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Zebra P640i User's Manual

1. Available from Priority 1 a v New Driver Spool print documents so program finishes printing faster Driver Zebra P640 Start printing after last page is spooled Start printing immediately Print directly to the printer C Hold mismatched documents Print spooled documents first C Keep printed documents Enable advanced printing features Printing Defaults Separator Page IDPrint Lite DPrint Lite is a simple utility designed for functional testing only It is not intended for ID card production DPrint Lite allows you to send bitmap bmp files to the ID card printer driver Unlike most applications used for page composing such as Microsoft Word or Adobe PageMaker IDPrint Lite can send up to four separate image files to the printer in a single transaction two for the front of the card two for the back IDPrint Lite has no page composing capability It is a means only of delivering to the printer driver previously composed image files samples of which are on the driver CD see below these image files also come with the P6401 driver when downloaded from the Web Test for alignment of lamin Test for ribbon wrinkling ate If you wish to use your own images instead of the samples compose them using any application that can save them in bmp format The standard image size for the P6401 is 952 x 578 pixels DPrint Lite can also be used for mag stripe encoding in two formats ISO
2. onto the surface of the card instead of migrating into it With mass transfer the printer has little control over a pixel s size or density it s either there or it isn t K printing is used for bar codes because it is machine readable whereas YMC dyes are not What makes the P640i a different kind of printer The print station in the P6401 has no pinch rollers that need cleaning to maintain accuracy 980541 001 Rev A P640i Card Printer User Guide Introduction Printing basics In the P6401 the card is transported on a belt driven truck that maintains precise registration through the entire process of picking cleaning and multi pass printing This means perfect color to color Transport registration time after time no slippage no motor p deterioration in print quality over time Toothed blet What to expect when you turn on the power Card truck Platen Nothing happens for two or three seconds then Card transport knob 2 The READY light flashes yellow indicating that the laminator is warming up and you will hear the fan running and a clicking sound inside the printer the flip station resetting itself Finally 3 After a few minutes 3 to 5 the READY light will show steady green indicating that the printer is ready to print The receiving tray for printed ID cards hooks onto the right side panel Power cord entry and ON OFF switch are located on the rear panel
3. Add Printer Wizard The manufacturer and model determine which printer software to use Select the manufacturer and model of your printer If your printer came with an installation Sa disk click Have Disk If your printer is not listed consult your printer documentation for a compatible printer Manufacturer A Printers EF AGFAAccuset vs23 fate E AGFAAccuSetSF v52 3 App SV AGFAAccuSet 800 APS PS r S agraAccuSet 8005F v52 3 1mm mao annm nmam dmm v windows Update Ey This driver is digitally signed Tell me why driver signing is important 9 On the next screen press the down arrow select the CD ROM drive containing the Driver CD then press OK This brings up a screen that offers another choice of printers this time only from Zebra Select Zebra Technologies and Zebra P6401 If you don t have the CD go to Step 10 Install From Disk Insert the manufacturer s installation disk and then A make sure that the correct drive is selected below Cancel Copy manufacturer s files from C ZEBRASDRIVER Ne Browse 980541 001 Rev A Add Printer Wizard Install Printer Software The manufacturer and model determine which printer software to use Select the manufacturer and model of your printer If your printer came with an installation Sa disk click Have Disk If your printer is not listed consult your printer documentation for compatible printer software Manufacturer P
4. Card direction Card direction Without compensation With compensation 2 Black panel density Color Calibration screen page TN4 x This control the amount of heat energy applied to any pixel required to be black A higher value gives darker printing but can cause undesirable blooming indefinite edges 3 Black panel preheat Color Calibration screen page TN4 x Think of this as a temperature offset applied across the entire head specifically for K panel printing A higher value results in better resin transfer on the leading edge of graphics and text than you would get with a cold start but it may lead to undesirable blooming indefinite edges overall The following default values deliver a good compromise between barcode readability and the appearance of text and signatures Compensation 55 Density 117 Preheat 15 Overlay Panel Speed Speed at which the OP overlay panel if any is printed rarely used in printers with laminating capability If a Uv ribbon 1s selected the text changes to say Uv Panel Speed 980541 001 Rev A Overlay Panel Compensation Mainly used with Uv ribbon to optimize the appearance of ultra violet visible text Ribbon Position mm This has to do with positioning the color ribbon relative to the print head such that when the head descends it lands solidly within the panel not too early not too late Keep in mind the following
5. Zebra P640i Card Printer Card Printer User Guide Card Printer d o Solutions 980541 001 Rev A 2004 ZIH Corp The copyrights in this guide and the printers described therein are owned by Zebra Technologies Corporation Un authorized reproduction of this manual or the software in the label print engine may result in imprisonment of up to one year and fines of up to 10 000 17 U S C 506 Copyright violators may be subject to civil liability Printer Software ZIH Corp All rights reserved worldwide Windows is a registered trademark of Microsoft Corporation All other brand names product names or trademarks belong to their respective holders Customer Order 980541 001 Manufacturer Part 980541 001 Rev A Caution labels on P640 Printers Pinch Hazard Keep fingers away from printer cover hinges and back of cleaning cassette Hot surfaces Danger of skin burns near laminator components Advisories used in this Guide Important Advises you of important information Caution Failure to follow instructions to the letter can cause malfunction dam age to the printer or personal injury ji P640i Card Printer User Guide 980541 001 Rev A 980541 001 Rev A A Zebra P640i Card Printer User Guide Caution The separate Quick Start Guide shows how to set up the printer using the standard USB interface If your printer was configured for the optional Parallel or Ethernet con
6. 3 Transport Parameters in the Driver Run Clean Cycle Run Clean Cycle Decontaminates the card cleaning roller by activating the cleaning cassette One clean cycle per click Printer Adjustment Print Station Adjust Laminate Station Adjust Flip Station Adjust OF Cancel Help Advanced Adjuzt Card Hopper Fick Position Adjust Fivela o E Cleaning Station Clean Frequency Every P640i Card Printer User Guide 39 Start gt Printers or Printers and Faxes gt _Right click Zebra P6401 gt Properties gt Device Settings gt Control gt Run Clean Cycle Card Presence Sensor Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Control gt Advanced Utilites gt Show Sensor Data gt Card Presence Sensor Also available through the Status screen Device Settings gt Status gt Advanced Card presence sensor values High around 250 card absent low around 10 card present Move Carriage Move Carriage moves the carriage to the position specified in the drop down menu on the Advanced Utilities window Select a destination then click Move Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Control gt Advanced Utilities gt Move Carriage 980541 001 Rev A Pick Position Adjust Pixels Start gt Printers or Printers and F
7. 980541 001 Rev A Firewall issues Firewalls restrict data transferred over the network only to those items specifically approved by the network administrator This can have the effect of making a network connected printer such as the Zebra P6401 unavailable to network users If a personal firewall is installed on the PC you are using to set up the P6401 Ethernet option 1 Probing for the printer will fail if the firewall does not allow broadcast UDP User Datagram Protocol requests 2 Probing for the printer will fail if the firewall does not accept responses from UDP probes often because the firewall does not properly register the outgoing UDP port as valid for response traffic 3 Probing for the printer will fail if the firewall disallows packets destined for UDP port 9099 4 Printing and printer communications will fail if the firewall disallows packets destined for TCP Transmission Control Protocol port 9100 The above caveats apply equally to a firewall installed in a network router the difference being that such a firewall affects ALL traffic across it not just traffic to and from a lone PC If probing fails you could in theory enter manually the IP address for the printer in the appropriate driver setup screen However because the IP address is not known until the printer is configured this is a Catch 22 situation Configuring the Ethernet option Installing any device via Ethernet can be challenging
