Zebra Z91-0M0C0000EM00 User Manual

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ZXP Series 9™

P1086707-002

Card Printer

User Guide

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Contents

Before Printing ................................................................................................................v

Card Type.............................................................................................................................................. vi

Single- or Double-Sided ........................................................................................................................vii

Ribbon Combination ............................................................................................................................viii

Print a Test Card ................................................................................................................................... ix

Introduction .....................................................................................................................1

Description ............................................................................................................................................. 1

Printer and Laminator Components ....................................................................................................... 2

Icons ......................................................................................................................................................3

Installation and Setup ....................................................................................................5

General Information ...............................................................................................................................5

Unpacking the Printer ............................................................................................................................6

Unpacking the Printer with a Laminator ................................................................................................. 7

Unpacking (continued) ........................................................................................................................... 8

Loading Cards ...................................................................................................................................... 11

Installing the Card Hoppers .................................................................................................................12

Input Hopper .................................................................................................................................. 12

Output Hopper ............................................................................................................................... 13

Installing the Software ..........................................................................................................................14

Supported Operating Systems ......................................................................................................14

Supported Sharing Combinations ..................................................................................................15

Installing the Cleaning Cartridge .......................................................................................................... 16

Installing the Cleaning Roller ...............................................................................................................17

Loading the Transfer Film ....................................................................................................................18

Loading Print Ribbon ...........................................................................................................................19

Replacing the Laminate .......................................................................................................................20

Opening the Laminator Door .........................................................................................................20

Removing the Laminate Cassette(s) ............................................................................................. 20

Loading the Laminate Cassette(s) .................................................................................................23

Installing the Laminate Cassette ...................................................................................................26

Using Partial-Width Laminate ........................................................................................................ 28

Laminating Contact Smart Cards ..................................................................................................30

Packing for Shipment ........................................................................................................................... 32

Printer ............................................................................................................................................ 32

Printer with Laminator ....................................................................................................................34

i ZXP Series 9 Card Printer User Guide P1086707-002

Operation .......................................................................................................................39

Introduction ..........................................................................................................................................39

Printing Preferences ............................................................................................................................40

Card Type Selection .............................................................................................................................41

Print Ribbon Selection .........................................................................................................................43

Printing a Test Card..............................................................................................................................45

Manual Card Feed ...............................................................................................................................48

Operator Control Panel (OCP) ............................................................................................................. 50

Printer Menu Information ............................................................................................................... 51

Messages .............................................................................................................................................59

Operational .................................................................................................................................... 59

Warning Messages ........................................................................................................................ 60

Error Messages .............................................................................................................................60

Maintenance .................................................................................................................. 61

Cleaning the Printer .............................................................................................................................62

When to Clean ............................................................................................................................... 62

Rollers ...........................................................................................................................................62

Platen ............................................................................................................................................64

Replacing the Cleaning Rollers ..................................................................................................... 64

Cleaning the Laminator ........................................................................................................................ 65

When to Clean ............................................................................................................................... 65

Laminator .......................................................................................................................................65

Cleaning the Printhead ........................................................................................................................70

Magnetic Encoder Cleaning ................................................................................................................. 71

Troubleshooting ........................................................................................................... 73

OCP Error Messages ........................................................................................................................... 73

Clearing a Card Jam ............................................................................................................................ 83

Printer ............................................................................................................................................ 83

Laminator .......................................................................................................................................84

OCP Test Cards ................................................................................................................................... 86

Identifying Job Quality Issues ..............................................................................................................87

Print Quality Issues ........................................................................................................................87

Transfer Quality Issues .................................................................................................................. 88

Ethernet Indicators—Detail .................................................................................................................. 90

Network Operations .....................................................................................................91

Printer Connections .............................................................................................................................92

Printer Sharing ...............................................................................................................................92

External Print Server .....................................................................................................................92

Internal Print Server .......................................................................................................................92

Adding a Network Printer (Windows 7) ................................................................................................ 93

Wi-Fi Connectivity ................................................................................................................................ 94

Description .....................................................................................................................................95

Security ..........................................................................................................................................95

Setup via Browser Console ...........................................................................................................96

Setup via OCP ............................................................................................................................... 99

Printer Pooling ...................................................................................................................................100

Setting Up Printer Pooling (Windows 7) ...................................................................................... 100

Using the Printer Pool ..................................................................................................................101

Printer Sharing ................................................................................................................................... 102

Setting Custom Card Specications ........................................................................103

Introduction ........................................................................................................................................103

Process .............................................................................................................................................. 104

Adjustments .......................................................................................................................................106

Overview ......................................................................................................................................106

ii ZXP Series 9 Card Printer User Guide P1086707-002

Partial Transfer ............................................................................................................................108

Warpage ...................................................................................................................................... 110

Laminator Adjustments ................................................................................................................ 11 5

Magnetic Card Encoder ............................................................................................. 117

Introduction ........................................................................................................................................ 117

Ribbon Selection ................................................................................................................................ 118

Driver Setting ..................................................................................................................................... 118

Media Loading Orientation ................................................................................................................. 120

Magnetic Encoding Type .................................................................................................................... 121

ISO (Default) ................................................................................................................................121

AAMVA ........................................................................................................................................122

CUSTOM ..................................................................................................................................... 122

BINARY .......................................................................................................................................122

Laminating Mag Cards ....................................................................................................................... 123

Using Partial-Width Laminate ............................................................................................................124

Smart Card Encoder ................................................................................................... 125

Introduction ........................................................................................................................................125

Ribbon Selection ................................................................................................................................ 126

Contact Smart Cards ................................................................................................................... 126

Printing on Contactless Smart Cards ..........................................................................................126

Driver Setting .....................................................................................................................................127

Media Loading Orientation ................................................................................................................. 128

Contact Smart Cards ................................................................................................................... 128

Contactless Smart Cards .............................................................................................................128

Contact Station Smart Card Interface ................................................................................................ 129

Laminating Contact Smart Cards ....................................................................................................... 129

P1086707-002 ZXP Series 9 Card Printer User Guide iii

iv ZXP Series 9 Card Printer User Guide P1086707-002

Before Printing

Before your rst print, there are several settings that need to be checked:

y Check that the proper card type is selected

y Check that either single- or double sided-printing is selected

y Check that the correct ribbon combination is selected

y Print a test card

v ZXP Series 9 Card Printer User Guide P1086707-002

Before Printing

Card Type

From the Printing Preferences Control Panel, select the Card type in use drop-down menu and select the appropriate card type.

The menu contains six different card types that are supported by the printer, if there is not a card type that suits your needs, select either Custom 1 or Custom 2 and enter the specications for the

custom card type (see “Setting Custom Card Specications” on page 101).

See “Card Type Selection” on page 39 for more detailed information.

vi ZXP Series 9 Card Printer User Guide P1086707-002

Before Printing

Single- or Double-Sided

The ZXP Series 9 Card Printer comes in either a single- or double sided conguration. If you have a single-sided printer, you can skip this step. If you have a double-sided printer, and want to be able to print on both sides of the card, select Yes from the Print on both sides drop-down menu.

P1086707-002 ZXP Series 9 Card Printer User Guide vii

Before Printing

Ribbon Combination

The ZXP Series 9 Card Printer supports many different ribbon types for many different printing

requirements, and each ribbon type may support multiple ribbon combinations. For example, a YMCK ribbon may support printing color on the front and black on the back (YMC Front / K Back), or color on the back and front (YMCK Front / YMCK Back). Depending on your printing requirements,

select the appropriate ribbon combination from the Ribbon combination drop-down menu.

See “Print Ribbon Selection” on page 40 for more detailed information.

viii ZXP Series 9 Card Printer User Guide P1086707-002

Print a Test Card

Once all your preferences have been set, click Test Print.

Before Printing

Print a Test Card

See “Printing a Test Card” on page 42 for more detailed information.

P1086707-002 ZXP Series 9 Card Printer User Guide ix

x ZXP Series 9 Card Printer User Guide P1086707-002

Introduction

Description

This manual contains installation, operation, maintenance, troubleshooting, and networking

information for the Zebra ZXP Series 9 Card Printer; and describes single- and double-sided

printers, and double-sided printers with either a single- or double-sided laminator; and is intended to be used by an operator, as well as an experienced IT person.

The Zebra ZXP Series 9 Card Printer uses reverse transfer printing technology to create photo-

quality and over-the-edge images on plastic identication cards. Zebra’s reverse transfer printers

provide fast throughput and a range of encoding options for a variety of markets and applications.

The single-sided laminator applies a laminating lm on the top surface of the printed card for added security; the double-sided laminator applies laminating lm on both the top and bottom surfaces of

the card.

References in this document to “the laminator” apply to either a single- or double-sided laminator.

1 ZXP Series 9 Card Printer User Guide P1086707-002

Introduction

Printer and Laminator Components

Transfer Film Take-Up

Transfer Station

Transfer Station Card Slot

Manual Advance Wheel

Transfer Film Supply

Print Ribbon Take-Up

Card Slot

Print Ribbon Supply

Input Hopper

Card Cleaning Roller

Card Cleaning Cartridge

Printhead

Output Hopper

Upper Laminate

Upper Laminate Cassette

Cassette Release

Cassette

Upper Laminate

Cassette Release

Lower Laminate

Cassette Release

Operator Control Panel

Manual Card Feed

Lower Laminate

Lower Laminate Cassette

Manual Advance Tool

Cassette

Output Hopper

2 ZXP Series 9 Card Printer User Guide P1086707-002

Power Switch

Introduction

Printer and Laminator Components

Power Connector

Power Connection

DB9 Connection (optional)

DB9 Connection

USB Connection

USB Connection Ethernet Connection

Wi-Fi Antenna (optional)

Ethernet Connection

Icons

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

Indicates information that emphasizes or supplements important points of the main text.

Advises you of information that is essential to complete a task, or points out the importance of specic information in the text.

Warns you of the potential for electrostatic discharge.

Warns you of a potential electric shock situation.

Warns you of a situation where excessive heat could cause a burn.

Advises you that failure to take or avoid a specic action could result in physical harm to you, or could result in physical damage to the hardware.

P1086707-002 ZXP Series 9 Card Printer User Guide 3

Introduction

Printer and Laminator Components

Zebra Supplies

Genuine Zebra supplies meet stringent quality standards and are recommended for optimal printing quality and proper printer performance. The ZXP Series 9 printer is designed to work only with

Zebra True Colours® i Series™ Ribbons, Zebra True Colours i Series Transfer Film, and Zebra True

Secure™ i Series Laminates. Go to the ZXP Series 9 support page at www.zebra.com/zxp9-info for ordering information.

4 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

General Information

This section provides information on the installation and setup of the ZXP Series 9 Card Printer— procedures should be performed in the order presented.

5 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Unpacking the Printer

Important • Save all the packing material and the shipping carton in case the printer needs to be

moved or shipped. If the original packing material is lost or damaged, a replacement shipping kit can

be ordered from Zebra.

