Zebra P630i, P640i User Manual
Zebra® P630
i /
P640
i
Card Printer
User’s Manual
980541-003 Rev. A
P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
This manual contains installation and operation information for the Zebra P630i and P640i
card printers manufactured by Zebra Technologies Corporation.
Copyright Notice
© 2006, ZIH Corp.
This document contains information proprietary to Zebra Technologies Corporation. This
document and the information contained within is Copyrighted by Zebra Technologies
Corporation and may not be duplicated in full or in part by any person without written
approval from Zebra Technologies Corporation. While every effort has been made to keep the
information contained within current and a ccurate 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 T echnologies Corporation reserve s the right to make changes, for the purpose of product
improvement, at any time.
Foreword
Trademarks
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.
980541-003 Rev. A P630i, P640i Card Printer User’s Manual i
Foreword
Return Materials Authorization
Product Disposal
Product Disposal Information • Do not dispose of this product in unsorted municipal waste.
This product is recyclable, and should be recycled according to your local st andards. For more
information, please see our web site at:
http://www.zebra.com/environment
Return Materials Authorization
Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-ofwarranty 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, Latin America, and Asia / Pacific:
Zebra Technologies Corporation
Zebra Card Printer Solutions
1001 Flynn Road
Camarillo, CA. 93012-8706.USA
Phone: +1 (805) 578-5001
FAX: +1 (805) 579-1808
• For Europe and Middle East:
Zebra Technologies Corporation
Zebra Card Printer Solutions
Pittman Way, Fulwood
Preston, PR2 9ZD
Lancashire, U.K.
Phone: +44 - 1 - 772 - 797555
FAX: +44 - 1 - 772 - 693000
ii P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
Declarations of Conformity
Foreword
Declarations of Conformity
89/336/EEC
modified by
92/31/EEC and
93/68/EEC
73/23/EEC modified
by 93/68/EEC
1999/5/CE
EMC Directive
EMC Directive
EMC Directive EN55024 (2001)
Low voltage
Directive
R&TTE Directive
EN 55022 (1998) RF Emissions control
EN 301489-3 V1.4.1 RF Emissions and Immunity for radio
equipment
Immunity to Electro-Magnetic
Disturbances
EN 60950-1 (2001) Product safety
EN300330-2 V1.1.1 Radio Frequency Interferences
For a formal certificate, please contact the Compliance Office at Zebra’s Camarillo facility.
EUROPE:
Norway Only: This product is also designed for IT power system with phase to phase
voltage 230V. Earth grounding is via the polarized, 3-wire power cord.
FI: “Laite on liitettävä suojamaadoitus koskettimilla varustettuun pistorasiaan”
SE: “Apparaten skall anslutas till jordat uttag”
NO: “Apparatet må tilkoples jordet stikkontakt”
FCC - DECLARATION OF CONFORMITY
Models P630i and P640i have been tested and found to comply with the limits for a Class
A device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment ge nerates, uses, and can radiate radio freq uency
energy and, if not installed and operated in accordance with the P630i / P640i User’s
Manual (this document), may cause harmful interference to radio communicat ion s .
Operation of this equipment in a residential area is likely to ca use harmful in terference, in
which case the user will be required to correct the interference at his own expense.
INDUSTRY CANADA NOTICE
This device complies with Industry Canada ICES-003 class A requirements.
Cet equipement est conforme a l’ICES-003 classe A de la norm Industrielle Canadian.
980541-003 Rev. A P630i, P640i Card Printer User’s Manual iii
Foreword
Icons
Icons
Throughout this manual, different icons highlight important information, as follows:
Note • Indicates information that emphasizes or supplements important points of the main
text.
Important • Advises you of information that is essential to complete a task, or points out the
importance of specific information in the text.
Electric Shock Caution • Warns you of a potential electric shock situation.
Electrostatic Discharge Caution • Warns you of a situation where electrostatic
discharge could cause damage to electronic components.