8. Enable EIN Readback Note Embedded Inventory EIN Readback requires magnetic cards with pre encoded inventory numbers 980541 001 Rev A Encoding choices and track layout Density AAMVA format bits inch Data Type sl Data Type Length A ce Lec Bll CN I cee A bod pa ae Rem e oe Not including start sentinel end sentinel or LRC characters Mag Encoder Verify On If this box is checked every card is run twice under the read write head The first pass writes the code and second reads it to check for accuracy and readability Any card not passing this test is ejected through the laminator without printing Verification adds only 3 seconds to the processing time per card and is recommended for all applications not calling for the highest possible throughput Bit by Bit Encoding This is used only in applications calling for a custom designed encoding format Call Zebra tech support for more information Enable EIN Reedback Applicable only in applications using cards with pre en coded embedded inventory numbers P640i Card Printer User Guide 43 Techncial Note 4 Print Station The print head is a precisely machined slice of ceramic on the bottom edge of which is a row of tiny heating elements resistors 300 to the inch A thin glaze coating protects the heating elements Under normal operating conditions the head is capable of printing many thousands of images Damage to the hea
9. Flip arms surface of the carrier molding with card 50 P640i Card Printer User Guide 980541 001 Rev A Flip station components Upside down views of the carrier drive component s omitted Flip station motor Viewed from the back of the printer A pinion on the motor shaft engages the rack at the rear of the carrier above Plastite screw Cam Rear arm adjust Carrier Flip station viewed from above Points to note 1 The stop pin integr al with the rear flipper arm rests on the bottom edge of the carrier alternating from one side to the other in consecutive flip cycles Plastite screw 2 Azimuth adjust rotates the entire assembly to bring the flipper arms parallel to the carriage a very sensitive adjustment 3 The arms must move freely without end float Over tightening of the screws will lock the arms 980541 001 Rev A Card held by flip arms As the carriage moves into the flip station the card slides into grooves in the flip arms The entire flip assembly is then elevated clear of the platen Caution Cards thicker than 0 033 0 84 mm may jam in the flipper arms AN Flip station adjustm en procedu re The flip station requires no routine maintenance other than occasional vacuuming out of debris Typically there should be no need to alter the factory settings If the flip station ceases to function or functions erratically the technician sh
10. Go to the Zebra Printer Setup screen from the Driver CD or from the downloaded software see above 3 Printer Setup Install a Printer and Driver Uninstall Printers and Drivers Install Uninstall DPrint Lite a simple card printing application View Print Release Notes Requires a text reader such as Notepad q y Card Printer Aur u Solutions Exit 1 Click Uninstall Printers and Drivers 2 In the next window to appear click Uninstall Printer Drivers Complete the process by re starting the computer Important Windows 2000 and Windows XP install printer drivers in different ways Although the overall process is similar the dialog boxes are not identical The screen shots in this section are for Windows XP Windows file missing A Caution If the computer you are configuring for a USB connection to the P640i has at some time run an Eltron C Series printer a Windows file necessary for the P640i installation will be missing Recover the missing Windows file as follows 1 Navigate to c windows inf Windows XP or c winnt inf Windows 2000 2 Find the file named usbprint in then rename it to usbprint inf P640i Card Printer User Guide 73 3 If the computer continues to display new hardware found messages disable them by choosing Install the software automatically then waiting for Windows to respond with Cannot install this hardware 4 Select Don t prompt m
11. International Organization for Standardization and AAMVA American Association of Motor Vehicle Administrators 980541 001 Rev A marana 100 000 texures a ated to van 1 Printed by a Zebra PSO printer on card stock tha toughest card around BOQ polyester PYG composite Te se Demo badge 1 portrait format EuroTravel_Front bmp EuroTravel_Back bmp STATE DRIVER S LICEMSE h Ii z Micro positionirg for perfect estar va Heg 1 Tetea Aap Demo driver license landscape format Driver_License_Front bmp Driver_License_Back bmp i TEBE tiodal Pan Teas ha T ET eT Ei Liatha TENE Print test 1 Portraits bmp Test for realistic skin tones YMC registration in small text etc Print test 3 Color_Gradients bmp Test for alignment of laminate light tone print quality Print test 5 Wedge_2 bmp Test for ribbon wrinkling 980541 001 Rev A George CONIACOS ARF Tati Content HUNTERDON COUNTY AIRPORT Demo badge 2 portrait format Airport_Front bmp Airport_Back bmp a a Pes I Pree y aij EXHIBITOR 4 Pine Ahil 4 Printad by a Zebra P620 printar on ROO polyester PVC composite card slack the toughest card arqund l f al l Micro positioning for perfec Waste free laminator colar registralton great colars applies film to both sides at noyitter bar code the same time minimizing heat distertion Tas
12. P640i Card Printer User Guide 980541 001 Rev A Introduction Push buttons and Indicator lights The P6401 printer receives data through one of three types of connector Ethernet optional feature USB standard feature or Parallel Centronics type optional feature Test card You may sometimes be asked to print a test card This is the pattern stored in the printer s memory it has nothing to do with the computer If the printer is functioning properly it will be printed when the PRINT button on the front panel is pressed following power up Push buttons and Indicator lights PRINT button Press the PRINT button to print the image stored in the printer s memory When the printer is powered up the memory is loaded with a checkerboard test pattern above In regular on line use the PRINT button reprints the last image downloaded from the computer to the buffer memory If you press and hold the PRINT button for more than two seconds the printer will continuously reprint the image in the buffer Stop this action by pressing the button momentarily while printing is in process Note that pressing the PRINT button will have no effect if any of the following applies 1 An error condition exists 2 You have set up the print driver to print color on both sides of the card or 3 The optional hardware lockout key ID Key is missing but this does not disable the checkerboard printout available after power up 980
13. a Spool print documents so program finishes printing faster A f v Start printing after last page is spooled Start printing immediately Print directly to the printer C Hold mismatched documents Print spooled documents first C Keep printed documents Enable advanced printing features Printing Defaults Separator Page Determines the spooling queuing of print jobs and how spooled jobs are handled relative to the most recent job Printing Defaults allows the system administrator to establish default settings such as print quality Print Processor and Separator Page should be left alone 36 P640i Card Printer User Guide 980541 001 Rev A Technical Note 2 Card The platen plays an part in ia re process providing a rigid supporting surface for the Transport card as it passes under the print head Because flatness is important the platen is surface ground to close tolerances Any irregularities in the surface due to abrasion dings or even seemingly unimportant Stepper eS eS a particles of debris can noticeably degrade printing performance see page TN2 3 Regular cleaning of the Platen es Transport belt Truck No slip card transport The P640 does not rely on friction rollers to drive the card through the print station Instead the entire pick platen helps maintain performance and print process is precisely controlled by a belt driven truck riding on para