Make sure the following items are included with your printer:

 Setup Guide (to be used as a reference poster)

 User CD

 Product Registration Card

 Printer Test Cards

 Input Hopper with stack of 100 cards

 Output Hopper

 Cleaning Cartridge

 Cleaning Roller

 USB Cable

 Power Cable

If any items are missing, please contact your Zebra representative.

Place the printer in a location that meets the following requirements:

y A reasonably dust- and dirt-free environment.

y Flat surface at least 27 x 28 inches (686 x 711 mm) that can support the weight of the printer;

additional space preferred. Allow a 4-inch minimum clearance on all sides.

y Vertical clearance at least 32 inches (813 mm).

y Temperature within the range of 59–95°F (15–35°C).

y Relative humidity 20–80% inclusive, non-condensing.

y AC power accessible.

6 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Unpacking the Printer with a Laminator

Important • Save all the packing material and the shipping carton in case the printer needs to be

moved or shipped. If the original packing material is lost or damaged, a replacement shipping kit can

be ordered from Zebra.

Make sure the following items are included with the printer:

 Setup Guide (to be used as a reference poster)

 User CD

 Product Registration Card

 Printer Test Cards

 Upper Laminate Cassette (for single- and double sided printers)

 Lower Laminate Cassette (for double-sided printers)

 Input Hopper with stack of 100 cards

 Output Hopper

 Cleaning Cartridge

 Cleaning Roller

 USB Cable

 Power Cable

If any items are missing, please contact your Zebra representative.

Place the printer in a location that meets the following requirements:

y A reasonably dust- and dirt-free environment.

y Flat surface at least 38 x 28 inches (965 x 711 mm) deep that can support the weight of the

printer; additional space preferred. Allow a 4-inch minimum clearance on all sides.

y Vertical clearance at least 32 inches (813 mm).

y Temperature within the range of 59–95°F (15–35°C).

y Relative Humidity 20–80% inclusive, non-condensing.

y AC power accessible.

P1086707-002 ZXP Series 9 Card Printer User Guide 7

Installation and Setup

Unpacking (continued)

THe ZXP Series 9 Card Printer ships with packing material and tape to protect the printer from damage during shipment—it is important to remove all packing material and tap prior to using the printer.

Remove the tape and packing material from the front and rear of the printer as shown in the gures

below.

8 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Unpacking (continued)

Then, open the printer by pressing the yellow release button and remove the packing material.

If the printer came with the optional laminator installed, remove the packing tape from the laminator as shown in the gure below.

P1086707-002 ZXP Series 9 Card Printer User Guide 9

Installation and Setup

Unpacking (continued)

Then, open the laminator cover by pulling forward on the tab on the left side of the laminator cover and remove the packing tape as shown in the gure below.

10 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Loading Cards

Caution • 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.

Step 1. Remove the wrapping from the card deck.

Step 2. Holding the card deck by the sides (do not touch the print surfaces), hold it vertically

against a at surface such as a desktop. If the deck is too thick for your hand to hold it comfortably, use about half a deck at a time.

Step 3. Push the stack back and forth to an angle of about 45° from vertical, so as to

separate all of the cards.

Note • Static charges and edge burrs from the card die-cutting process can render

individual cards stuck together with signicant adhesion force. These cards must be physically separated from each other before inserting into the feeder; if not separated,

feeding or printing problems may occur.

Step 4. Restore the card stack to its original squared-off condition.

Step 5. Open the input hopper door—cards can be loaded into the hopper while it is attached

to the printer.

Step 6. Place the cards in the input hopper in the orientation shown: smart card contacts (if

present) up and toward the body of the printer; mag stripe (if present) down and to

the rear). Ensure that the cards are seated at on the bottom of the hopper.

Step 7. Close the input hopper door.

P1086707-002 ZXP Series 9 Card Printer User Guide 11

Installation and Setup

Installing the Card Hoppers

Input Hopper

The input hopper is positioned on the right side of the printer and holds the cards to be printed.

Step 1. Install the input hopper by sliding it into the receptacle so that the guide posts on the

hopper (circled below) align with the guide slots (arrows below).

Step 2. Ensure that the input hopper locks securely in place.

12 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Installing the Card Hoppers

Output Hopper

The output hopper is positioned on the left side of the printer (or the left side of the laminator if the printer includes a laminator as shown below) and receives the printed cards.

Step 1. Install the output hopper by placing the hopper onto the printer or laminator, and then

sliding downward into the corresponding slots on the printer or laminator.

P1086707-002 ZXP Series 9 Card Printer User Guide 13

Installation and Setup

Installing the Software

The CD that comes with the printer contains the latest driver software at the time of shipping.

It is recommended that the latest driver software be downloaded from the ZXP Series 9 support page at www.zebra.com/zxp9-info.

When installing the software, follow the on-screen instructions to install and congure your printer for

the desired network.

Supported Operating Systems

Supported Windows Drivers Microsoft OS 1

Windows 10 (32 bit)

One to One One to Many Many to One Many to Many

1 Printer - 1 Host

One Host Many Printers

Multiple Hosts (Drivers) One Printer

Multiple Hosts (Drivers) Many Printers

Yes Yes Yes Yes Yes

Printer Pooling

Windows 10 (64 bit) Yes Yes Yes Yes Yes

Windows 8 (32 bit)

Yes Yes Yes Yes Yes

Windows 8 (64 bit) Yes Yes Yes Yes Yes

Server 2008 (64 bit) Yes Yes Yes Yes Yes

Server 2008 (32 bit) Yes Yes Yes Yes Yes

Server 2012 Yes Yes Yes Yes Yes

Server 2003 No No No No No

Windows 7 (64 bit) Yes Yes Yes Yes Yes

Windows 7 (32 bit) Yes Yes Yes Yes Yes

Vista (64 bit)

Vista (32 bit)

No No No No No

Windows XP No No No No No

1. Driver installed on individual Client PCs

2. Printer Pooling Sharing not supported.

3. Windows 10 Home and Pro only (No support for Windows 10 Mobile)

4. No support for Win 8 Metro GUI print driver environment.

5. Need to qualify Service Pack support

14 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Installing the Software

Supported Sharing Combinations

Windows OS (Driver Clients)

Windows OS Server (Driver Host)

Server 2012 Yes Yes Yes Yes Yes Yes No

Server 2008 (64 bit) Yes Yes Yes Yes Yes Yes No

Server 2008 (32 bit) Yes Yes Yes Yes Yes Yes No

Server 2003 Yes No Yes No Yes No No

Windows 10 (64 bit) Yes Yes Yes Yes Yes Yes No

Windows 10 (32 bit) Yes No Yes No Yes No No

Windows 8 (64 bit) Yes Yes Yes Yes Yes Yes No

Windows 8 (32 bit) Yes No Yes No Yes No No

Windows 7 (64 bit) Yes Yes No No Yes Ye s No

Windows 7 (32 bit) Yes No No No Yes No No

Windows XP (All Editions) SP 2 and above

Win 10 (32 bit)

No No No No No No No

Win 10 (64 bit)

Win 8

(32 bit)

Win 8

(64 bit)

Win 7

(32 bit)

Win 7

(64 bit)

Windows

P1086707-002 ZXP Series 9 Card Printer User Guide 15

Installation and Setup

Installing the Cleaning Cartridge

The card cleaning cartridge (X-Cleaning Roller) cleans the cards entering the printer through the input hopper. The cleaning cartridge consists of a cartridge frame and an adhesive roller.

Step 1. While holding the cleaning cartridge by the frame, peel the protective wrapper from

the adhesive roller. Do not touch the adhesive surface of the roller.

Step 2. Install the cleaning cartridge into the area shown in the gure below by sliding the

cartridge guide pins into the guide slots on the printer.

Step 3. Press down on the cartridge until it is fully seated.

Note • To ensure print quality, the card cleaning cartridge requires periodic replacement.

New card cleaning rollers are included with each print ribbon or may be purchased

separately. Before replacing the card cleaning cartridge or its adhesive roller, clean

the printer (see “Cleaning the Printer” on page 60). To replace the X-Roller, refer to

“Replacing the Cleaning Rollers” on page 62.

16 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Installing the Cleaning Roller

The cleaning roller (Y-Cleaning Roller) cleans the cards entering the printer from either the input hopper or the manual feed slot.

Step 4. Peel the protective wrapper from the cleaning roller.

Step 5. Install the cleaning cartridge into the area shown in the gure below by placing it into

the notches on the printer. Use the protective wrapper to push the cleaning roller into place until it locks into position.

Note • To ensure print quality, the card cleaning cartridge requires periodic replacement.

New card cleaning rollers are included with each print ribbon or may be purchased

separately. Before replacing the card cleaning cartridge or its adhesive roller, clean

the printer (see “Cleaning the Printer” on page 60). To replace the Y-Roller, refer to

“Replacing the Cleaning Rollers” on page 62.

P1086707-002 ZXP Series 9 Card Printer User Guide 17

Installation and Setup

Loading the Transfer Film

The ZXP Series 9 Card printer is designed to work only with Zebra True Colours® i Series™ Transfer Film for near photographic print resolution and over-the-edge printing.

Step 1. Locate the transfer lm supply spindles and the transfer lm take-up spindles. Note

that the anges and spindles are color coded (white-to-white, green-to-green).

Step 2. Unroll about 1 foot (30 cm) from the full roll of transfer lm on the supply spool and

wind it (about 2 wraps) onto the empty take-up spool.

Step 3. Load transfer lm supply spool onto the supply spindles—green ange side to the

left.

Step 4. Load the empty take-up spool onto the take-up spindles—white ange side to the

right.

Step 5. Make sure the spring-loaded spindles on the right seat into the spools.

Step 6. Make sure the transfer lm comes off the bottom of the supply spool and feeds to the

bottom of the take-up spool.

Step 7. Route the transfer lm under the retaining tab.

18 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Loading Print Ribbon

The ZXP Series 9 Card printer is designed to work with Zebra True Colours® i Series™ Ribbons. Each new ribbon comes with a replacement set of cleaning rollers. It is recommended that they

be replaced for each new ribbon or every 5,000 cards. Refer to “Cleaning the Printer” on page

60 for recommended cleaning intervals, and “Replacing the Cleaning Rollers” on page 62 for

replacement instructions.

Step 1. Locate the print ribbon supply spindles and the print ribbon take-up spindles. Note

that the anges and spindles are color coded (blue-to-blue, purple-to-purple).

Step 2. Load the print ribbon supply spool onto the supply spindles—purple ange side to the

left.

Step 3. Load the empty take-up spool onto the take-up spindle, blue ange side to the right—

make sure the spring-loaded spindles on the left seat into the spools.

Step 4. Make sure the print ribbon comes off the bottom of the supply spool and feeds to the

bottom of the take-up spool.

P1086707-002 ZXP Series 9 Card Printer User Guide 19

Installation and Setup

Replacing the Laminate

Opening the Laminator Door

Step 1. Grasp the door at the side tab front and pull forward and lift the door to its upright

position.

Removing the Laminate Cassette(s)

Step 1. Unlock the laminate cassette by rotate the locking lever in the direction indicated in

the gure below.