Caution • Advises you that failure to take or avoid a specific action could result in
physical harm to you, or could result in physical damage to the hardware.
Pinch Hazard • Keep fingers away from printer cover hinges and back of cleaning
cassette.
Hot Surface • Danger of skin burns near laminator components.
iv P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
P630i and P640i Printer Models
The Zebra Product Number tells a story. Model numbers include identifiers that specify
options using the following conventions:
Part Number Description
Base Printer
P 6 3 0 i - _ _ _ _ _ - _ _ _
P 6 3 0 is- _ _ _ _ _ - _ _ _
P 6 4 0 i - _ _ _ _ _ - _ _ _
P 6 4 0 is- _ _ _ _ _ - _ _ _
_ _ _ _ _ - 0 _ _ _ _ - _ _ _
_ _ _ _ _ - B _ _ _ _ - _ _ _
_ _ _ _ _ - D _ _ _ _ - _ _ _
_ _ _ _ _ - E _ _ _ _ - _ _ _
_ _ _ _ _ - H _ _ _ _ - _ _ _
_ _ _ _ _ - _ 0 _ _ _ - _ _ _
_ _ _ _ _ - _ M _ _ _ - _ _ _
_ _ _ _ _ - _ _ 0 _ _ - _ _ _
_ _ _ _ _ - _ _ 3 _ _ - _ _ _
_ _ _ _ _ - _ _ _ 0_ - _ _ _
_ _ _ _ _ - _ _ _ _ A - _ _ _
_ _ _ _ _ - _ _ _ _ C - _ _ _
_ _ _ _ _ - _ _ _ _ U - _ _ _
_ _ _ _ _ - _ _ _ _ _ - I _ _
_ _ _ _ _ - _ _ _ _ _ - U _ _
_ _ _ _ _ - _ _ _ _ _ - _ D _
P630i Dual-Sided Color Card Printer w/Single Linerless
Laminator
P630iS Dual-Sided Color Card Printer w/Single Linerless
Laminator with Advanced ID/Key Security Feature
Base Printer
P640i Dual-Sided Color Card Printer w/Dual Linerless
Laminator
P640iS Dual-Sided Color Card Printer w/Dual Linerless
Laminator with Advanced ID/Key Security Feature
Smart Card Options
None
Contact Encoder
Contact encoder & MIFARE contactless
Contact Station
MIFARE contactless
Magnetic Encoder
None
Yes (select defaults below)
Magnetic Encoder Defaults
None
Stripe Up, HiCo
Memory Expansion
None
Interface
USB Standard Configuration)
USB & Built-InEthernet 10/100T
USB and Parallel (Minimum Printer Order Applies)
Power Cords
120V A.C. US & 230V A.C. European
U. K. and Australia
Windows Drivers and User Documentation / Training
Windows Driver CD (Win 2K and XP) & User
Documentation & Training CD
Foreword
P630i and P640i Printer Models
_ _ _ _ _ - _ _ _ _ _ - _ _ G
980541-003 Rev. A P630i, P640i Card Printer User’s Manual v
RoHS
Compliant
Foreword
P630i and P640i Printer Models
vi P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
Contents
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Copyright Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Return Materials Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Declarations of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
P630i and P640i Printer Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
1 • Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control Panel Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control Panel Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear of Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 • Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove the Printer from the Shipping Carton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove Shipping Tape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Attach the Output Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Attach the Ribbon Take-Up Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Connecting Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Ribbon Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installing the Cleaning Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Loading Laminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Loading the Laminate Cassette(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
980541-003 Rev. A P630i, P640i Card Printer User’s Manual vii
Contents
Using Partial-Width Laminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installing the Laminator Cassette(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Clearing the Laminate Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Loading Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Connecting the Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 • Printer Driver Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installing the Printer Driver (USB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installing the Printer Driver (Ethernet). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4 • Settings and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Sensors and Interlock Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Access Printer Sensor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Printer Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Sharing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Color Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Device Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Printing Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Card Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Image Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
YMC (Color) Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
K (Black) Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Color Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Flip Station Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Laminator Station Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Indicator Light Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Unusual Noises/Unreported Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Quality Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Laminate Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Examples of Printhead Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