14. symmetrically positioned relative to the transfer rollers with its attachement screws central in their slots A Laminate Station Adjust Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Printer Adjustment gt Laminate Station Adjust Length Adjust mils This is the length of the laminate patch If the patch is too long decrease this number and vice versa Horizontal Offset mils Adjusts laminate placement on the card 980541 001 Rev A Heater Temperature This is the set point temperature desired not the actual temperature For actuals see Sensor Data preceding page NOTE Temperatures are monitored by thermocouples at the core Of the heated rollers Surface temperatures may differ significantly Caution Do not set the temperature ABOVE 180 C or BELOW room temperature A Line Voltage If Auto is selected the printer guesses line voltage based on line frequency assuming that 110V will be 60Hz and 230V 50Hz If this isn t the case in your locality the printer will guess wrong and you should set the voltage manually 7 Note Running the printer at 220V 60Hz in Auto mode may cause premature failure ofthe heaters Running the printer at 110V 50Hz in Auto mode may cause abnormally long heat up time and poor temperature control This setting has nothing to do with the printer power supply Like the laminator hea
15. then gently wiggle the cassette TOOLS to clean the rollers out of its pocket You can make this easier by cutting the laminate above the latch Remove all laminate square as you can with scissors then reel it in as Even after allowing cooling time the assembly will scraps Cut the leading edge of the fresh laminate as A be HOT so hold it only ny its outer cover described in Section 2 Media Handling Re install and latch the cassette Important e Any time you unlatch a cassette it s a good idea to check that the laminate is even with the lips of the cassette before re latching Problem Card jammed in laminator This can be caused by any of the following 1 Dings or rough edges on the card depending on vendor card quality can vary even from batch to batch 2 Either of the cutters fails to cut so the card is stopped dead by a tail of laminate now firmly held by the laminate feed roller which can not be rotated by tugging on the laminate Important All rollers in the main drive train of the laminator not the cassette outfeeds are connected by toothed belts If any of them fails to rotate suspect loose set screws on the toothed pulleys 3 Heated rollers not rotating 4 Infeed rollers not rotating 5 Outfeed rollers not rotating 60 P640i Card Printer User Guide 980541 001 Rev A Technical Note 7 ID Log ID Log 18 a driver utility that builds a database of card transacti
16. Faxes gt Right click Zebra P6401 gt Properties gt Color Management amp Zebra P640i Properties General Sharing Ports Advanced Color Management Security Device Settings These settings let you associate color profile s with your color A printer Color profiles control the color on your printer based on the type of media being used and the printer configuration Automatic Windows will automatically select the best color profile from the list of associated color profiles Recommended O Manua Manually select the default color profile for all output from this device from the list of associated color profiles Default color profile lt None gt Color Profiles currently associated with this printer Not currently supported 34 P640i Card Printer User Guide 980541 001 Rev A Printer Properties Properties Table 1 Sharing Printer Properties Properties Table 1 Ports Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Sharing amp Zebra P640i Properties Device Settings Advanced Security Sharing Ports Color Management General You can share this printer with other users on your network To a enable sharing for this printer click Share this printer Do not share this printer Share this printer Drivers If this printer is shared with users running different versions of Windows you may want to install additional drivers so that the u
17. While the head is down and printing ribbon motion is controlled by the card itself not by the ribbon takeup which at this time serves only to peel the ribbon cleanly off the card The color panels are about 2 12 mm longer than the image printed on the card This means that between one color printing pass and the next when the head briefly lifts the takeup drive has to shift the ribbon rapidly to bring the next color panel under the head The transition from one panel to the next in the color ribbon is marked by a black stripe which activates the ribbon sensor below the supply roll It is used together with a count of pulses from the motion sensor to determine ribbon position P640i Card Printer User Guide 47 Adjusting the ribbon position drives the leading edge of the panels forward or backward relative to the printhead the aim being to ensure that each swipe of the head is centered in its color panel this you can easily check by inspecting image negatives from on the takeup roll The photos below show the effect of incorrect ribbon positioning Ribbon positioning problems The arrows show the direction of card movement In the example at left the ribbon has advanced too far with the result that the head swipes a few millimeters of the following panel see inside the circle Reduce the ribbon position parameter to correct this The example at right is the exact opposite ribbon not advancing far enough so incr
18. a clam shell by separating its two halves Grasp the two halves firmly with the fingers then pull Do NOT use tools to pry it apart Loading the cassettes 1 Discard the spent core Hold the open cassette with its cavities toward you white idler wheel to the top Caution You need partial width laminate for the LOWER cassette if there is a mag stripe or signature stripe on the card 2 Place aroll of laminate in the cassette so that it feeds from the bottom of the roll UP and OUT to the front Pull out an inch or two of laminate Caution If the lower cassette is intended for partial width laminate it will have an edge guide to keep the laminate on track Make Sure it is in the correct position for the partial width laminate you are using 980541 001 Rev A P640i Card Printer User Guide 17 Media Handling Laminating Station 3 Close the cassette then pull out a little more laminate If it suddenly stops resisting further pulling a spring detent on the cassette photo below has snagged a notch on the end of the core This means that the core was installed the wrong way round If you follow the installation diagram on the inside of the cassette this won t happen 4 With the white roller up and pointing to your left rotate the core counter clockwise to reel in the laminate Stop when the end of the laminate is even with the lips of the cassette no overhang but make sure it is not clear of the whi
19. an authorized service center Customers are not required to purchase Zebra supplies media and or ribbons for warranty qualification However if it is determined that the use of other manufacturer supplies has caused any defect in the printhead for which a warranty claim is made the user is responsible for Zebrais labor and material charges required to repair the defect The warranty becomes void if the printhead is physically worn or damaged also if it is determined that failure to follow the preventative maintenance schedule listed in the Useris Guide has caused defect in the thermal printhead for which warranty claim is made Software Software is warranted to be free of defects in material and workmanship for 30 days from the date of purchase In the event of notification within the warranty period of defects Zebra will replace the de fective CD or documentation Supplies Supplies are warranted to be free from defect in material and workmanship for a period of six 6 months for media and twelve 12 months for ribbon from the date of shipment by Zebra This is pro vided the user has complied with storage guidelines handling and usage of the supplies in Zebra printers Zebrais sole obligation under these warranties is to furnish parts and labor for the repair or possible replacement of products found to be defective in material or workmanship during the warranty period Zebra may in its discretion issue a credit for any such defective
20. best color profile from the list of associated color profiles Recommended Sharing Security Device Settings These settings let you associate color profilefs with your color printer Color profiles control the color on your printer based on the type of media being used and the printer configuration Manua Manually select the default color profile for all output from this device from the list of associated color profiles Default color profile lt None gt Color Profiles currently associated with this printer Start gt Printers or Printers and Faxes gt Right click Printer Properties Sharing Zebra P6401 gt Properties gt Sharing See Tech Notes TN1 General Information amp Zebra P640i Pro perties Color Management Security Ports Device Settings Sharing Advanced General YA You can share this printer with other users on your network To Sa enable sharing for this printer click Share this printer Do not share this printer Share this printer Drivers If this printer is shared with users running different versions of Windows you may want to install additional drivers so that the users do not have to find the print driver when they connect to the shared printer Additional Drivers P640i Card Printer User Guide 69 Printer Properties Security Printer Properties Advanced Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties g
