 100 30mil
104524-103 Premier plus grade composite HiCo 100 30mil

Part Number Description Card/pack thickness

104523-110 Premier grade PVC w/adhesive back 200 10mil
104524-101 Premier plus grade composite 100 30mil
104524-102 Premier plus grade composite LoCo 100 30mil
104524-103 Premier plus grade composite HiCo 100 30mil

APPENDIX C

54

ACCESSORIES

Accessories available for P520i printers appear below. Always refer to the part num­ber when placing an order.

Documentation

Part Number Description

105572-004 i-Series Documentation CD
980415-001 EPCL Programmer’s Guide (English only)
980327-001 P520/P520i Maintenance Manual (English only)

Printer supplies

Part Number Description

300320-001 Centronics Parallel cable (36 pins)
206851-001 Additional Card Output Hopper
105909-112 Replacement Print Head Kit

Cleaning Supplies

Part Number Description

105909-169 Premier Cleaning Kit (25 swabs, 50 cards)
105912-003 Adhesive Cleaning Roller Kit (set of 5)
105912-002 Cleaning Cartridge, complete
104531-001 Cleaning Card Kit (box of 100 cards)
105909-057 Cleaning Swab Kit (box of 25 swabs)

Miscellaneous

Part Number Description

105600-008 Driver CD
806503-001 Card Punch (slots card for lapel clip)
104527-001 Lapel Clips (pack of 100 clips)

55

APPENDIX C

World Wide Sales and Support:

Zebra Technologies Corporation
Card Imaging Division

1001 Flynn Road
Camarillo, CA 93021-8706.USA
Phone: + 1(805) 579 1800
Fax.: + 1 [phone]
Toll Free in US: [phone]
e-mail: [e-mail]

Zebra Technologies Corporation
Card Imaging Division, (Europe, Middle East, Africa)

The Valley Centre, Gordon Road, High Wycombe
Buckinghamshire HP13 6EQ, England
Phone: + 44 (0) 870 241 1527
Fax.: + 44 (0) 870 241 0765
e-mail: [e-mail]

Zebra Technologies Corporation
Card Imaging Division, Latin America

6175 NW 153 Rd, Suite # 121
Miami Lakes, FL 33014 USA
Phone: + 1 [phone]
Fax: + 1 [phone]
e-mail: [e-mail]

Zebra Technologies Corporation
Card Imaging Division, Asia/Pacifique

1 Sims Lane # 06-11
387355 Singapore
Phone: + 65 84 20 322
Fax.: + 65 84 20 514
e-mail: [e-mail]

CORPORATE HEADQUARTERS
Zebra Technologies Corporation

333 Corporate Woods Parkway
Vernon Hills, IL 60061-3109 USA
Phone: [phone]
Fax.: + 1 [phone]
e-mail: [e-mail]