System Related Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Invalid IP address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
DHCP is enabled but the printer is not connected to your network . . . . . . . . . . . . . . 77
viii P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
Contents
Valid host name has not been assigned to the printer . . . . . . . . . . . . . . . . . . . . . . . . 77
Color differences may be attributable to the Windows operating system installed . . . 77
6 • Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
P640i Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Appendix A • Magnetic Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Magnetic Card Stripe Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
ISO Standard Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
AAMVA Standard Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Magnetic Encoder Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Media Loading Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Appendix B • Smart Card Contact Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Media Loading Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Laminating Smart Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Appendix C • Printer Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
ID/Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Replacing a Lost ID/Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Printer Parameters in the Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
ID/Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Update Backup Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Restoring the Backup Configuration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Password Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Appendix D • Worldwide Sales & Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Sales and Support Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Corporate Headquarters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Website . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
980541-003 Rev. A P630i, P640i Card Printer User’s Manual ix
Contents
x P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
1
Introduction
Thank you for choosing the Zebra P630i or P640i Card Printer. This manual guides you to
efficient start up and operation of your new Card Printer.
The Zebra P630i and P640i Card Printers provide high speed, full color dual-sided card
printing. A micro-positioning card transport system pr ovides enhanced color photos. A range
of interface, encoder/reader, and security options allow ordering the specific configuration
suitable for a particular application.
The difference between the P630i and the P640i is that the P630i has a single-sided
laminator (i.e., it lays down and seals a laminating film on the top surface of the
printed card), while the P640i has a dual-sided laminator (i.e., it lays down and seals
laminating film on both surfaces of the printed card).
References in this document that refer to either or both of the models will be in the form of
“the printer” or “the P630i/P640i Printer”; references that are specific to one or the other will
be in the form of “the P630i Printer” or “the P640i Printer.”
980541-003 Rev. A P630i, P640i Card Printer User’s Manual 1
Introduction
Printer Features
Printer Features
The following figure shows features of the P630i/P640i Printer.
Security
Key
(Optional)
Card
Feeder
Control
Panel
RibbonCleaning Cassette
Magnetic Encoder
(Optional)
Ribbon Take-Up Spool
Print
Head
Flip Station
Output
Hopper
Laminator Station (P640i)
Laminator Station (P630i)
Power Switch
2 P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
AC Power Connector
Controls and Indicators
Control Panel Buttons
A limited amount of control and status information is available at the Control Panel on the
front of the printer. Additional control functions and status information is available via the host
or networked computer(s).
Introduction
Controls and Indicators
Buttons
PRINT Button
Press the PRINT button to print the image stored in the printer’s me mory. When the printer is
powered up, the memory is loaded with a checkerboard test pattern.
PRINT
RIBBON
LAMINATE
READY
ALARM
EDIA
M
Indicators
In regular on-line use, the PRINT button reprints the last image downloade d from the
computer to the buffer memory . If you hold the PRINT button down and powe r up the pri nter,
the Ribbon Syncronization feature (which no rmally force s a ribbon synchroni zation wh enever
the door is closed or the printer is powered up) is disabled.
980541-003 Rev. A P630i, P640i Card Printer User’s Manual 3
Introduction
Controls and Indicators
If you press and hold the PRINT button for more than two seconds, the printer will
continuously reprint the image in the buffer. Stop this action by pressing the button
momentarily while printing is in proces
Note that pressing the PRINT button will have no effect if any of the following applies:
• An error condition exists
• You have set up the print driver to print color on both sides of the card
• The optional hardware lockout key, ID/Key, is missing (but this does not disable the
checkerboard printout available after power-up).
RIBBON button
This button is used to synchronize the ribbon – in other words, to position it correctly under
the print head. If you hold the RIBBON button down and power up the printer, it toggles on/
off the Ribbon Syncronization feature when the door is closed.