21. blocked pressed closed Close Heater Temperatures Temperatures measured by thermocouples in the top and bottom laminator heater cores Laminate Sensors Reflective sensors that detect the presence of laminate on the transfer rollers The threshold numbers are Below 124 laminate present Above 140 laminate absent The threshold numbers are not adjustable Caution Accurate positioning of the A laminate sensors is essential If they do not detect laminate reliably performance of the entire printer is compromised 980541 001 Rev A It is possible to get a false good reading if the sensors are too close to the feed rollers Upper laminate Sensor Infeead sensor ransfer roller Outfeed rollers Ou oF Card ext Outfeed sensor gt Card n ilow Transfer roller Lower laminate Sensor Functional test of the sensors From each of the laminators upper and lower remove the transfer guide and the laminate patch if any beneath it The sensor should read high around 250 Replace the guide and the sensor should read no lower than 180 If lower than 180 move the sensor board away from the transfer rollers to the left diagram below Complete the test by running laminate onto the rollers press the LAMINATE button The sensor should read below 20 Adjust sensor board to correct Caution The sensor board must be
22. eens 32 E Y oe wege eee eo ee ae ee aig ee oe bee ae ode wees eee eee 33 Printer Parameters in the Drivers 1 2 0 0 0 0 cee ee ee eee 33 Password IOlCCUOM eos 65 6655e055555 nenn ern eh eeeeeeGus gst bees 34 Technical Note 2 Card Transport 0020 cee eee 37 No slip card transport lt ccdceteeecweedsed SedeGe ohh wee e hte eees thee ceae de 37 Card transport knob 1 ee ee eee eee 37 Take care of the platen 1 2 0 eee 37 Removing the platen 0 0 0 eee e eens 37 Truck interlock arrowed 0 0 0 0 ccc ee en eee ee eee 38 TRUCK WOME SENSOF 2255054 4 ner oru 43544 54565665 056844e 8058 5650044565 38 Card presence Sensor 665446544460 ndodt50005G5 0604 0b eee Coa ndadwde nae 38 Cleaning cassette 1 ee eee eee eens 39 Underside of hopper base molding 0 ee eee 39 Transport Parameters in the Driver 0 0 0 0 ccc eens 39 Avoid These Problems vi cdcasewee cera cGdencagedea aces cdtadwetweod amp eed 40 TEchnical Note 3 Magnetic Stripe Encoder 2 0 ce cence eee eee 41 Mag encoder installation 0 0 ccc eee eens 41 Mag encoder components 0 00 ccc eee eee 41 Cleaning the read write head 2 0 ee eee eee 41 Replacing the read write head 2 0 ce eee 41 Magnetic Encoding Functions in the Driver 0 0 0 eee 41 Magnetic Encoding Preferences 0 0 43 Techncial Note 4 Print Station 0 0 0 ees 44 Examples
23. even to the experienced technician There is no universal formula for success If you do not achieve satisfactory results after following the directions given here contact Zebra support for further advice Hardware setup Make sure the computer on which you are installing the P6401 is connected to the network Switch on the printer then test for functionality by printing a test card press the PRINT button Connect the Ethernet port RJ45 receptacle on the P6401 printer to the network through a hub switch or router Use only a pass through cable also known as straight through Software setup 1 Obtain from your network administrator the following three sets of numbers Static IP address Netmask a k a Subnet mask Gateway optional 980541 001 Rev A 2 Using either downloaded software or the provided CD display the Zebra printer setup screen then click Install a Printer and Driver Printer Setup Install a Printer and Driver Uninstall Printers and Drivers Install Uninstall IDPrint Lite a simple card printing application View Print Release Notes Requires a text reader such as Notepad x Card Printer AY Solutions Exit 3 Select Ethernet Internal then click Next Add Zebra Printer Port x D Ethernet Internal Please choose your printer s interface Parallel Port 4 Click Browse and allow the computer to search for the printer s default IP address Confi
24. force bringing the cleaning tape into contact with the cleaning roller The motor continues to rotate for a second or two pulling fresh tape out of the supply roll This in turn rotates the cleaning roller at the same time removing debris from its surface BOTTOM Feedback on motor rotation is provided by the encoder disk and sensor behind the cleaning mechanism 980541 001 Rev A Underside of hopper base molding The base molding is secured to the aluminum transport by buttonhead screws through the six stand off springs seen here The molding is NOT screwed hard down It floats on the springs and is adjusted up and down by the buttonheads to set the card gate height relative to the platen at just over the thickness of a single card If the base molding is set too high the truck will attempt to make off with more than one card if too low it will leave the hopper area without a card Advanced Utilities Flip Pause Flip Test 2 Eject Card Flip Test 3 Password Protection Run Test C Flip No Flip Use Password Move Carriage ID Code Move Home Position X Calibration Mag Position Adjust Mag Amplitude Adjust Show Sensor Data Flip Station Calibration Update Backup Config Upgrade Firmware Send Features File Set ID Code l Disable Printer s Print Button Status Disabled Disable Printer s Other Buttons Status Polling Frequency Normal Reduced None Number of Times to Retry
25. in the Drivers See Tech Note 8 Windows Printer Driver for more information Change ID Code Current ID Code Status Disabled To disable the ID Code Feature clear the password field Old Fassword New Password Confirmation mooo E Help Cancel Refer also to other Tech Notes specific to the functional element in question Card Transport Mag Encoder Print Station etc Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Control gt Advanced Utilites ID Code Sends an ID Code password of your choice to the printer synchronizing the driver to printer ID Code This prevents use of the printer with a PC not having the same ID Code Update Backup Config Most of the parameters affecting operation of the printer e g laminate station adjustments are set up using the printer driver and are then saved in the printer s flash memory as current configuration The original factory configuration also resides in a Separate backup memory allowing you to recover the as shipped settings Update Backup Config instructs the printer to replace the factory configuration with the current configuration but DO NOT DO THIS CASUALLY On the same lines as System Restore in Windows XP you can revert to the backup config as follows 1 Power OFF 2 Remove the color ribbon 3 Press and hold the PRINT RIBBON an
26. of good will or any other special or consequential damages whatsoever with respect to any claim made under agreement with Zebra Specifically for software Zebra is not liable for any inciden tal or consequential damages caused by abuse or misapplication of the software or by its use in vio lation of the U S copyright law or international treaty 980541 001 Rev A P640i Card Printer User Guide V AGENCY APPROVALS Product Disposal web site at http www zebra com recycle CONTACT INFORMATION Zebra Technologies Card Printer Solutions www zebracard com North America 1001 Flynn Road Camarillo CA 93012 8706 USA Telephone 1 805 579 1800 Fax 1 805 579 1808 Toll free in the US 800 452 4056 e mail cards zebra com Europe Middle East and Africa The Valley Centre Gordon Road High Wycombe Buckinghamshire HP13 6EQ UK Telephone 44 870 241 1527 Fax 44 870 241 0765 Asia Pacific 16 New Industrial Road 05 03 Hudson TechnoCentre Singapore 536204 Telephone 65 6858 0722 Fax 65 6885 0836 e mail asiasales zebra com Latin America 9800 NW 41St Street Suite 220 Doral FL 33178 Telephone 1 305 558 3100 Fax 1 805 558 8485 vi P640i Card Printer User Guide Do not dispose of this product in unsorted municipal waste This product is recyclable Please recycle according to your local standards For more information please see our 980541 001 Rev A Table of Contents Table OF COMIEINS 2222 646