20 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Replacing the Laminate

Step 2. Rotate each cassette in the direction indicated below until it stops.

Step 3. Remove each cassette by pulling straight out from its spindle.

P1086707-002 ZXP Series 9 Card Printer User Guide 21

Installation and Setup

Replacing the Laminate

Step 4. Open each cassette by separating its two halves at the hinge—grasp the two halves

rmly then pull apart. Do NOT use tools.

Step 5. If there is an empty laminate core in the cassette, remove it.

22 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Replacing the Laminate

Loading the Laminate Cassette(s)

Note • The laminate roll is specic to either the top (blue) or the bottom (yellow) laminate

cassette.

Note • The lower laminate cassette (yellow) is used on a double-sided laminator only.

Important • The geared ange on the laminate spool is removable, but do not remove it. If it does come off, snap it back onto the end of the spool.

Step 1. Remove a new roll of laminate from its packaging and place it in the upper laminate

cassette—note the orientation of the laminate spool with respect to the laminate

cassette as shown in the gure below.

Step 2. Pull out an inch or two of laminate past the lip of the cassette.

Step 3. Close the cassette—press the two halves of the cassette together until it clicks.

Step 4. Cut the laminate square (as close to perpendicular as possible) with scissors. Hold

the scissors in one hand. Hold the cassette with the other hand. Press the laminate

rmly against the white roller thereby keeping the laminate from moving while cutting.

P1086707-002 ZXP Series 9 Card Printer User Guide 23

Installation and Setup

Replacing the Laminate

Step 5. Remove a second new roll of laminate from its packaging and place it in the lower

laminate cassette—note the orientation of the laminate spool with respect to the

laminate cassette as shown in the gure below.

Step 6. Pull out an inch or two of laminate past the lip of the cassette.

Step 7. Close the cassette—press the two halves of the cassette together until it clicks.

Step 8. Cut the laminate square (as close to perpendicular as possible) with scissors. Hold

the scissors in one hand. Hold the cassette with the other hand. Press the laminate

rmly against the white roller thereby keeping the laminate from moving while cutting.

24 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Replacing the Laminate

Step 9. Rotate the core to adjust the laminate overhang. Stop when the end of the laminate

is just beyond the lip of the cassette, as shown below.

Important • Check for laminate overhang any time the locking lever is pressed or the cassette is removed.

0 - 0.5 mm 0 - 1/32"

P1086707-002 ZXP Series 9 Card Printer User Guide 25

Installation and Setup

Replacing the Laminate

Installing the Laminate Cassette

Step 1. Slide the cassette onto the spindle.

Step 2. Rotate each cassette (in the direction indicated in the gure below).

26 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Replacing the Laminate

Step 3. Continue to turn the cassette. The locking lever will move to the left as the cassette

rotates over the locking mechanism, and will then click into the locked (green)

position.

P1086707-002 ZXP Series 9 Card Printer User Guide 27

Installation and Setup

Replacing the Laminate

Using Partial-Width Laminate

Note • Since partial-width laminates are only used for the back (i.e., lower) surface of the card, this section only applies to the double-sided laminator.

Laminates come in three widths:

y Full-Width laminate is 2 inches (51 mm) wide. The full-width laminate is used on the front

(i.e., upper) or back (i.e., lower) surface of the card.

y “Partial-Width” laminate is available as 1.33 inch (33 mm) wide (used for cards with a

magnetic stripe).

2”

1.3”

FRONT OF CARD

Full Width

BACK OF CARD

Magnetic Stripe

Step 1. Remove the lower laminate cassette.

Step 2. Open the cassette, and remove the laminate if present.

28 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Replacing the Laminate

Step 3. Load the partial-width laminate into the cassette. Note that the collar on the laminate

spool is on the end opposite the geared ange and keeps the laminate positioned

correctly.

Collar

Step 4. Trim the partial-width laminate.

Step 5. Rotate the core to adjust the laminate overhang—stop when the end of the laminate

is even with the edge of the cassette.

Step 6. Install the cassette.

P1086707-002 ZXP Series 9 Card Printer User Guide 29

Installation and Setup

Replacing the Laminate

Laminating Contact Smart Cards

The laminate for the top surface of a contact smart card has a repeating pattern of an index hole and

a rectangular cutout to expose the card’s electrical contacts.

Electrical Contacts

Electrical Contacts Cutout

Index Hole

Step 1. Remove the upper laminate cassette.

Step 2. Open the cassette, and remove the laminate if present.

Step 3. Load the smart card laminate into the cassette.

Step 4. Cut the laminate, splitting the index hole as shown.

30 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Replacing the Laminate

Step 5. Rotate the core to adjust the laminate overhang. Stop when the end of the laminate

(not the edge of the index hole) is even with the edge of the lips of the cassette.

Step 6. Install the cassette (see “Installing the Laminate Cassette” on page 26).

P1086707-002 ZXP Series 9 Card Printer User Guide 31

Installation and Setup

Packing for Shipment

If the printer is to be shipped, it is important to use the original packing and shipping material to

prevent damage to the printer.

If the original material is lost, a replacement shipping kit can be ordered from Zebra. Go to the ZXP

Series 9 support page at www.zebra.com/zxp9-info for more details.

Printer

Note • The specics of the shipment and the printer condition may inuence which of the following

steps are followed; common sense should prevail.

Step 1. Ensure the printer power is set to the off ( ) position.

Step 2. Disconnect the power cable from the power source, then from the rear of the printer.

Step 3. Disconnect the USB cable from the host computer, then from the rear of the printer;

or disconnect the Ethernet cable from the network source, then from the rear of the

printer.

Step 4. Remove any cards from the input and output hoppers—place the hoppers into the

foam insert.

Step 5. Open the printer door.

Step 6. Remove the print ribbon and transfer lm (if you wish to save the print ribbon and lm

for future use, you may want to put them in a plastic bag for storage).

Step 7. Remove the card cleaning cartridge and card cleaning roller—place them in the foam

insert.

Step 8. Close the printer door.

Output Hopper

Input Hopper

Cleaning Cartridge

Cleaning Roller

Step 9. Place the printer in its protective bag.

Step 10. Place the lower foam insert with the accessories into the shipping carton.

32 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Packing for Shipment

Caution • The printer weighs approximately 27.5 lbs (12.5 kg). Two people may be necessary to lift the printer.

Step 11. Carefully place the printer into the recess in the lower foam insert (shown out of box

for clarity).

Step 12. Place the upper foam insert onto the printer, and gently press it down so it makes

a snug t on the printer—the top of the upper foam insert should be even with the

upper edge of the shipping carton.

Step 13. Roll up the power cord and USB cable and place them in the recess of the upper

foam insert.

Step 14. Close the shipping carton and tape it securely.

P1086707-002 ZXP Series 9 Card Printer User Guide 33

Installation and Setup

Packing for Shipment

Printer with Laminator

Step 1. Ensure the printer power is set to the off ( ) position.

Step 2. Disconnect the power cable from the power source, then from the rear of the printer.

Step 3. Disconnect the USB cable from the host computer, then from the rear of the printer;

or disconnect the Ethernet cable from the network source, then from the rear of the

printer.

Step 4. Remove any cards from the Input and output hoppers—place the hoppers into the

lower foam insert.

Step 5. Open the printer door.

Step 6. Remove the print ribbon and transfer lm (if you wish to save the print ribbon and lm

for future use, you may want to put them in a plastic bag for storage).

Step 7. Remove the card cleaning cartridge and card cleaning roller—place them in the foam

insert.

Step 8. Close the printer door.

Output Hopper

Input Hopper

Cleaning Roller

Cleaning Cartridge

Step 9. Open the laminator door.

Step 10. Place the lower foam insert with the accessories into the shipping carton.

34 ZXP Series 9 Card Printer User Guide P1086707-002

Installation and Setup

Packing for Shipment

Step 11. Remove the laminate cassette(s)—any unused laminate can remain in the

cassette(s)—and place the cassette(s) into the upper foam insert from the underside.

Laminate Cassette(s)

Step 12. Close the laminator door.

Step 13. Place the unit in its protective bag.

Caution • The printer weighs approximately 44 lbs (20 kg). Use two people to lower it into

the shipping carton.

Step 14. With two people, carefully lift and place the unit into the recess in the lower foam

insert.

P1086707-002 ZXP Series 9 Card Printer User Guide 35

Installation and Setup

Packing for Shipment

Step 15. Place the two corner blocks on top of the right front and left front corners of the lower

foam insert.

Step 16. Place the upper foam insert onto the unit, and gently press it down so it makes a

snug t on the unit—the top of the upper foam insert should be even with the upper

edge of the carton.

Step 17. Roll up the power cord and USB cable and place them in the recess of the upper

foam insert.

Step 18. Close the shipping carton.

Step 19. Tape the shipping carton securely.

36 ZXP Series 9 Card Printer User Guide P1086707-002

Operation

Introduction

Printing with the ZXP Series 9 Card Printer is similar to printing with any other printer in a Windows

environment:

y The printer is connected to either a host computer (via USB), or to a network (via Ethernet).

y The printer is selected by either the operating system or the appropriate software application.

y Printer properties are set via the printer driver (although the factory default values will be

appropriate for many applications).

37 ZXP Series 9 Card Printer User Guide P1086707-002

Operation

Printing Preferences

The Printing Preferences Control panel can be used to determine preferences such as which ribbon

panels will be used to print images on the card, what card type will be used, where the card comes from (i.e., the input hopper or the manual feed slot) and its destination. It is also used to make

adjustments to colors and black panel quality.

The following tabs are included in the Printing Preferences Control Panel:

y Card Setup Tab

y Encoding Tab

y Black Panel (K) Optimization Tab

y Color (YMC) Optimization Tab

y About Tab

The Restore Defaults button sets the printing preferences back to factory settings.

The OK button applies the settings and closes the Printing Preferences Control Panel.

The Cancel button closes the Printing Preferences Control Panel without applying the changes made.

The Apply button makes (or applies) the changes. The Printing Preferences Control panel remains open.

The Help button shows this help content.

To open the Printing Preferences Control Panel:

y Windows 7: Select Start > Devices and Printers, right click the Zebra ZXP Series 9 Card

Printer, and select Printing preferences from the pop-up menu.

y Windows 8: Right-click the screen’s bottom-left corner (or press Windows+I) and choose

Control Panel from the pop-up menu, right click the Zebra ZXP Series 9 Card Printer, and

select Printing preferences from the pop-up menu.

y Windows 10: Select the Start menu and then select Settings > Devices, right click the Zebra

ZXP Series 9 Card Printer, and select Printing preferences from the pop-up menu.

38 ZXP Series 9 Card Printer User Guide P1086707-002

Operation

Card Type Selection

The Printing Preferences Control Panel enables you to specify the card type in use. Based on your

selection, the printer makes adjustments for optimum print quality.

Step 1. Open the Printing Preferences Control Panel (“Printing Preferences” on page 38).