In typical applications, the ribbon type is YMCK, and the back of the card is printed first. In
such cases, pressing the RIBBON button will advance the color ribbon to bring the leading
edge of the next black panel under the print head.
If back side printing is not enabl ed, the p rinter will synchronize on the n ext yello w panel when
the RIBBON button is pressed.
LAMINATE button
(For the P640i Printer, this applies to the Upper and Lower Laminator; the P630i Printer has
only the Upper Laminator.)
If either (or both) of the laminate transfer rollers is not loaded with a laminate patch, then
pressing the LAMINATE button will correct the condition , p r ov id ed the cassette is not out of
laminate, and if the cassette latch is closed (locked). If both transfer rollers are already loaded,
the LAMINATE button has no effect. If you hold the LAMINATE button down and power
up the printer, it toggles on/off the Ribbon Syncronization feature when the printer is powered
up.
A typical use of the LAMINATE button is in reloading a transfer roller after removing the
first hand-cut patch of laminate following installation of a fresh roll.
4 P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
Control Panel Indicators
Depending on the condition they are reporting, the three indicator lights, READY, MEDIA,
and ALARM, can be in one of three states: Off, On (steady), or Flashing.
Note • The READY indicator is bi-colored. Its two color channels, green and yellow,
function independently.
READY Indicator Green: Steady = Ready to print
Introduction
Controls and Indicators
Flashing = Printer busy
Yellow:
MEDIA Indicator Off: Normal
On:
ALARM Indicator Off: Normal
On:
= LIGHT ON
READY MEDIA ALARM
GREEN YELLOW ORANGE RED
Steady = Laminator(s) in sleep mode
Flashing = Laminator(s) not at operating temperature
Steady = Any media outage
Flashing = Magnetic encoding failure
Steady = Error condition requiring intervention
Flashing = Printhead temperature error, or major
internal control problem requiring power cycling of
the printer (OFF, pause, then ON)
= LIGHT FLASHING
PRINTER STATUS
Ready to print
Printer busy
Laminator heating up, but not yet at operat in g t empe ra tu re
980541-003 Rev. A P630i, P640i Card Printer User’s Manual 5
Laminator heaters in sleep mode (when not in use, the
o
heaters cool at 1
F per minute)
Printhead temperature error, or internal firmware problem.
No cards in hopper, color ribbon out, cleaning tape out,
laminator cassette(s) out.
Magnetic encoding write failure
Serious error conditions, including: Main cover open,
Laminator too hot, card transport stalled, card not seated
properly, magnetic encoding verification error, head lift
failure, ribbon jam, card jam (any location), card missing
(any location), no gap between laminator patches.
Introduction
Controls and Indicators
Rear of Printer
The Power Connector, Power Switch, and Int erface Connect or(s) are located on t he rear of the
printer, as shown below.
Power
Switch
6 P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
AC Power
Connector
DB9 Serial Interface
Connector for Contact
Smart Card Contact
Station (Optional)
USB
Connector
Ethernet
Connector
(Optional)
Parallel
Connector
(Optional)
Introduction
Installation includes setting up the printer, installing the printer driver in the computer(s) that
will be sending print jobs to the printer, connecting the interface, installing the Cleaning
Cartridge, loading the cards, ribbon, and laminate, and verifying that the printer can print a test
card.
2
Installation
Loading the Printer Driver software is described in Section 3.
Installation Procedure
Important • Execute the procedures that follow in the order given.
Remove the Printer from the Shipping Carton
Step 1. Open and remove the plastic handle/latches on either end of the shipping carton.
Step 2. Lift the upper part of the shipping carton off the lower part.