27. products in such amount as it deems reasonable Spare Parts All parts maintenance kits options kits and accessories are warranted to be free of defects in mate rial and workmanship for 90 days except where otherwise denoted from date of purchase This war ranty becomes void if the item is modified improperly installed or used or damaged by accident or neglect iV P640i Card Printer User Guide 980541 001 Rev A Warranty Exclusions and Conditions The warranties provided above are the only warranties applicable No other warranties expressed or implied are given Zebra does not make any IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE in connection with its sale of products or services While Zebrais desire is to be responsive to specific needs and questions Zebra does not assume respon sibility for any specific application to which any products are applied including but not limited to com patibility with other equipment All statements technical information or recommendations relating to Zebra products are based upon tests believed to be reliable yet do not constitute a guaranty or war ranty Zebrais maximum liability for warranty claims is limited to the invoice price of the product claimed de fective Zebra does not assume responsibility for delays or replacement or repair of products Zebra shall not under any circumstances whatsoever be liable to any party for loss of profits lost data dim inution
28. roller is loaded with a patch of laminate cut from the top and bottom cas settes shortly after the previous card passed through the laminator As the card passes between the transfer rollers the laminate patches are rolled into place They are then permanently bonded to the card by a pair of heated rollers applying pressure to the top and bottom surfaces P640i Card Printer User Guide 9 Media Handling Loading cards When loading cards open ONLY the hopper cover left If you open the main cover the interlock switch disables the printer resulting in a Start up delay after the cover is closed 1 Card orientation in the hopper the back side of the card faces up and the mag stripe of the card is to the front of the printer Note If there is no mag stripe and if there is pre printed information on the card your system administrator will tell you which edge of the card goes to the front 2 Load the magazine a few cards at a time holding the cards by the edges as shown Don t try to load an entire pack at one time because that would mean handling the upper and lower surfaces see STOP above right Caution Plastic cards attract dust and dirt Keep them clean Handle them by the edges and avoid touching the surfaces Do not use cards that are dirty or have been dropped on the floor 3 Place the weight on top of the card stack 980541 001 Rev A P640i Card Printer User
29. station station station Hopper buttons Card transport knob For manual repo Mag encod er optional 980541 001 Rev A P640i Card Printer User Guide 1 Introduction Overview Overview The P6401 Printer is a complete fully automatic photo ID card fabricator It comprises six functional elements e Card hopper e Magnetic mag encoder optional feature e Cleaning station e Print station e Flip station e Laminator Because the P6401 Printer is fully automatic it requires no attention from the operator other than media loading and an occasional vacuuming Although you don t need a detailed knowledge of the printer to use the printer effectively an overall understanding of what goes on can help you troubleshoot effectively How you load the cards color ribbon and laminate is important see Section 2 Careful attention to media handling takes care of most problems Photo ID card printing The process used in the P6401 Printer is known as digital thermal transfer a means of printing clean durable images directly onto the PVC surface of photo ID cards There are two different thermal transfer technologies both used in the P640i Printer dye sublimation dye sub which uses the three process colors Yellow Magenta Cyan for photos and graphics and mass transfer for machine readable black text and bar codes Both types of printing are done with a single print head comprising a row of tiny heating
30. sure the ribbon is between the arms of the ribbon sensor left of the printhead 14 P640i Card Printer User Guide 980541 001 Rev A Media Handling Laminating Station 4 Close the printer cover then press the RIBBON button to initialize the color ribbon If the MEDIA light fails to go out check the ribbon sensor Caution Color ribbon wrinkling and fold over AN can seriously affect print quality Unless you are sure the ribbon is installed properly proceed to Step 6 5 Re open the printer cover to inspect the ribbon path for wrinkles and folds Correct if nec essary then close the cover Laminating Station Important e When loading or unloading AN laminate cassettes stay away from nearby heated rollers When either of the laminate cassettes is empty a warning message appears on the monitor and the MEDIA light on the printer turns on Overlay laminates come in three widths e For the front UPPER of the card full width plain or with special graphics Full width 2 51 mm e For the back LOWER of the card partial width if there is a writable signature panel or mag stripe otherwise full width Usually there are no graphics on lower laminate Partial width signature panel 1 66 42 mm Partial width mag stripe 1 3 33 mm Laminate Cassettes The upper and lower cassettes are mirror images almost identical twins This can be confusing if you don t follow the procedure ou
31. this error occurred while printing the card will be reprinted automatically This dialog box will close automatically once the error is cleared or you may click Close to close it now e Check all cable connections including power e Check that the power switch is ON FLIP STATION JAM The printer is reporting that the flip station is jammed To correct 1 Open the front cover and remove any obstructions from the flip station path Do not try to manually force the flip station 2 Close the front cover The printer will automatically try to lower the flip station If this error occurred during printing the card may need to be reprinted Select Reprint to reprint the card or Cancel to cancel the print job Cancel RIBBON OUT The printer is reporting a Ribbon Out The problem might also be that the ribbon is jammed To correct 1 Open the front cover 2 Load new ribbon or clear jammed ribbon 3 Close the front cover 4 Press the Ribbon button on the printer front panel to re synchronize the ribbon If this error occurred while printing the card will be reprinted automatically This dialog will close when the error is cleared or you may click Close to close it now LAMINATOR IS WARMING UP DO NOT OPEN THE FRONT COVER The printer is heating the laminator which may require up to 4 minutes There may be a pause in the printer operation no noise The Ready LED will flash during this tim
32. 24 Laminate not parallel with card edges 2 0 00 eee 25 Laminate wrinkling sn cent twed 6h a eeeeee nase eee owe Rares oe eed eees 25 Unusual Printer Lmainator Events 002 e eee eee 25 Color ribbon runs for longer than 2 or 3 seconds when cover is closed MEDIA NOME Stays ON s2 2 tet dee aecee tb eee ke aeara Pere end be eho ees ee nee 25 ALARM light stays ON after error condition is cleared 00000 0 25 Card has both front and back images printed on same side 25 MEDIA light ON steady but no obvious visual problem 0005 25 Completely unexpected print results 2 0 0 0 ee eee 26 YMC color panels stick to Card 1 ee eee eee 26 K Black panel sticks to Card 1 eee eee eens 26 Loud rattling screeching from card transport 0 00 eee 26 Brief rattling noise before every print job 2 0 ee 26 Rattling noise every 10 CardS 1 ee ee ee ee 26 LMUSU ACV CUS tcc a 6 2 artnet EE ton Ge ee oe Be Re ee 4 be ee 27 Laminator spot check 0 000 ccc eee eee e eee ene 27 POGIMONGL NCIS a2 esssssss epinis rnp a eE AAE E R Max 27 Error i 6 ee eee EE ee ee eee ee eee 27 viii P640i Card Printer User Guide 980541 001 Rev A 10 15 2004 Table of Contents 4 Technical Notes 00504 cane shoe dee ee denade eee ee da ceaeens beak es 31 Technical Note 1 General Information 000 cee eee eee 32 P640i Specifications 0 eee
33. 4 P640i Card Printer User Guide Electric Shock Caution Make sure power is disconnected before working on the print head Also note that the head will likely be destroyed if power is reapplied while you are in porcess of reconnecting the cable or if the plug is not seated properly A Cleaning the print head Do this only if print quality has deteriorated and all other corrective actions have failed 1 Open the main cover this will raise the print head 2 Remove the color ribbon 3 Wipe the bottom edge of the print head a few times using a Q Tip moistened with Isopropyl alcohol 4 Dry off with the lint free cloth taking care not to touch the active edge Important The angle of the print head relative to the surface of the card is set by this 4 40 button head screw and lock nut 5 64 hex wrench 5 16 open end wrench Replacement heads are shipped with theis screw preset but some fine tuning may be required 4 40 shoul der screws Yaw adjust technician only 980541 001 Rev A Print head attachment hardware Connector Head angle adjust Print head pivot Print head assembly Replacement print heads are shipped pre assembled to the mounting bracket shown here To ensure uniform contact pressure across its width the head is free to rotate 2 about its center pivot It is secured to the bracket by four button head screws tightened to allow a sliding fit Electric Sh