Step 2. From the Card Setup tab, click the Card type in use drop-down menu and select the

appropriate card type (circled below). Supported card types are:

y PVC, Standard y PVC, Mag Stripe y PVC, Contactless SC y PVC, Contact SC y Composite, Standard y Composite, Mag Stripe

If your card type is not listed in the drop-down menu, select Custom and ll out the Card Specications pop-up screen (see “Setting Custom Card Specications” on

page 101 for details).

For help setting the custom card specications for your card type, contact the Zebra Card Testing Service at 866-569-9086 (Toll Free), or cardtestingservice@zebra.com.

Step 3. Click Apply and then click OK.

P1086707-002 ZXP Series 9 Card Printer User Guide 39

Operation

Print Ribbon Selection

A variety of ribbons are available for use with the ZXP Series 9 Card Printer.

For example, the YMC ribbon prints yellow (Y), magenta (M), and cyan (C) on the front and the back (if the printer is double-sided). The YMCK ribbon prints yellow, magenta, and cyan on the front of the card, and black on the back of the card (if the printer is double-sided).

The YMCKI ribbon is for use with mag stripe cards, and will print yellow, magenta, and cyan on the front of the card, and black on the lower half of the back—avoiding printing over the mag stripe.

The YMCUvK ribbon adds a layer of ultra-violet (Uv) to print invisible images (text or graphics) that will glow in the visible spectrum when exposed to a Uv light.

The printer will recognize the type of print ribbon installed and display it in the Ribbon type eld

of the Printing Preferences Control Panel Card Setup tab, and (as shown in the following gure)

will make available the ribbon combinations from the Ribbon combinations drop-down menu. Additionally, selecting Yes or No (double- or single-sided, respectively) from the Print on both sides drop-down list will affect the available ribbon combinations.

The table below shows the supported print ribbons and their respective combinations for single- and double-sided printing.

Ribbon Print on both sides Ribbon Combinations

No YMCK

YMCK

YMCKK

YMCKI

YMCKKI

YMCUvK

YMC

K (Monochrome)

Yes

No YMCK Front

Yes

No YMCKI Front

Yes

No YMCKI Front

Yes

No YMCUvK Front

Yes

No YMC Front

Yes YMC Front / YMC Back

No K Front

Yes K Front / K Back

YMC Front / K Back

YMCK Front / YMCK Back

YMCK Front / K Back

YMCK Front / YMCK Back

YMC Front / KI Back

YMCI Front / K Back

YMCKI Front / YMCKI Back

YMCK Front / KI Back

YMCKI Front / K Back

YMCKI Front / YMCKI Back

YMCUv Front / K Back

YMC Front / UvK Back

YMCUvK Front / YMCUvK Back

40 ZXP Series 9 Card Printer User Guide P1086707-002

Operation

Print Ribbon Selection

Step 1. Open the Printing Preferences Control Panel (“Printing Preferences” on page 38).

Step 2. From the Card Setup tab, click the Ribbon combination drop-down menu and make

the appropriate selection (circled below).

In the example above, the available ribbon combinations for the installed YMCK ribbon are YMC on the front of the card, and K on the back of the card; or YMCK on both the front and back of the card.

The available Ribbon combinations is also dependent on if printing is set to single- or double sided.

P1086707-002 ZXP Series 9 Card Printer User Guide 41

Operation

Printing a Test Card

The Printing Preferences Control Panel has the option for printing a test card. This is a simple device

to ensure the printer is working properly, and to check the quality of the print. The test card is printed

according to the settings in the Card Setup tab.

Step 1. Open the Printing Preferences Control Panel (“Printing Preferences” on page 38).

Step 2. From the Card Setup tab, adjust the Card Options, Printing Options, etc., to suit your

preferences.

Step 3. Click Test Print (circled below).

42 ZXP Series 9 Card Printer User Guide P1086707-002

Operation

Printing a Test Card

An enhanced test print feature is also available from the ZXP Toolbox. This feature offers a wider range of test cards to showcase the quality of print from the ZXP Series 9 Card Printer. The test card is printed according to the settings in the Card Setup tab.

To print a test card from the ZXP Toolbox:

Step 1. Open the Printer Properties control panel:

y Windows 7: Select Start > Devices and Printers, right click the Zebra ZXP Series 9

Card Printer, and select Printer Properties from the pop-up menu.

y Windows 8: Right-click the screen’s bottom-left corner (or press Windows+I) and

choose Control Panel from the pop-up menu, right click the Zebra ZXP Series 9 Card Printer, and select Printer Properties from the pop-up menu.

y Windows 10: Select the Start menu and then select Settings > Devices, right click

the Zebra ZXP Series 9 Card Printer, and select Printer Properties from the pop-

up menu.

Step 2. Select the Device Information tab and click the ZXP Toolbox button.

P1086707-002 ZXP Series 9 Card Printer User Guide 43

Operation

Printing a Test Card

Step 3. Select the Tools & Utilities page (the Test Cards menu is displayed by default).

Step 4. Select an image from the Test Card Library and click either Set as Front or Set as

Back to set the front and back of the test card; or you can add your own images to

the library and use them for the test card.

Step 5. When the front and the back images are set, click Print Test Cards.

44 ZXP Series 9 Card Printer User Guide P1086707-002

Operation

Manual Card Feed

A manual feed slot is available for feeding single cards. Note that this option works with cards in the input hopper.

Step 1. Open the Printing Preferences Control Panel (“Printing Preferences” on page 38).

Step 2. From the Card Setup tab, click the Card source drop-down menu and select Manual

Feed (circled below).

Step 3. Click Apply.

Step 4. Send the print job to the printer. When ready, the printer OCP will prompt you to

insert the card.

P1086707-002 ZXP Series 9 Card Printer User Guide 45

Operation

Manual Card Feed

Step 5. Insert a single card into the slot in the correct orientation. Do not feed more than one

card at a time.

Caution • DO NOT bend cards, and refrain from touching print surfaces as much as

possible 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.

Step 6. The printer will feed in the card and start printing.

Step 7. Once the printing job is complete, the card is ejected from the printer into the output

hopper.

46 ZXP Series 9 Card Printer User Guide P1086707-002

Operation

Operator Control Panel (OCP)

The printer is equipped with an OCP display and three OCP buttons which give access to the printer menus.

READY

MENU INFO PRINT

y Press the MENU button to access the Main Menu.

y Press the INFO button to access and view the printer information pages.

y Press the PRINT button to print the last card stored in memory.

P1086707-002 ZXP Series 9 Card Printer User Guide 47

Operation

PREV NEXT EXIT

Displays Settings: Top and Bottom temperature; and Current:

Displays Settings: SSID, Channel Noise Floor, WEP, DHCP,

Displays Settings: Top and Bottom temperature; and Current

Displays RX Bytes, Discards, TX Bytes, Discards, Errors; TX

Operator Control Panel (OCP)

Printer Menu Information

Info Menu

INFO Button

(Operating Mode Display)

PRINTER INFO

NETWORK INFO

RIBBON INFO

FILM INFO Displays Type, # Images, and % Remaining.

PRINTHEAD USAGE

REJECT BIN Displays Card Count.

CONFIGURATION INFO

TEMPERATURE INFO

LAMINATOR INFO *

TOP LAMINATE INFO * Displays P/N, Type, # Images, and % Remaining.

Displays MCB FW Ver, HCB FW Ver, MAB FW Ver, and Mfr

Serial Number.

Displays DHCP, IP, Mask, GW, and MAC.

Displays Type, # Images, and % Remaining.

Displays Card Count and Printhead Lines.

Displays RAM, Single or Dual Sided, and Options Installed: Mag, Encoder, Laminator.

Temperature: Top and Bottom.

Displays LCB, MAB, LSN, Top installed (yes/no), Bottom

installed (yes/no).

48 ZXP Series 9 Card Printer User Guide P1086707-002

BTM LAMINATE INFO * Displays Type, # Images, and % Remaining.

LAM TEMPERATURE INFO *

LAMINATOR ODOMETER *

CAL LUT INFO Displays Look-Up Table info for LUT1 and LUT2.

WIRELESS INFO **

WIRELESS STATISTICS **

Info Menu

Top and Bottom temperature.

Displays Unit on (# days), Top on (# days), Bottom on (# days), # Laminated, # Processed.

IP, Mask, GW, and MAC. Only applies to Printers with the

Wireless option installed.

Success, TX Retry, RX Success, RX Duplicate, and RTS Success. Only applies to Printers

with the Wireless option installed.

* Applies to printer with attached laminator. ** Applies to printer with optional wireless upgrade.

Main Menu

Operation

Operator Control Panel (OCP)

MENU Button

(Operating Mode Display)

RETURN

PRINT TEST CARDS See see page 42

NETWORK SETTINGS Network Settings Menu (see page 51)

ADVANCED SETTINGS

ENCODER SETTINGS

WIRELESS SETTINGS Wireless Settings Menu (see page 55)

Main Menu

UP DOWN SELECT

Advanced Settings Menu (see page 52)

Encoder Settings Menu (see page 53)

P1086707-002 ZXP Series 9 Card Printer User Guide 49

Operation

Operator Control Panel (OCP)

Print Test Cards Menu

Main Menu

RETURN

> COUNT

> SIDES Selects single-sided or double-sided printing.

> CARD TYPE

GRADIENT BOXES Prints a test card with varying gradient boxes.

DENSITY SETUP

MONOCHROME ONLY

Print Test Cards Menu

UP DOWN

SELECT /

Selects the number of cards to be printed (1, 5, 10, 25, 50, 75, 100)

Selects the type of cards being printed on (varying types of

PVC, Composite, etc.).

Prints a test card with varying color densities.

Prints a test card with monochrome bitmap elements. Only works when monochrome ribbon is installed.

50 ZXP Series 9 Card Printer User Guide P1086707-002

Network Settings Menu

UP DOWN SELECT

RETURN WITHOUT SAVE

Operation

Operator Control Panel (OCP)

Main Menu

SAVE SETTINGS

DHCP MODE

SET IP ADDRESS

SET SUBNET MASK Change the subnet mask.

SET DEFAULT GATEWAY Change the gateway.

Network Settings Menu

Enable or disable DHCP mode.

Change the IP address of the printer.

P1086707-002 ZXP Series 9 Card Printer User Guide 51

Operation

Operator Control Panel (OCP)

Advanced Settings Menu

Main Menu

RETURN

SELECT LANGUAGE

FLUSH PRINT QUEUE

PRINTER ONLINE

CLEAN PRINTER

SET SLEEP TIMER

SET SCREEN CONTRAST

CLEAR REJECT BIN

HOST USB SETTINGS

SET WARMUP DELAY

Select the language of the OCP.

Deletes all pending print jobs stored in the printer.

Toggles printer online/ofine.

Runs the cleaning routine (see “Maintenance” on page 59).

Sets the idle duration before entering sleep mode.

Sets the contrast level of the OCP.

Resets the reject bin count to zero.

Host USB settings.

Sets the idle duration before beginning warm-up.