980541-003 Rev. A P630i, P640i Card Printer User’s Manual 7
Installation
Installation Procedure
Step 3. Remove the items from the cutouts in the foam block atop the printer. Verify that the
following items are included:
Printed Quick-St art Guide
Cleaning Cartridge
Output Hopper
Ribbon Take-up Spool
Two Power Cords
Card Weight
Documentation & Driver CD
USB Interface Cable
8 P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
Installation
Installation Procedure
Step 4. Remove the foam block from the top of the shipping carton.
Step 5. Lift the printer from the shipping carton.
Caution • The printer weighs approximately 15.9 kg (35 lbs).
Step 6. Remove the protective plastic bag from the printer.
Important • Save all the packing material and the shipping carton in case the print er needs to
be moved or shipped. If the original material is lost or damaged, a replacement Shipping Kit
can be ordered from Zebra.
Step 7. Place the printer in a location that meets the following requirements:
• A reasonably dust- and dirt-free environment will give better print quality.
• Flat surface at least 699 mm (27.5 in) x 246 mm (9.7 in) that can support the weight of the
printer; additional space preferred. Vertical clearance at least 450 mm (17 in). There
should be easy access to all sides of the printer.
• Temperature within the range of 10° to 35°C (50° to 95°F).
• Relative Humidity 20 to 80%, non-condensing.
• AC power accessible.
980541-003 Rev. A P630i, P640i Card Printer User’s Manual 9
Installation
Installation Procedure
Remove Shipping Tape
Step 1. Open the printer Main Co ver. Locate and remove the blue tape that secures the flip
station in position.
10 P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
Attach the Output Hopper
Step 1. The Output Hopper is positioned on the right side of the printer to receive the printed
cards. Install the Output Hopper by in serting the tab on the si de of the Output Hopp er
into the slot on the right side of the printer.
Attach the Ribbon Take-Up Spool
Installation
Installation Procedure
Step 1. Attach the Ribbon T ake-Up Spool by sliding it onto the Ribbo n Take-Up Spindle and
pressing it straight back until in clicks into place.
Important • Make sure that the Ribbon Take-Up Spool is attached with its “toothed” end
toward the rear of the printer.
980541-003 Rev. A P630i, P640i Card Printer User’s Manual 11
Installation
Installation Procedure
Connecting Power
The AC Power is connected and turned on so that in the next procedure, Ribbon Installation,
when the printer’s main cover is opened the Print Head will raise automatically.
Step 1. Verify that the printer’s Power Switch is set to OFF (O).
Step 2. Select the proper power cord for the local ac power source from the accessories that
are shipped with the printer.
Caution • If you do not have the proper power cord for your local power source, or if the
power cord appears frayed or damaged in any way, or if the power cord will not securely
plug into the printer’s power connection or the source outlet, STOP! Use of a damaged or
incorrect power cord could cause equipment damage, result in an electrical fire, or
possibly cause injury.
Step 3. Plug the power cord into the printer’s power connection and a grounded AC power
source connection.
Step 4. Turn the printer on by setting the Power Switch to ON (I).
Ribbon Installation
Power Switch
Note • In normal printer operation, when the ribbon is exhausted, a warning message appears
on the monitor and the MEDIA indicator on the printer lights.
12 P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
Installation
Installation Procedure
Step 1. Open the printer Main Cover. The printhead will raise for easy ribbon loading.
Step 2. Remove the ribbon from its packaging. Remove the tape that holds the end of the
ribbon (save this tape; it will be used shortly).
Step 3. Install the Ribbon on the left (supply) spindle, with the free end of the ribbon coming
from the roll pointing down to your right. Note that the “flanged” end of the ribbon
spool is toward the rear of the printer, and make sure the internal grooves on the core
engage the teeth on the supply spindle.
980541-003 Rev. A P630i, P640i Card Printer User’s Manual 13
Installation
Installation Procedure
Step 4. Route the Ribbon as shown in the figure below. The Ribbon Supply Spindle is free-
wheeling; pull ribbon off it as needed. If the tape removed from the new ribbon in
step 2 is undamaged, use it to attach the end of the ribbon to the Take-Up Spool;
otherwise use other adhesive-backed tape.