34. 4c8s444cbesecrtet ewe ee tadue ted e wees bene eae vii DP INUOCOUCHON 2sce ee ees et ttt ewe AE E eset tee E eee eee eee 1 OVGIVIEW a6 55 he ea ee ee Be eee ee eee ak ee a ee a ee ee ee RENI 2 Photo ID Cara pring 22 06 268 tb temeedd dpe eeeeete dd db teed a a eee ees 2 PRUAUNG BASICS canccusoteesatacroadanessgneeeeseeeeeenengeuanes Dena ewee ae 3 What makes the P640i a different kind of printer 0 0 00 2 eee 3 What to expect when you turn on the power 0 00 cece eee eee 4 WOSE CaN oh hee od Gee be es eae uhoeee oka eee ode Se eee eh uae eee eee eee ees 5 Push buttons and Indicator lightS 0 2 00 eee 5 PRIN DUMOM s lt 4 cbcn5495 50c005 eeaed ta0 2a ne oed pone nn Sees atau nee es 5 RIBBON DUHOM cuducecec ceceece decade AERES Gs once eeseecaaee snag RE 6 LAMINATE DUON oc 2225 44208 oe os eee epee a a oo om Gao hee eee eee 6 INDICATOR LIGHT SUMMARY 0200 c eee eee 7 A typical card production sequence 2 0 ce eens 8 2 Media Handling 000 cee es 11 Boscolo CaldS adc0 centaur ecdcesentaenes ceo we dante eee E E es eens 11 POLCON bn pree ERE eee ones nee neete see ae e eee oes ee eee 12 Loading the cleaning cassette 0 000 es 12 Why 10 cards is the normal clean frequency 2 000 c eee eee eee 13 Loading the color ribbon 0 es 13 Laminating Station 24 46 lt 6 tons hate eer eo a ee ear ee oe ore Ware eee eh es 15 Lami
35. 541 001 Rev A P640i Card Printer User Guide 5 Introduction Push buttons and Indicator lights RIBBON button This button is used to synchronize the ribbon in other words to position it correctly under the print head In typical applications the ribbon type is YMCK and the back of the card is printed first In such cases pressing the RIBBON button will advance the color ribbon to bring the leading edge of the next black panel under the print head If back side printing is not enabled the printer will synchronize on the next yellow panel when the RIBBON Figure 1 Standard YMCK color ribbon button is pressed LAMINATE button If either or both of the laminate transfer rollers is not loaded with a laminate patch then pressing the LAMINATE button will correct the condition provided the cassette s is not out of laminate If both rollers are already loaded the LAMINATE button has no effect A typical use of the LAMINATE button is in reloading a transfer roller after removing the first hand cut patch of laminate following installation of a fresh roll 6 P640i Card Printer User Guide 980541 001 Rev A Introduction INDICATOR LIGHT SUMMARY INDICATOR LIGHT SUMMARY Depending on the condition they are reporting the three indicator lights READY MEDIA and ALARM can be in one of three states Off On steady or Flashing The READY indicator is bi colored Its two color channels green and yellow function independen
36. Card Printer User Guide 77 Add Printer Wizard Piit Teat Page To conin that the pria n inehalled propery pou can pond a bes page Do p u anand 1o pemi a best paga Ove Ho 13 Click Next to bring up the Completing the Add Printer Wizard screen Add Printer Wizard Completing the Add Printer Wizard You have successfully completed the Add Printer Wizard You specified the following printer settings Name Zebra P6401 Share name lt Not Shared gt Pott ATLUSBOO1 Model Zebra P640 Default No Test page Nd To close this wizard click Finish 14 The next screen warns that installation of the driver software may destabilize your system The P6401 driver software has been exhaustively tested in many installations and has caused no problems of which Zebra is aware Click Continue Anyway to complete the printer driver installation Hardware Installation The software you are installing for this hardware pee us installation now and dor for software that has _ testing STOP Installation 78 P640i Card Printer User Guide Install using Add a Printer The third way to install the printer driver is through the standard Windows Add a Printer procedure Go to the Windows Start menu select Printers or Printers and Faxes then click Add a Printer Click Next on the welcome screen and you are at the same stage as adding a parallel port or USB port Add Printer Wizard Welco
37. Device Settings gt Status Print Jobs The number of the print job that is currently being processed Next is meaningful only when the printer is not being driven by a PC If the printer is being driven by a PC the PC sets the job number to be the same as the PC assigned spooler job number before sending to the printer Printer Information Device Information Vendor Name ZEBRA Model P640 0 55 Media Firmware Version 2 09 15 Images Left Serial Number 0002119 Cards Printed 2199 Driver Version Memory Configuration DRAM Size 8 MB Print Jobs Recieve Buffer Size 5711K Next 112 In Receive Buffer 0 In Print Buffer 0 Enabled Features UY Printing No ID Code No ID Key No Advanced Error Conditions Card hopper door open Error Conditions Normally this displays No Error Images Left The exact number of YMCK sets remaining on the color ribbon as reported by the color ribbon core Enabled Features Uv Printing is enabled in manufacture or by field technician ID Code the user password is enabled by the user ID Key requires installation of a physical key This displays Yes once the printer has locked itself to the key not just because it has the key installed Advanced Click the Advanced button to display Sensor Data below Another way to display this screen is through this sequence see page TN8 5 Start gt Printers or Printers and Faxes gt Righ
38. Device Settings Status amp Zebra P640i Properties Caution Some of the sub menus under Device Settings are specific to the Print Advanced Device Settings General Sharing Ports Color Management Security Maintenance These maintenance screens are used primarily to calibrate the printers at the factory Modifying these values could cause undesirable results Printer Adjustment The status screen displays the current state of the printer which is updated every few seconds Status Control The control screen allows manual control over the printer These functions are similar to the buttons on the front of the printer Control Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Status Navigate to Properties by following this sequence Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties Most of the tabs on the Properties screen General Sharing etc are of the set and forget variety page TN8 8 We start here with Device Settings the location for all driver controlled adjustments and displays AN Device Settings Caution Some of the sub menus under Device Settings are specific to the Print station Mag encoder and Laminator Refer to the relevant Tech Notes section 980541 001 Rev A Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt
39. Flip Station Flip Test 2 see Tech Notes TN5 Flip Station Flip Test 3 see Tech Notes TNS Flip Station Eject Card see Tech Notes TN5 Flip Station Flip Pause see Tech Notes TN5 Flip Station Move Truck see Tech Notes TN2 Card Transport Mag Position Adjust see Tech Notes TN3 Magnetic Encoder Mag Amplitude Adjust see Tech Notes TN3 Magnetic Encoder Flip Station Calibration see Tech Notes TN5 Flip Station Show Sensor Data Click to display Sensor Data below Also available through the Status screen Device Settings gt Status gt Advanced 980541 001 Rev A Sensor Data Sensor Data Ribbon Temperature Ribbon Panel Detect 220 Panel Threshold 130 Ribbon Encoder Count 504 Printhead T emp Controller Board Temp Top Heater Temp Bottom Heater Temp Laminate Top Laminate Sensor Logic States Bottom Laminate Sensor Hopper Door Lam Present Threshold Lam Absent Threshold Main Door Truck Near Hopper Truck Home Printhead Lift Flip Station Card Lam Enter Card Lam Exit 0 Miscellaneous Card Presence Sensor 249 Printhead Voltage 23 760 Y AC Frequency 60 Hz Assumed AC Voltage 110 0 unblocked not pressed open 1 blocked pressed closed Close Ribbon Panel Detect The current reading of the color ribbon sensor Panel Threshold The current value of the detection threshold for the color ribbon Above this value is termed black below this value is termed not blac