Advanced Settings Menu

UP DOWN SELECT

52 ZXP Series 9 Card Printer User Guide P1086707-002

Encoder Settings Menu

Operation

Operator Control Panel (OCP)

Main Menu

RETURN

USB ENCODING

ETHERNET ENCODING

Encoder Settings Menu

UP DOWN SELECT

Select if printer is connected via USB.

Select if printer is connected via Ethernet.

P1086707-002 ZXP Series 9 Card Printer User Guide 53

Operation

Operator Control Panel (OCP)

Clean Printer Menu

Main Menu

RETURN

CLEAN SIDE CARD PATH

CLEAN FRONT CARD PATH

CLEAN HEATER ROLLERS

CLEAN LAM CARD PATH *

CLEAN MED LAM ROLLERS * Use the Cleaning Swab and follow the OCP instructions.

CLEAN LAM OVEN *

Clean Printer Menu

UP DOWN SELECT

Use the X Roller Cleaning Card and follow the OCP instructions.

Use the Y Roller Cleaning Card and follow the OCP instructions.

Use the Hot Roller Cleaning Card and follow the OCP instructions.

Use the Laminator Cleaning Card and follow the OCP instructions.

Use the Laminator Hot Roller Cleaning Card and follow the OCP instructions.

* Applies to printer with attached laminator.

54 ZXP Series 9 Card Printer User Guide P1086707-002

Wireless Settings Menu

RETURN WITHOUT SAVE

SAVE SETTINGS

Operation

Operator Control Panel (OCP)

Main Menu

RADIO CONTROL

SETUP WIZARD

DHCP MODE

SET IP ADDRESS Change the IP address of the printer.

SET SUBNET MASK

SET DEFAULT GATEWAY

SET DEFAULTS

Advanced Settings Menu

UP DOWN SELECT

Enable or disable the radio.

Easily connect you printer to a wireless network. †

Enable or disable the DHCP.

Change the subnet mask.

Change the gateway.

Return to the default wireless settings.

† See “Setup via OCP” on page 97 for additional information.

P1086707-002 ZXP Series 9 Card Printer User Guide 55

Operation

Messages

Operational

Operational messages are displayed during normal operation.

MESSAGE DESCRIPTION

ALARM

CANCELING

CONFIG DATA

CONTACT OPERATION

CONTACTLESS OPERATION

COOLING

COOLING PRINT JOB WAITING Print job received, cooling rollers to temperature.

COOLING PRINTHEAD TEMPERATURE Cooling printhead to temperature.

COOLING WAITING TO LAMINATE Print job completed, laminator cooling to temperature.

DIAGNOSTIC Diagnostic testing in progress.

JOB DATA Data is being transferred from the computer to the printer.

LAMINATING Print job received, laminating in process.

MAG OPERATION

MANUALLY INSERT CARD FROM FRONT

OFFLINE Status toggled (ofine/online) via the OCP Advanced Settings Menu.

PRINTING Print job received, printing in process.

READY Ready and at temperature.

STANDBY Printer is in “sleep” mode; i.e., power save mode.

WAIT INITIALIZING Performing a self test on startup.

WARMING

WARMING PRINT JOB WAITING Print job received, warming rollers to temperature.

WARMING

WAITING TO LAMINATE

WARMING PRINTHEAD TEMPERATURE Warming printhead to temperature.

WARNING

An error message needs to be cleared before normal operations can resume.

The Cancel button was pressed, and the current operation is being

terminated.

Conguration data is being transferred from the computer to the

printer.

Contact Smart Card is being encoded; i.e., the card is in position and

data is being transferred.

Contactless Smart Card is being encoded; i.e., the card is in position

and data is being transferred.

Ready to accept a print job, rollers cooling; e.g., when switching from

2-sided printing to 1-sided printing.

A Magnetic Stripe Card is being encoded; i.e., card is in position and

data is being transferred.

Waiting for manual card feed.

Ready to accept a print job, rollers heating; e.g., at startup or when

switching from 1-sided printing to 2-sided printing.

Ready to accept a print job, laminator warming; e.g., when switching

from 1-sided laminating to 2-sided laminating.

Indicates that additional OCP instructions need to be performed; e.g., PRINT RIBBON LOW, etc.

56 ZXP Series 9 Card Printer User Guide P1086707-002

Operation

Messages

Warning Messages

Warnings alert the operator to action that should be taken—the printer will generally continue operation.

WARNING (Printer will still operate)

BOTH LAMINATES LOW

BOTTOM LAMINATE LOW

CLEAN FEEDER Indicates that the Feeder needs cleaning.

CLEAN FRONT CARD PATH

CLEAN LAM CARD PATH

CLEAN LAM MED ROLLERS

CLEAN LAM OVEN

CLEAN SIDE CARD PATH

CLEAN TRANSFER PATH

PRINT RIBBON LOW

TOP LAMINATE LOW

TRANSFER FILM LOW

DESCRIPTION

Indicates that the Top Laminate cassette and the Bottom Laminate cassette are low.

Indicates that the Bottom Laminate cassette is low (see “Loading the

Laminate” on page 21.

Indicates that the Front Card Path (Y-Drive Rollers) needs cleaning (see Maintenance on page 69).

Indicates that the Laminator Card Path needs cleaning (see Maintenance on page 69).

Indicates that the Laminator Media Feed Rollers need cleaning (see Maintenance on page 69).

Indicates that the Laminator Transfer Path (Heated Rollers) needs cleaning (see Maintenance on page 69).

Indicates that the Side Card Path (X-Drive Rollers) needs cleaning (see Maintenance on page 69).

Indicates that the Transfer Path (Heated Rollers) needs cleaning (see Maintenance on page 69).

Indicates that the Print Ribbon spool is low (see “Loading a Print

Ribbon” on page 18).

Indicates that the Top Laminate cassette is low (see “Loading the

Laminate” on page 21).

Indicates that the Transfer Film spool is low (see “Loading the

Transfer Film” on page 18).

Error Messages

Errors are displayed when a situation causes the printer to stop operating. Depending on the cause

of the error message, restarting the printer or clearing the displayed error may return the printer to

operational status; or the printer may require troubleshooting and repair.

See “Troubleshooting” on page 71 for a list of the error messages, possible causes, and possible solutions.

P1086707-002 ZXP Series 9 Card Printer User Guide 57

58 ZXP Series 9 Card Printer User Guide P1086707-002

Maintenance

Caution • PROTECT YOUR FACTORY WARRANTY!

The recommended maintenance procedures must be performed to maintain the factory

warranty. Other than the recommended cleaning procedures described in this manual,

allow only Zebra authorized technicians to service the 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 from the printer.

59 ZXP Series 9 Card Printer User Guide P1086707-002

Maintenance

Cleaning the Printer

The regular use of cleaning cards will clean and maintain important parts of your printer that cannot

be reached, including the printhead, transport rollers, and optional magnetic encoder station.

Printer usage (total number of cards printed and total number of cards laminated) can be found

on the printer Properties, Device Information tab, or via the OCP Info Menu (see “Printer Menu

Information” on page 48).

To order cleaning supplies, please visit www.zebra.com/zxp9-info.

When to Clean

y X-Cleaning Roller and Y-Cleaning Roller replacement should occur every 5,000 cards (see

“Replacing the Cleaning Rollers” on page 62).

y Heated Roller cleaning should occur every 20,000 cards.

Rollers

Important • Do not reuse cleaning cards.

To initiate the cleaning process:

Step 1. On the operator control panel (OCP) select Menu.

Step 2. From the Main Menu select Advanced Settings.

Step 3. From the Advanced Settings menu select Clean Printer.

To clean the X-drive rollers:

Step 1. Select Clean Side Card Path to run the X-roller cleaning routine.

Step 2. Use the X-roller cleaning card.

Step 3. Follow the OCP instructions.

Step 4. When complete, the OCP will return to the Clean Printer Menu.

60 ZXP Series 9 Card Printer User Guide P1086707-002

To clean the Y-drive rollers:

Step 1. Select Clean Front Card Path to run the Y-roller cleaning routine.

Step 2. Use the Y-roller cleaning card.

Step 3. Follow the OCP instructions.

Maintenance

Cleaning the Printer

Step 4. When complete, the OCP will return to the Clean Printer Menu.

To clean the heated rollers:

Note • To avoid a long wait while the heated rollers cool to 70°C, perform cleaning before the rollers heat up (i.e., when rst turned on and the rollers are still cold).

Step 1. Select Clean Transfer Path to run the heated roller cleaning routine.

Step 2. Use the hot roller cleaning card.

Step 3. Follow the OCP instructions.

Step 4. When complete, the OCP will return to the Clean Printer Menu.

P1086707-002 ZXP Series 9 Card Printer User Guide 61

Maintenance

Cleaning the Printer

Platen

Platen cleaning is done manually, there is no OCP cleaning routine.

Step 1. Open the printer door.

Step 2. Remove the transfer lm.

Step 3. Manually run the hot roller cleaning card over the platen.

Step 4. Re-install the transfer lm.

Step 5. Close the printer door.

Replacing the Cleaning Rollers

The X-cleaning roller is part of the cleaning cartridge assembly—only the roller is replaceable.

To replace the X-cleaning roller:

Step 1. Open the printer and remove the cleaning cartridge from the printer.

Step 2. Grasp the used roller and pull it out from the cartridge.

Step 3. Insert the new cleaning roller into the cartridge—press rmly until it snaps into place.

Step 4. Remove the protective cover.

To replace the Y-cleaning roller:

Step 1. Open the printer.

Step 2. Grasp the used cleaning roller and pull down and out in a singular motion.

Step 3. Grasp the new roller by the edges and remove the protective cover.

Step 4. While still holding the roller at the edges, insert the new cleaning roller into position

by pressing in and up in a singular motion.

62 ZXP Series 9 Card Printer User Guide P1086707-002

Maintenance

Cleaning the Laminator

The regular use of cleaning cards will clean and maintain important parts of your laminator that cannot be reached.

Printer usage (total number of cards printed and total number of cards laminated) can be found

on the printer Properties, Device Information tab, or via the OCP Info Menu (see “Printer Menu

Information” on page 48).

When to Clean

y Cleaning should occur every 5,000 cards.

y Heated Roller cleaning should occur every 20,000 cards.

Laminator

Note • To avoid a long wait while the card transport rollers cool to 60°C, perform cleaning before the rollers heat (i.e., when rst turned on and the rollers are still cold).

Important • Do not reuse cleaning cards.

To initiate the cleaning process:

Step 1. On the operator control panel (OCP) select Menu.

Step 2. From the Main Menu select Advanced Settings.

Step 3. From the Advanced Settings menu select Clean Printer.

To Clean the Card Path:

Step 1. Select Clean Lam Card Path to run the laminator cleaning routine.

Step 2. Use the laminator cleaning card in the laminator cleaning kit.

Step 3. Follow the OCP instructions.

Step 4. When complete, the OCP will return to the Clean Printer Menu.

P1086707-002 ZXP Series 9 Card Printer User Guide 63

Maintenance

Cleaning the Laminator

To Clean the Media Feed Rollers:

Step 1. Select Clean Lam Med Rollers to run the laminator media roller cleaning routine.

