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.

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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.

iv

DECLARATIONS OF CONFORMITY

	89/336/EEC		EN 55022 (1998)	RF Emissions control
				RF Emissions and immunity
	modified by		EN 301489-3 V1.4.1
	92/31/EEC	EMC Directive		for radio equipment
	and
				Immunity to Electromagnetic
	93/68/EEC		EN 55024 (2001)
				Disturbances
	73/23/EEC	Low voltage	EN 60950 (1992) and
	modified		Amendments A1 to	Product safety
		Directive
	by 93/68/EEC		A11 (1997)
	1999/5/CE	R&TTE Directive	EN300330-2 V1.1.1	Radio frequency interferences

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

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

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.

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:

Ship-away kit

}

P520i - X X X X X - X DO

Smart Card:
O = No
E = Yes
Magnetic Encoder:
O = No
M = Yes
Magnetic Encoder Options:
O = No
1	= Stripe down HICO
2	= Stripe Down LOCO
3	= Stripe Up HICO
4	= Stripe Up LOCO
Memory:
O = Standard
Interface:
U = Parallel & USB
C = Ethernet & USB

Windows Driver

& User Documentation

Power Cord:

I = 120 Vac (US) and

220 Vac (Europe)

U = 240Vac (UK)

vi

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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.

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TABLE OF CONTENTS

GETTING STARTED • • • • • • • • • •	1
11•1 Unpacking your • • • • • • • • • • • • • • • • • • • • • • • • • •	1
1•2 Indicators and control • • • • • • • • • • • • • • • • • • • • • •	3
1•3 Printer installation • • • • • • • • • • • • • • • • • • • • • • • •	4

OPERATION • • • • • • • • • • • • • •		7
22•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
33•1 Install P520i Printer Driver • • • • • • • • • • • • • • • • • • •		24
3•2 printing a sample card	• • • • • • • • • • • • • • • • • • • • •	25
CLEANING • • • • • • • • • • • • • • •		27
44•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
55•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
6		41
TECHNICAL SPECIFICATIONS • • • • •

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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

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ix

x

GETTING STARTED1

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.

GETTING STARTED 1

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

CLEANING KIT

CARD HOPPER

POWER CABLE(5)

CLEANING CARTRIDGE

	PRINTER DRIVER CD	Parallel CABLE
	(Printer Documentation CD)
		(for “U” Interface Option only)

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

2 GETTING STARTED

1 • 2 Indicators and Control

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

LCD

Display:

LEDs:

Panel

Buttons:

LCD Display

Clear Button “Select”

Menu Button “Next”

Alert LED

Power LED

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.

GETTING STARTED 3

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.

4 GETTING STARTED

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 5

Ethernet Indicators

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

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 Push Button

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.

LEDs

Ethernet Push

Button

TCP/IP ENABLED STATUS 101.2.228 ADDRESS 255.225.25.0 SUBNET MASK 10.1.2.1 DEFAULT GATEWAY Enabled TIMEOUT GATEWAY	NETWARE ENABLED STATUS Unknown FRAME FORMAT Unknown MODE	GENERAL 2159748 SERIAL NUMBER 00074D20F484 HARDWARE ADDRESS 8.00 (3133A FIRMWARE (DATE CODE)	ERROR None GENERAL None TCP/IP None NETWARE	JET ADMIN ENABLED STATUS	PORT CONFIGURATION PORT NAME Online PRINTER STATUS Enabled BIDIRECTIONAL CONNECTED TO None ERROR	ZebraNet Print Server Confiruration	FIRMWARE IS COPYRIGHTED

Ethernet Test Card

6 OPERATION

OPERATION2

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 7

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.

8 OPERATION

1

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.

2

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.

OPERATION 9

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.

2

1

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.

10 OPERATION