40. Guide 11 Media Handling Loading the cleaning cassette Hot Loading You can load cards while the printer is powered up and operating If there are no cards left in the hopper close the hopper cover then wait until the printer hascompleted its current print job and returned the truck to its home positon under the hopper Note When the hopper cover is open the truck can not drive to its home position Loading the cleaning cassette Before being printed each surface of the card is cleaned by a soft tacky roller that is itself cleaned periodically by adhesive tape in the cleaning cassette Typically the roller is cleaned every 10 cards The printer driver software allows the card count to be modified When the cleaning cassette is exhausted a warning message appears on the monitor and the MEDIA light on the printer turns on 1 Open the main cover of the printer then remove the spent cleaning cassette by pulling it toward you 2 Remove the protective foil from the replacement cleaning cassette 12 P640i Card Printer User Guide 980541 001 Rev A Media Handling Loading the color ribbon 3 Install a fresh cleaning cassette by locat ing the rectangular pin on the cleaning mechanism in the receptacle on the cas sette Push the cassette gently home ensuring that the internal grooves on the upper spool engage the teeth on the takeup drive Why 10 cards is the normal clean frequency If the cleaning sys
41. Mode Using Dongle Cancel 6 Click Finish to complete the installation Found New Hardware Wizard Completing the Found New Hardware Wizard The wizard has XC KOY oo vftware for aA A aw al wer e we Click Finish to close the wizard 980541 001 Rev A Install using Zebra s Printer Setup screen 1 Referring to First things first page TN9 1 place the Driver CD in the CD ROM drive or double click setup exe in the file folder containing the unzipped downloaded driver Printer Setup _ruePnewitogne __ DIAS yt ee o of a Such as Notepad Card Printer We s 8 Solutions Exit 2 This is the Zebra Printer Setup screen From here you can install or uninstall the print driver on your computer Additionally you can install DPrint Lite a simple card printing application for functional testing The two View Print buttons provide information for the technician 3 Click Install a Printer and Driver This brings up the Zebra Add Printer Port screen 4 Unless you are conecting to a network through the optional Ethernet port select either Parallel Port or USB Port depending on your choice of cable connection between computer and printer then click Next For information on the Ethernet option see page TN9 6 Contact Zebra support if necessary Parallel Port If you selected Parallel Port the next screen displays Zebra Enhanced LPT 1 This is the default recommended port Clic
42. Printer Adjustment gt Laminate Station Adjust Reference Technical Note 6 24 P640i Card Printer User Guide 980541 001 Rev A Troubleshooting Unusual Printer Lmainator Events Laminate not parallel with card edges e Skew adjust mechanical adjustment Reference Technical Note 6 e If using partial width laminate edge guide not properly installed one of two positons Section 2 e Transfer guide not properly installed Section 2 e Laminate patch wrapped around heated roller Page 3 3 Laminate wrinkling e Can occur at end of roll Remove cassette If nearly out discard Install fresh roll e If not end of roll problem suspect obstructions in laminate feed path Unusual Printer Lmainator Events Color ribbon runs for longer than 2 or 3 seconds when cover is closed MEDIA light stays on e Color ribbon not in ribbon sensor Section 2 e Both ribbon cores not fully engaged on arbors Section 2 e Ribbon not secured to takeup core Section 2 e No ribbon type or wrong ribbon type specified in Printer Properties Reference Technical Note 8 ALARM light stays ON after error condition is cleared Note There is a delay after closing the cover before the ALARM y 7 light goes out e Main cover interlock switch may not have actuated when cover closed Reference Technical Note 1 e Alarm condition s not corrected Card has both front and back images printed on same side e Check selections made in Printing Pr
43. Reference Technical Note 4 e Toothed transport belt pulley may be slipping on drive shaft Tighten set screws make sure the screws bear on flats on the shafts Examples of color mis registration Left is the test card in the printer s firmware Right is an enlargement showing fringing on process black text generated from Y M and C Poor color rendering e Possible source issues poor quality photos or graphics card layout application settings Isolate the problem by printing a known image such as Portraits bmp through IDPrint Lite Reference Technical Note amp e Vary brightness and contrast controls in Preferences gt Image Adjustment preceding page Fine tune if necessary using Contrast Adjust in Properties gt Device Settings gt Color Calibration Reference Technical Note 4 Faint non uniform image e Printhead pressure too low Adjust downward Reference Technical Note 4 e Printhead not pivoting freely Reference Technical Note 4 Gaps in image at edges and corners e Possible de lamination wear of platen s rubber surface Try cleaning platen If unsuccessful replace platen Reference Technical Note 2 e Possible non uniformity of card thickness or card surface defects 22 P640i Card Printer User Guide 980541 001 Rev A Troubleshooting Troubleshooting quality problems Continuous white or black stripes on card s longer dimension White stripe means blown pixel non functioning heating elemen
44. Reference Technical Note 4 Printer Adjustment e Check ribbon takeup and supply torques Reference Technical Note 4 K Black panel sticks to card e Printhead running too hot Can happen after head replacement if head resistance incorrectly entered through printer driver Reference Technical Note 4 Printer Adjustment e Black panel density and or preheat set too high Reference Technical Note 4 Color Calibration e Check ribbon takeup and supply torques Reference Technical Note 4 Loud rattling screeching from card transport e Card s has fallen onto truck drive belt and is jammed at some point Open cover remove all cards from hopper Remove jammed card if accessible Look for card s in the transport bed Using card transport knob hand crank truck to push card into one of two areas for easy removal under hopper or under flip station lift carrier for access then push it down again Brief rattling noise before every print job e Make flip station rest position adjust parameter less positive But be sure the carrier still descends to its physical end stop otherwise it may fail to pick card off platen Reference Technical Note 5 Flip Station Adjustment Rattling noise every 10 cards e Cleaning cassette not firmly engaged Reference Technical Note 2 26 P640i Card Printer User Guide 980541 001 Rev A Troubleshooting Error messages Unusual events In all of the following cases and all other unusual events try power
45. YMC and K iM 1 black extracted on an Image 2 front K on back YMC and K A Image 2 black extracted on Image 3 front K on back DPrint Lite can also be used to write to the magnetic stripe if applicable Before entering data in the Track windows you must first select the format AAMVA or ISO in the Magnetic Encoding screen found in Printing Preferences Note The Save function disk symbol on the IDPrint Lite tool bar applies only to magnetic stripe data not to the image assignments Image assignments are stored automatically when the DPrint Lite program is closed 72 P640i Card Printer User Guide 980541 001 Rev A Technical Note 9 Installing the Windows Printer Driver First things first For any of the operations described in this section you need the P6401 Driver Software This is on the Driver CD It may also be downloaded from the Zebra Support Web page Driver CD If you have the CD place it in the computer s CD ROM drive This will display the Zebra Printer Setup screen Follow the screen instructions to Uninstall or Install referring where necessary to the additional information in this section Download Downloaded software comes to you as a self executing application available from zebracard com atlantek Before you download make a note of the file name and where it will be saved on the computer s hard drive 1 Click Download then choose somewhere to s
46. acks not selected for Bit By Bit will default to ISO AAMYVA selection Enable EIN Readback Note Embedded Inventory EIN Readback requires magnetic cards with pre encoded inventory numbers Printing Preferences ID Log Reference Technical Note 7 ID Log amp Zebra P640i Printing Preferences Card Setup Image Adjustment YMC Color Printing K B lack Panel Magnetic Encoding ID Log About V Enable Logging Log File Definition Create New Log File Each Day File l Separator Character Delete Existing Log Files Log File Contents Time Date Printer Serial Number Static Text Max 16 characters IP Address Magnetic Track 1 Data Magnetic Track 2 Data ja Magnetic Track 3 Data Application will send data with L xxx TextOut Spooler Job Number z e a P User Name NOTE EIN Readback must be enabled in order to log EIN data EIN Readback Enable can be found on the Magnetic Encoding tab 980541 001 Rev A Printer Properties Navigate to Properties by following this sequence Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties Most of the tabs on the Properties screen General Sharing etc are of the set and forget variety page TN8 8 We start here with Device Settings the location for all driver controlled adjustments and displays A station Mag encoder and Laminator Refer to the relevant Tech Notes section