Step 2. Lift the laminator door to its upright position.

Step 3. Remove the laminate cassette(s) (see “Removing the Laminate Cassette(s)” on

page 20).

Step 4. Leave the laminator door open

Step 5. Use the cleaning swab in the laminator cleaning kit. Bend the swab to release the

cleaning uid.

Step 6. Press Next when ready, then press To p.

Step 7. Clean the top media roller (circled below) by moving swab tip side-to-side as it turns

ve full revolutions. Only use moderate force.

64 ZXP Series 9 Card Printer User Guide P1086707-002

Step 8. For the double-sided laminator only:

a. Locate the roller (circled below) for the lower cassette.

Maintenance

Cleaning the Laminator

b. Use a second cleaning swab in the laminator cleaning kit. Bend the swab to

release the cleaning uid.

c. Press Bottom.

d. Clean the bottom media roller by moving swab tip side-to-side as it turns ve full

revolutions. Only use moderate force.

e. When the operation is complete, press Exit.

Step 9. Reinstall the laminate cassette(s).

Step 10. Close the laminator door.

P1086707-002 ZXP Series 9 Card Printer User Guide 65

Maintenance

Cleaning the Laminator

To Clean the Heater Assembly Rollers:

Step 1. Select Clean Lam Oven to run the laminator oven cleaning routine.

Step 2. Observe the OCP, and wait until the laminator temperature goes below 60°C.

Note • To avoid a long wait while the card transport rollers cool to 60°C, perform cleaning before the rollers heat (i.e., when rst turned on and the rollers are still cold).

Step 3. Lift the laminator door to its upright position.

Step 4. Remove the four thumb screws holding the heater assembly in place and slide the

heater assembly out of the laminator (shown below).

Step 5. Use the laminator hot roller cleaning card (with adhesive) from the laminator cleaning

kit.

Step 6. Prepare the card for use.

Step 7. Insert the card into the slot (arrow below), adhesive side down.

66 ZXP Series 9 Card Printer User Guide P1086707-002

Maintenance

Cleaning the Laminator

Step 8. Pull the card all the way through the heater assembly thereby cleaning the heater

rollers.

Step 9. Remove the card from the heater assembly.

Step 10. Turn the card over, adhesive side up; and repeat Step 8, Step 9, and Step 10.

Step 11. Reinstall the heater assembly.

Step 12. Close the laminator door.

Step 13. Press Exit on the OCP when done.

P1086707-002 ZXP Series 9 Card Printer User Guide 67

Maintenance

Cleaning the Printhead

Printhead cleaning removes deposits when print anomalies persist. To avoid deposits, only use

foam-tipped swabs or pens.

Caution • Never use a sharp object or any abrasive to scrape deposits from the printhead. Permanent damage to the printhead will result.

Hot Surface • Do not touch the printhead if the printer has been in service in the last 10 minutes. It could be very hot and cause a burn.

Step 1. Place the printer power switch in the OFF ( ) position.

Step 2. Open the door, and remove the print ribbon.

Step 3. Bend the cleaning swab to release the cleaning uid.

Step 4. Clean printhead by moving cleaning swab tip side-to-side across the printhead

elements. Only use moderate force.

Step 5. Reinstall the print ribbon, and close the door.

Step 6. Place the printer power switch in the ON ( ) position.

68 ZXP Series 9 Card Printer User Guide P1086707-002

Maintenance

Magnetic Encoder Cleaning

The magnetic encoder is cleaned as part of the printer cleaning process . If the frequency of

encoding errors increases, the head may need additional cleaning. To clean, only use foam-tipped swabs. To order cleaning swabs, go to the ZXP Series 9 Card Printer Support Page at www.zebra.

com/zxp9-info.

Caution • Never use a sharp object or any abrasive to scrape deposits from the magnetic encoder. Permanent damage to the magnetic head will result.

Step 1. Open the printer cover.

Step 2. Open the idler roller assembly door.

Step 3. Bend the cleaning swab to release the cleaning uid.

Step 4. Clean the magnetic encoder by moving cleaning swab tip side-to-side across the

head elements.

Step 5. Close the idler roller assembly door.

Step 6. Close the door.

P1086707-002 ZXP Series 9 Card Printer User Guide 69

70 ZXP Series 9 Card Printer User Guide P1086707-002

Troubleshooting

OCP Error Messages

The table offers causes and solutions to symptoms related to improper operation. Check the table when experiencing any loss of operation or print quality.

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

1 SYSTEM NOT READY A problem was detected during

printer start-up.

2–4 SYSTEM ERROR Internal logic error. Power cycle the printer, and

5 FW UPGRADE ERROR Firmware upgrade

incompatibility.

6 DIAGNOSTIC ERROR Error encountered in

Diagnostic Mode.

7 FW UPGRADE ERROR Firmware upgrade failed. Verify the version, and retry

8 CRITICAL ERROR

SHUTTING DOWN

3001 PRINTER OFFLINE Status toggled (ofine/online)

4002 INVALID CARD TYPE Encoding error. • Ensure that you are using

Major malfunction encountered. Contact Zebra Tech Support.

via the OCP Advanced Settings Menu.

Power cycle the printer, and retry. If problem persists,

contact Zebra Tech Support.

retry.

Verify the version, and retry installing the rmware.

Power cycle the printer, and

retry.

installing the rmware.

Change status to online via the OCP Advanced Settings Menu.

the correct card type.

• In the Encoding tab of the

driver Printing Preferences,

check that the settings are correct for the cards you are using.

• Ensure that the data conforms to ISO

Specications.

• Retry writing and reading.

71 ZXP Series 9 Card Printer User Guide P1086707-002

Troubleshooting

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

4003 CARD JAM Card is jammed in the Printer Clear the card path.

4010 OUT OF FILM The transfer lm has run out. • Conrm proper installation.

• Load new roll of transfer lm.

4011 INTM INVALID Transfer lm does not match

the printer—incorrect OEM code.

4012 FILM JAM The transfer lm is jammed. • Check the transfer lm.

4013 FILM MOTION ERROR Transfer lm not correctly

responding to motion commands.

4014 CARD FEED ERROR Card is jammed in Feeder

Cartridge.

4015 CARD NOT INSERTED Card was not fed into the

Single Card Feed Slot within 30-second period.

4016 OUT OF CARDS • The Feeder Cartridge is

empty.

• Card is stuck in Feeder Cartridge.

4017 INTM AUTH FAIL RFID auth invalid or corrupt. • Contact Zebra Tech Support.

5001 OUT OF RIBBON Print ribbon has run out. Load a new roll of print ribbon.

5002 INVALID RIBBON Ribbon does not match the

printer—incorrect OEM code.

5003 RIBBON JAM Print ribbon is jammed. • Check the print ribbon.

5004 RIBBON MOTION ERROR Print ribbon not correctly

responding to motion commands.

5005 RIBBON ADC ERROR Possible hardware issue. Contact Zebra Tech Support.

5006 RIBBON BEMF ERROR Problem with the Back EMF

(BEMF) of the ribbon motors.

• Verify the part number of the

transfer lm is correct on lm

RFID tag.

• Contact Zebra Tech Support.

• Reinstall the transfer lm.

• Repair the break in the

transfer lm and reinstall.

• Check the transfer lm.

• Reinstall the transfer lm.

• Power cycle the printer.

• Clear card jam in Feeder

Cartridge, and re-seat

Feeder Cartridge.

• Ensure that cards are not stuck together and that they are the correct thickness (30 mil only).

Retry and feed card into the

Single Card Feed Slot, or

cancel the operation.

• Load cards in the Feeder Cartridge.

• Re-seat the Feeder Cartridge.

• Verify the part number of the

ribbon is correct on lm RFID

tag.

• Contact Zebra Tech Support.

• Reinstall the print ribbon.

• Repair the break in the print ribbon and reinstall.

• Check the print ribbon.

• Reinstall the print ribbon.

• Repair the break in the print ribbon and reinstall.

Contact Zebra Tech Support.

72 ZXP Series 9 Card Printer User Guide P1086707-002

Troubleshooting

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

5007 RIB COLOR DETECT ERR • Print ribbon is not installed

correctly.

• Tricolor sensor error.

5008 RIBBON AUTH FAIL RFID auth invalid or corrupt. • Contact Zebra Tech Support.

6001–6008 GENERAL MEMORY

ERROR

6009 FLASH ERASE ERROR There is a problem when

6010 FLASH ERASE VERIF ERR There is a problem when

6011 FLASH PROGRAM ERROR There is a problem when

6012 FLASH PROG VERIFY ERR There is a problem when

6013 INVALID FW SRECORD There is a problem when

6015–6025 GENERAL MEMORY

ERROR

7001 CARD FEED ERROR Card is jammed in Feeder

7003 PRINTHEAD CABLE

ERROR

7005 PRINTHEAD TOO HOT Printhead temperature out of

7006 PRINTHEAD TOO COLD Printhead temperature out of

7008 COVER OPEN This warning will be displayed if

7010 PRINTHEAD MOTION ERR Printhead did not move

There is a problem when accessing general memory.

accessing ash memory.

There is a problem when accessing general memory.

Cartridge.

Printhead cable loose or disconnected.

proper range (HOT).

proper range (COLD).

the cover protecting the Printer Module is opened.

to proper position during initialization.

• Reinstall the print ribbon.

• Perform tricolor calibration in ZMotif Service Partner Tool.

• Contact Zebra Tech Support.

• Power cycle the printer, and retry.

• Contact Zebra Tech Support.

• Power cycle the printer, and retry.

• Contact Zebra Tech Support.

• Power cycle the printer, and retry.

• Contact Zebra Tech Support.

• Power cycle the printer, and retry.

• Contact Zebra Tech Support.

• Power cycle the printer, and retry.

• Contact Zebra Tech Support.

• Power cycle the printer, and retry.

• Contact Zebra Tech Support.

• Power cycle the printer, and retry.

• Contact Zebra Tech Support.

• Clear the card jam in the

Feeder Cartridge, and re-

seat the Feeder Cartridge.

• Ensure that cards are not stuck together and that they are the correct thickness (30 mil only).

Check printhead cable

connection, reconnect if loose

or disconnected.

Contact Zebra Tech Support.

This warning will be cleared when the printer cover is closed.

• Power cycle the printer, and retry.

• Re-seat the printhead.

P1086707-002 ZXP Series 9 Card Printer User Guide 73

Troubleshooting

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

7011 ROLLERS OVER TEMP Heated Rollers (used to

transfer the image from the

transfer lm to the Card) are

too hot for proper operation.

7012 ROLLERS UNDER TEMP Heated Rollers (used to

transfer the image from transfer

lm to Card) are not hot

enough for proper operation.

7013 MOTOR VOLTAGE ERROR Incorrect voltage detected at

one or several motors in the unit.