Important • When the end of the ribbon is attached to the Take-Up Spool, any slack in the
ribbon can be taken up by rotating the Ribbon Supply Spool; do not try to turn the Take-Up
Spool
14 P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
1. Pass Ribbon
Over the
Round
Guide Bar
Installation
Installation Procedure
4. Attach
Ribbon to
Take-Up
Spool
With Tape
2. Ribbon Goes
Through the
Ribbon
Sensor
3. Ribbon
Goes
Under
the
Print
Head
Step 5. Close the printer main cover, then press the RIBBON button on the Control Panel.to
initialize the color ribbon. If the MEDIA light fails to go out, check the ribbon
sensor.
Important • Color ribbon wrinkling and “fold-over” can seriously affect print quality
980541-003 Rev. A P630i, P640i Card Printer User’s Manual 15
Installation
Installation Procedure
Step 6. Re-open the printer cover to inspect the ribbon path fo r wrinkles and folds. Correct if
necessary, then close the cover. If you do not then hear the ribbon motor advancing
the ribbon, press the RIBBON button.
Installing the Cleaning Cassette
Before being printed, each surface of the card is cleaned by a soft tacky roller that is itself
cleaned periodically by adhesive tape in the Cleaning Cassette. Typically, the roller is cleaned
every 10 cards. The printer driver software allows the card count to be modified.
By cleaning the roller every 10 cards, the Cleaning Cassette contains sufficient tape
for 3,000 cards. This matches the other components of the standard Zebra media pack
(3,000 cards, 3,000 color ribbon images).
Step 1. Open the main cover of the printer.
Step 2. Remove the Cleaning Cassette from its packaging.
Step 3. Remove the protective foil from the Cleaning Cassette. Avoid touching the exposed
tacky surface.
Step 4. Install the Cleaning Cassette on the printer by locating the rectangular pin on the
cleaning mechanism in the receptacle on the cassette. Push the cassette gent ly home,
ensuring that the internal grooves on the upper spool engage the teeth on the takeup
drive; you will hear a click when it is fully engaged.
16 P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
Loading Laminate
Installation
Installation Procedure
Note • In this description of loading laminate, references to the lower Laminate Cassette
apply only to the P640i Printer. The P640i Printer can apply laminate to both surfaces of the
card; the P630i Printer only to the upper surface.
The Laminate (laminating film) is loaded into cassettes to protect it from dirt or other
contaminants.
See the figure below. The “Upper Laminate Cassette”, used on both the P630i and P640i
Printers, has a label with the word “UPPER” and another “label” of a red dot. The “Lower
Laminate Cassette”, used only on the P640i Printer, has a label with the word “LOWER” and
another “label” of a yellow dot.
“Upper
Laminate
Cassette”
(P630i and
P640i)
Removing the Laminate Cassette(s)
“Lower
Laminate
Cassette”
(P640i only)
Step 1. The Laminate Cassette(s) (Upper only for the P630i Printer; Upper and Lower for the
P640i) are held in position by latch plates. The Upper Cassette is freed by turning its
Latch Plate counter-clockwise to a full vertical position; the Lower Cassette (only
present on the P640i Printer) is freed by turning its Latch Plate clockwise. Then pull
the cassette straight out from its holder.
980541-003 Rev. A P630i, P640i Card Printer User’s Manual 17
Installation
Installation Procedure
Upper Laminate
Cassette Latch Plate
(P630i and P640i)
Heater
Cores
area
Lower Laminate
Cassette Latch Plate
(P640i only)
Hot Surface • If the printer has been in use, the Heater Cores area of the Laminator
may be hot.
Important • If either Latch Plate is opened, even unintentionally, the corresponding Cassette
must be removed and the Laminate reeled in.
18 P630i, P640i Card Printer User’s Manual 980541-003 Rev. A
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