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: +1 (805) 579-1800
FAX: +1 (805) 579-1808
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.
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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.
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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
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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
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
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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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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.
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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
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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
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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
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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
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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.
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OPERATION
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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.
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