7014 SCRIPT PROCESSING

ERROR

7015 MAG MOTION ERROR Printhead did not move

7017 REJECT ERROR A problem during the reject

7018 SMARTCARD ERROR • Encoding error.

7019 SCRIPT CONTENT ERROR Internal logic error. Power cycle the printer, and

7020 SCRIPT SEND ERROR Internal logic error. Power cycle the printer, and

7034 REJECT BIN FULL

REMOVE CARDS

9001 MAG READ ERROR • Encoding error.

Internal logic error. Power cycle the printer, and

to proper position during initialization.

process.

• Faulty card.

The Reject Bin is full. Remove the cards from the bin,

• Defective magnetic stripe.

Turn off power, and contact

Zebra Tech Support.

Turn off power, and contact

Zebra Tech Support.

Power cycle the printer, and

retry.

Power cycle the printer, and

retry.

Contact Zebra Tech Support.

• Ensure that you are using the correct card type.

• Check that the cards are loaded in the correct orientation.

• Ensure that the data conforms to ISO

Specications.

• Retry writing and reading.

retry.

and reset the reject bin card count to 0 via the OCP (Main

Menu > Advanced Settings >

Clear Reject Bin).

• Ensure that you are using the correct card type.

• Check that the cards are loaded with the magnetic stripe in the correct orientation.

• Ensure that the cards are set-up correctly in the printer driver (coercivity setting).

• Ensure that the data conforms to ISO

Specications.

• Retry reading.

74 ZXP Series 9 Card Printer User Guide P1086707-002

Troubleshooting

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

9002 MAG WRITE ERROR • Encoding error.

• Defective magnetic stripe.

9004 NO MAG STRIPE Magnetic stripe not detected. • Ensure that you are using

10001 CONTACT READ ERROR • Faulty card.

• Incorrect card orientation.

• Incorrect Mode or Protocol setting.

• Faulty reader.

10002 CONTACT WRITE ERROR • Faulty card.

• Incorrect card orientation.

• Incorrect Mode or Protocol setting.

• Faulty writer.

11001 CONTACTLESS READ

ERROR

11002 CONTACTLESS WRITE

ERROR

14001 MISSING HCB The Halogen Controller Board

14002 HCB BULB ERROR The Halogen Controller

• Faulty card.

• Incorrect Mode or Protocol setting.

• Faulty reader.

• Faulty card.

• Incorrect Mode or Protocol setting.

• Faulty writer.

(HCB) is missing.

Board (HCB) is unable to pulse the upper and lower heaters to bring the upper and lower rollers to the proper temperature.

• Ensure that you are using the correct card type.

• Check that the cards are loaded with the magnetic stripe in the correct orientation.

• Ensure that the cards are set-up correctly in the printer driver (coercivity setting).

• Ensure that the data conforms to ISO

Specications.

• Retry writing.

the correct card type.

• Check that the cards are loaded with the magnetic stripe in the correct orientation.

• Try another card.

• Try another card (check orientation).

• Correct the Mode or Protocol setting.

• Contact Zebra Tech Support.

• Try another card.

• Try another card (check orientation).

• Correct the Mode or Protocol setting.

• Contact Zebra Tech Support.

• Try another card.

• Correct the Mode or Protocol setting.

• Contact Zebra Tech Support.

• Try another card.

• Correct the Mode or Protocol setting.

• Contact Zebra Tech Support.

• Check connection to HCB.

• Contact Zebra Tech Support.

• Power cycle the printer, and retry.

• Contact Zebra Tech Support.

P1086707-002 ZXP Series 9 Card Printer User Guide 75

Troubleshooting

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

14003 HCB SENSOR ERROR The Halogen Controller Board

(HCB) is unable to detect temperature of the upper or lower rollers.

14004 HCB FIRMWARE MISSING The Halogen Controller Board

(HCB) rmware is missing.

15001 MISSING MAB An error occurred when

reading the RFID Tag by the MAB (Media Authentication Board).

15002 MAB FIRMWARE MISSING MAB (Media Authentication

Board) Firmware is missing.

17001 LAMINATOR MISSING Laminator data cable loose or

disconnected.

17002 LAMINATOR FAILED

INITIALIZATION

17003 LAMINATOR UNKNOWN

ERROR

17004 MISSING LAMINATOR MAB An error occurred when

17005 TOP LAMINATE FEED FAIL • Top laminate cartridge is not

17006 BOTTOM LAMINATE FEED

FAIL

17007 TOP LAMINATE

REGISTRATION ERROR

Laminator was detected by

the printer, but was unable to

communicate to it.

An unknown error has occurred – this is an indication of a FW problem and should not occur.

reading the RFID Tag by trying to communicate to the Laminator MAB (Media Authentication Board).

installed properly.

• Cartridge is not removed when that side of the card is not being laminated.

• A mis-cut piece of laminate (rare) is obscuring the media sensor.

• Bottom laminate cartridge is not installed properly.

• Cartridge is not removed when that side of the card is not being laminated.

• Improperly prepared registered laminate.

• Media misfeed.

• Patch length improperly set.

• Unexpected end of laminate roll detected.

Contact Zebra Tech Support.

• Update printer rmware.

• Contact Zebra Tech Support.

• Check print ribbon orientation.

• Verify part number of the print ribbon.

• Power cycle the printer, and retry.

• Contact Zebra Tech Support.

Install the rmware.

Contact Zebra Tech Support.

Press RETRY on the OCP.

• Check laminate orientation.

• Power cycle the printer, and retry.

• Contact Zebra Tech Support.

• Remove, reposition, and re-install the top laminate cartridge.

• Remove the top laminate cartridge.

• Remove the mis-cut piece of laminate.

• Remove, reposition, and re-install the bottom laminate cartridge.

• Remove the bottom laminate cartridge.

Remove and recut laminate in

the center of the index notch, re-install, and retry.

76 ZXP Series 9 Card Printer User Guide P1086707-002

Troubleshooting

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

17008 LAMINATOR CARD FEED

FAIL

17009 LAMINATOR EARLY CARD

JAM

17010 LAMINATOR MIDDLE CARD

JAM

17011 LAMINATOR LATE CARD

JAM

17012 LAMINATOR POLL

TIMEOUT

17013 LAMINATOR TOP HEATER

FAIL

17014 LAMINATOR BOTTOM

HEATER FAIL

17015 LAMINATOR TOP

TEMPERATURE HIGH

Printer has not fed the card far enough into laminator mechanism for infeed rollers to grab it.

Card did not make it to the staging rollers.

Card and laminate have jammed inside heater

assembly, often due to mis-

positioned laminate patch sticking to heated rollers.

Card did not unblock the exit

sensor in the specied time.

The laminator expects the printer to periodically send commands to it within a

specied time period. If it fails to do so, it assumes that

something is wrong with the communication link or that the printer is down. This error may occur if the printer-to-laminator communications is having intermittent problems.

Top heater did not turn on after being instructed to do so. When the heater

is enabled, the controller will wait a certain specied

amount of time for it to attain the set target temperature. If the heater fails to reach the

target in the specied time, the

TopHeaterFail fault will be set.

Bottom heater did not turn on after being instructed to do so. When the heater

is enabled, the controller will wait a certain specied

amount of time for it to attain the set target temperature. If the heater fails to reach the

target in the specied time, the

BotHeaterFail fault will be set.

If the top roller temperature

ever exceeds a xed temperature threshold, the over

temp error occurs.

Open the Laminator and printer doors to check for jammed/

stuck cards. Note: Only 30 mil

cards supported.

Remove the card and/or laminate that is stuck in the laminator staging/cutting area.

Remove the oven, and inspect

for stuck cards.

• Check for card jam in the exit area.

• Assure that the sliding exit door is not partially blocking the exit path.

Power cycle the printer, and

retry.

• Power cycle the printer, and retry.

• Replace the top halogen bulb.

• Power cycle the printer, and retry.

• Replace the bottom halogen bulb.

• Power cycle the printer, and retry.

• Contact Zebra Tech Support.

P1086707-002 ZXP Series 9 Card Printer User Guide 77

Troubleshooting

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

17016 LAMINATOR BOTTOM

TEMPERATURE HIGH

17017 LAMINATOR TOP CUTTER

STALL

17118 LAMINATOR BOTTOM

CUTTER STALL

17019 LAMINATOR TOP CUTTER

FAIL

17020 LAMINATOR BOTTOM

CUTTER FAIL

17021 LAMINATOR TOP TEMP

SENSOR FAIL

17022 LAMINATOR BOTTOM

TEMP SENSOR FAIL

17023 LAMINATOR FAN FAIL This should only happen if one

17024 LAMINATOR EEPROM

DEFAULT

17025 LAMINATOR TOP

TEMPERATURE LOW

17026 TOP AND BOTTOM

LAMINATES OUT

17027 TOP LAMINATE OUT The top laminate has run out. Load new roll of laminate.

17028 BOTTOM LAMINATE OUT The bottom laminate has run

17029 INVALID TOP LAMINATE Wrong OEM code, laminate not

17030 INVALID BOTTOM

LAMINATE

If the bottom roller temperature

ever exceeds a xed temperature threshold, the over

temp error occurs.

Top cutter blade is obstructed,

or top cutter mechanism is damaged.

Bottom cutter blade is

obstructed, or bottom cutter

mechanism is damaged.

Top cutter has failed. Contact Zebra Tech Support.

Bottom cutter has failed. Contact Zebra Tech Support.

The top temperature (thermopile) sensor has failed.

The bottom temperature (thermopile) sensor has failed.

or both cooling fans fail or the cooling vents near the heated roller assembly are blocked or the fan(s) have failed.

The parameters stored in EEPROM have been reset to their default values. This

will not normally happen, but

could be seen with certain FW upgrades when new parameters have been added by Engineering. It could also indicate a problem with the

Laminator’s EEPROM.

If the top roller temperature

does not reach a xed temperature threshold, the

under temp error occurs.

The top and bottom laminates have run out.

out.

supported.

Wrong OEM code, laminate not

supported.

• Power cycle the printer, and retry.

• Contact Zebra Tech Support.

Contact Zebra Tech Support.

Check for blocked vents.

• Press RETRY on the OCP when this error occurs.

• Power cycle the printer, and retry.

Power cycle the printer, and

retry.

Load new rolls of laminate.

Load new roll of laminate.

• Power cycle the printer, and retry.

• Replace with valid Zebra laminate.

• Power cycle the printer, and retry.

• Replace with valid Zebra laminate.

78 ZXP Series 9 Card Printer User Guide P1086707-002

Troubleshooting

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

17031 BOTTOM LAMINATE

REGISTRATION ERROR

17038 LAMINATOR COVER OPEN This warning will be displayed

17040 LAMINATOR INITIALIZING This warning will be displayed

17041 LAMINATOR FIRMWARE

MISSING

17042 LAMINATOR MAB

FIRMWARE MISSING

18001 ETHERNET COMM ERROR Ethernet communication

19001 WIFI COMM ERROR Wireless Ethernet

19002 WIFI ACCESS POINT

MISSING

19003 WIFI LINK LOST • Connection to the access

19004 WIFI INCOMPATIBLE

NETWORK

• Improperly prepared registered laminate.

• Media misfeed.

• Patch length improperly set.

• Unexpected end of laminate roll detected.

if the cover protecting the laminator is opened.

after the laminator door is closed and laminate spools are re-read/detected.

LCB (Laminator Controller Board) Firmware is missing.

Laminator MAB (Media Authentication Board) Firmware is missing.

problem.

communication problem.

Access point, specied by printer wireless settings, not

found during initial printer scan after power up.

point was lost.

• Poor signal quality or low signal strength.

• Interference.

• Access point power has been lost.

• Printer, after power up, found

the access point specied by the wireless settings,

but found the access point settings incompatible.

• Access point conguration

has been modied.

Remove and recut laminate in

the center of the index notch, re-install, and retry.

This warning will be cleared when the laminator cover is closed.

No action needed

Install the rmware.

• Disconnect and reconnect the network cable.

• Power cycle the printer, and retry.

• Power cycle the printer.

• Re-run the set-up wizard to

• re-establish the wireless settings.

• Contact Zebra Tech Support.

Verify access point, specied by the printer wireless settings,

is properly connected to the network and turned on.

• Verify access point is properly connected to the network and powered ON.

• Put the printer antenna in a similar orientation than

access point’s antenna, and

re-run the set-up wizard to re-establish the wireless settings.

Re-run the set-up wizard to establish the new wireless settings.

P1086707-002 ZXP Series 9 Card Printer User Guide 79

Troubleshooting

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

19005 WIFI ASSOCIATION FAILED • During association with an

access point, the association

failed.

• Poor signal quality.

• Low signal strength.

19006 WIFI CONNECTION FAILED • They key handshake

following the association failed.

• WEP Key or WPA passphrase is incorrect.

Put the printer antenna in a similar orientation as the

access point’s antenna, and

re-run the set-up wizard to reestablish the wireless settings.

Ensure that you have the

correct key/passphrase, then

re-run the set-up wizard to establish new wireless settings.

80 ZXP Series 9 Card Printer User Guide P1086707-002

Troubleshooting

CARD

Clearing a Card Jam

A card jam is reported by the printer when a card fails to reach a sensor as expected, or a card

blocks a sensor unexpectedly.

Caution • Do not use tools to remove stuck cards, this will void the product warranty and

may cause damage to the equipment.

Printer

A card jam in the printer will normally occur in one of two places: the card path, or the transfer

station.

Step 1. Open the printer.

Step 2. Open the idler cover.

Step 3. Remove the card (if present). If no card present, continue to next step.

P1086707-002 ZXP Series 9 Card Printer User Guide 81

Troubleshooting

CARD

Clearing a Card Jam

Step 4. Turn the manual advance wheel next to the transfer station. Continue turning until the

wheel stops or the card has been ejected sufciently enough to remove it.

Caution • Card may be hot.

Laminator

A card jam in the laminator will normally occur along the lamination path.

Step 1. Open the laminator.

There are three areas along the lamination path and six rollers that can be manually advanced if a card is stuck.

Note • For rollers 1 through 4, use the narrow side of the manual advance tool; for rollers 5 and 6, use the wider side of the manual advance tool.

82 ZXP Series 9 Card Printer User Guide P1086707-002

Troubleshooting

Clearing a Card Jam

Step 2. Identify the location of the card and, using the manual advance tool, turn the

appropriate roller counter-clockwise. Advance the card to the next area or until it has

been ejected sufciently enough to remove it.

In some cases, a card may get wrapped around the laminator heater assembly rollers. In this case,

the laminator heater assembly can be removed.

Step 1. Remove the four thumb screws holding the heater assembly in place and slide the

heater assembly out of the laminator (shown below).

Step 2. Remove the card—do not use tools. If the card is wrapped around the heater

assembly rollers, contact Zebra to replace the heater assembly.

P1086707-002 ZXP Series 9 Card Printer User Guide 83

Troubleshooting

OCP Test Cards

Image Title Description Use

GRADIENT BOXES

DENSITY SETUP

MONOCHROME ONLY Barcode and text

3 sets of light-to-dark grayscale ramps

Mid-gray and maximum

density elds on a at gray

surface

Used to validate the tonal scale of the printer.

Also used to check the left/right and top/bottom offsets or the centering of the image on the card.

Used to verify monochrome print capability and quality.

84 ZXP Series 9 Card Printer User Guide P1086707-002

Troubleshooting

Identifying Job Quality Issues

For the ZXP Series 9 printer, image quality can be broken down into two areas: print quality and transfer quality. Print quality refers to the quality of the text, barcodes, and images that are printed on the lm, while transfer quality refers to the quality of the transfer of the lm onto the card, as well as card warpage and ash artifacts.

Print Quality Issues

Color Accuracy

When the colors on the printed card do not match the expected result, there are several steps that

may be taken to get the desired output.

1. If using the driver, make adjustments in the Color Optimization tab of Printer Preferences.

2. If using the driver, create and apply a Windows ICC color prole.

3. Whether using the driver or not, contact Zebra to create a custom lookup table that can be

downloaded to the printer using the ZXP Toolbox.

Dirt and Debris

Spots and speckles appearing on the card may be caused by dirt and debris in the printer.

y Replace the cleaning rollers

y Clean the printer

Image Placement

If the image printed on the card seems to have shifted, this may be an image placement issue.

y Use the Print Position adjustment feature in the ZXP Toolbox, located in the Calibration tab.

Smear

Smear may occur when a sudden shift from a dark color to a light color occurs and the printhead has

not sufciently cooled when printing the light color, thereby the dark color appears to “smear” into the

light color.

y Lower the Preheat value on the Color Optimization tab in the Printing Preferences Control

Panel.

y Switch to Fine print mode on the Card Setup tab.

Black Extraction

When the black text or images does not appear black or crisp, or text that is supposed to be black appears muddy or not sharp, this may be an issue where the black text or image was not printed

using the black panel.

P1086707-002 ZXP Series 9 Card Printer User Guide 85

Troubleshooting

Identifying Job Quality Issues

y Check the source image; RGB values up to 25,25,25 can be printed as black by using the

sliders on the K Extraction page. If RGB values are greater than 25,25,25, then the

y image will need to be modied to bring the RGB values under this threshold

y Adjust the properties in the Front or Back K Extraction menu (refer to the Help content in the

Printing Preferences Control panel).

Ribbon Wrinkle

Ribbon wrinkle appears as a streak of color that was not part of the original image. It typically

originates from the edges of the card, and sometimes occurs when printing a really dark image, or

near the transition between really dark and really light images

If this occurs, contact Zebra Tech Support.

Mis-registration

Mis-registration occurs when the Y, M, C, and/or K panels are not properly aligned with each other. The effect may appear as a lack of sharpness, or a color halo.

If this occurs, contact Zebra Tech Support.

Transfer Quality Issues

Lack of Transfer

A printed image that appears incomplete on the card may be a sign of lack of transfer. Lack of

transfer typically occurs because there is not enough energy to properly adhere the transfer lm to

the card. There are several steps that can be taken to eliminate lack of transfer.

1. Adjust the transfer settings—raise the top and/or bottom transfer temperature, and/or lower

the in and/or out transfer speed. These settings are available by selecting one of the Custom card types in the Printing Preferences control panel.

2. If lack of transfer only occurs for the rst few cards after the printer is turned on, set or

increase the warm-up delay to allow the transfer station to fully warm up before printing. The warm-up delay can be set in the Advanced menu on the OCP.

Warpage

Card warpage is caused by an imbalance in the amount of energy applied to the top and bottom of the card. There are several steps that can be taken to improve card warpage.

1. Adjust the transfer settings - lower the top and/or bottom transfer temperature, and/or

increase the in and/or out transfer speed. These settings are available by selecting one of

the Custom card types in Printer Preferences, in the Driver.

2. Switch to a card type that is more resistant to high temperatures.

3. Contact Zebra about custom ribbons with a Helper panel, that may enable good transfer at

lower transfer temperatures.

86 ZXP Series 9 Card Printer User Guide P1086707-002

Troubleshooting

Identifying Job Quality Issues

Flash

Flash is an artifact of the transfer process, that appears like little shards of transfer lm. The shards may be clear or colored, depending on the image being printed. Flash may appear on the sides or

top of the card.

y If ash is seen on the top of the card, adjust the image placement downward. Use the Print

Position adjustment feature in the ZXP Toolbox, located in the Calibration tab. If this does not minimize or resolve the issue, contact Zebra Technical Support.

y If ash is seen on the sides of the card, contact Zebra Technical Support.

Delamination

Delamination is the separation of the card layers and may be caused by using substandard cards.

If this occurs, contact Zebra Tech Support.

P1086707-002 ZXP Series 9 Card Printer User Guide 87

Troubleshooting

Ethernet Indicators—Detail

Link/Activity Indicator (Green)

Off No link (disconnected)

On Network link has been established

Blinking Network activity has been detected

Speed Indicator (Orange)

Off No link (disconnected)

The LED blinks once (one blink, pause,

1 Blink

2 Blinks

one blink, etc.) when a 10Base link has

been established.

The LED blinks twice (two blinks, pause, two blinks, etc.) when a

100Base link has been established.

If both LEDs are off, the printer has not detected the presence of a network cable. To solve the problem:

Step 1. Verify that the network cable is appropriate and has an RJ-45 connector.

Step 2. Remove the network cable from the printer. Plug the network cable back in until you

hear a positive click. Check the other end of the cable in the same manner. If the

printer still does not detect a cable, then continue.

Step 3. Connect the printer to a known good network. If the printer is still unable to detect the

network cable, contact Technical Support for assistance

88 ZXP Series 9 Card Printer User Guide P1086707-002

Zebra Z91-0M0C0000EM00 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Before Printing

Card Type

Single- or Double-Sided

Ribbon Combination

Print a Test Card

Introduction

Description

Printer and Laminator Components

Icons

Installation and Setup

General Information

Unpacking the Printer

Unpacking the Printer with a Laminator

Unpacking (continued)

Loading Cards

Installing the Card Hoppers

Input Hopper

Output Hopper

Installing the Software

Supported Operating Systems

Supported Sharing Combinations

Installing the Cleaning Cartridge

Installing the Cleaning Roller

Loading the Transfer Film

Loading Print Ribbon

Replacing the Laminate

Opening the Laminator Door

Removing the Laminate Cassette(s)

Loading the Laminate Cassette(s)

Installing the Laminate Cassette

Using Partial-Width Laminate

Laminating Contact Smart Cards

Packing for Shipment

Printer

Printer with Laminator

Operation

Introduction

Printing Preferences

Card Type Selection

Print Ribbon Selection

Printing a Test Card

Manual Card Feed

Operator Control Panel (OCP)

Messages

Maintenance

Cleaning the Printer

When to Clean

Rollers

Platen

Replacing the Cleaning Rollers

Cleaning the Laminator

When to Clean

Laminator

Cleaning the Printhead

Magnetic Encoder Cleaning

Troubleshooting

OCP Error Messages

Clearing a Card Jam

Printer

Laminator

OCP Test Cards

Identifying Job Quality Issues

Print Quality Issues

Transfer Quality Issues

Ethernet Indicators—Detail