47. applications where durability is important Ribbon This is the color ribbon installed in the printer Choice of two for most applications YMCK 3 color panels 1 black panel and YMCKK 3 color panels 2 black panels For secure applications a third type of ribbon is available YMCUvK Uv is a panel of ultraviolet responsive resin Front Back Allows you to apply color or black or both to either side of the card For example with a 4 panel YMCK ribbon the usual arrangement is YMC Color on the front K Black on the back If you check both YMC and K on one side this sets up a special condition known as black extraction page TN8 2 Laminate Allows you to choose whether laminate will be applied to the front side to both sides or to neither side 62 P640i Card Printer User Guide Orientation Allows you to set up the front and back images independently for driver license landscape or badge portrait configurations By checking the Rotate box you can also flip either image upside down The following combination is not available Front landscape Back portrait amp Zebra P640i Printing Preferences ID Log About K Black Panel Magnetic Encoding YMC Color Printing Image Adjustment Card Setup Image Size CR 80 Oversize 600 952 pixels bi Cards Zebra Card Ribbon Type Color Uv YMCUvK DNP v YMC Color K Black Uy Front V ja y Back E 7 Laminate Off Front Fro
48. are The manufacturer and model determine which printer software to use A Select the manufacturer and model of your printer If your printer came with an installation ba disk click Have Disk If your printer is not listed consult your printer documentation for compatible printer software Manufacturer Printers Atlantek Zebra P620 A This driver is not digitally signed Tell me why driver signing is important Zebra Technologies Zebra P640i windows Update 980541 001 Rev A 14 On the following screen type in a name for the printer This can be anything you like such as Printer A Typically check No don t make this the default printer Add Printer Wizard Name Your Printer You must assign a name to this printer Type a name for this printer Because some programs do not support printer and server name combinations of more than 31 characters it is best to keep the name as short as possible Printer name Zebra P640i Do you want to use this printer as the default printer O Yes No 15 Typically you do NOT want to share the printer Add Printer Wizard Printer Sharing You can share this printer with other network users IF you want to share this printer you must provide a share name ou can use the suggested name or type a new one The share name will be visible to other network Share name 16 You can print a test page if you wish Add Printer Wizard P
49. ation Replacement read write heads are shipped pre assembled to the bracket shown here Check the location of the yellow wire This must be in the lower right corner Shoulder Adjustomg Nylon screw screw 3 32 Washer Spring Clamp Steel Washer Mag encoder components Shoulder screws at the two ends of the bracket allow vertical float Springs hold the read write head firmly in contact with the card s mag stripe Cleaning the read write head The head needs to be cleaned only if encoding becomes troublesome This will show up as extra passes of the card under the head if the Mag Verify function is enabled recommended in Printing Preferences To clean the head turn power OFF and remove all cards from the hopper Drive the truck to the right clear of the mag encoding station by rotating the card transport knob left of the laminator Reaching down through the floor of the hopper clean the head with a Q Tip dipped in isopropyl alcohol Allow several minutes drying time before running the printer 980541 001 Rev A Replacing the read write head As shipped the replacement read write head is a complete assembly comprising mounting bracket and clamp hardware Other screws and springs are not included Remove setting aside for re use the shoulder screws and adjustment screw from the defective assembly together with springs and washers Install the adjustment screw in the replacement bracket bringi
50. axes gt Right click Zebra Defects at top left and on the bottom edge were P6401 gt Properties gt Device Settings gt Printer Adjustment gt caused by lack of support under the card Card Hopper gt Pick Position Adjust Pixels Clean Frequency Clean Frequency adjusts how often the card cleaning roller is itself cleaned by contact with sticky tape in the cleaning cassette Acceptable values 1 card to 20 cards default 10 cards Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Printer Adjustment gt Cleaning Station gt Clean Frequency Avoid These Problems The truck platen is an important contributor to print quality To provide adequate support for the card the platen s neoprene surface must be clean and intact Look for signs of delamination especially at the edges of the platen and be sure to keep the surface free of debris Delaminated platen Pick Position Adjust fine tunes the extent of truck motion relative to the home sensor located left of the card hopper Modify this value only if the printer has repeated difficulty in card picking Dirt on platen These image defects were caused by a foreign object under the card a tiny piece of card less than 0 01 0 25 mm thick P640i Card Printer User Guide 40 Technical Note 3 Magnetic Stripe Encoder The mag encoder is a factory option for the P6401 Mag encoder install
51. ch is all of them Using the printer pool Send print jobs to the pool not to an individual printer When the first printer has taken as many jobs as it can handle that being two jobs one to be printed immediately the other waiting the following jobs spill over to the second printer and then to the third printer Notice that if you are only printing two jobs they would both go to the first printer Pooling is a spill over methodology It does not balance printer usage Once the pool has been set up maintenance and configuration changes should be done through the menus for each individual printer e g Zebra P6401 1 not through the pool which can produce undesirable results 3 Note The effect of any maintenance or changes can and should be tested by sending print jobs separately to each printer not to the pool P640i Card Printer User Guide 83
52. ck Open If you wish to use a file of your own instead of the samples navigate to the location in which you saved the file click and hold the down arrow to display your computer s various file locations Select Image File Look in D Samples EA c EJ N wedge_2 bmp I EuroTravel_Back bmp N EuroTravel_Fror A Wedge_1 bmp N Airport Back bmp D Portraits bmp N Driver _License_Back bmp RI Color_Gradients bmp N Airport_Front bmp N Graytone bmp N Driver_License_Front bmp N Flower_Show_Back bmp A Flower_Show_Front bmp ce ii gt File name Portraits bmp Files of type Files TGA BMP v Cancel How Images 1 2 and 3 are applied to the front and or back of the card and the way in which they are processed is determined by two selections that must be made in the Printing Preferences Card Setup screen 1 P640i Card Printer User Guide 71 The type of color ribbon installed YMCK YMCKK or YMCUvkK and 2 The assignment of YMC Color Uv ultraviolet and K Black to front and back To bring up the Card Setup screen follow this sequence Start gt Printers or Printers and Faxes gt Right click Zebra P640 gt Printing Preferences gt Card Setup Card Setup Ribbons image numbers and front back assignments YMC K Black uV Color YMC on front Front 47 _ OE e K on back aT Ter extracted on front black extracted on ae Image 2 both front and back
53. coder 980541 001 Rev A Device Settings Color Calibration Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Color Calibration See Tech Notes TN4 Print Station Printer Adjustment Print Station Adjust Cancel Flip Station Adjust Advanced Adjuzt Laminate Station Adjust Card Hopper Pick Pasition Adjust Pixels 0 Cleaning Station Clean Frequency Every Printer Properties Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt General See Tech Notes TN1 General Information amp Zebra P640i Pro perties Security Parts Device Settings Advanced Color Management General Sharing h A ebra P640i Location Comment Model Zebra P640 Features Color Yes Double sided Yes Paper available CR 80 Standard 578x952 pixels CR 80 Oversize 6004952 pixels CR 80 Oversize 610x968 pixels Staple No Speed Unknown Maximum resolution 300 dpi Printing Preferences Print Test Page 980541 001 Rev A Printer Properties Color Management Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Color Management See Tech Notes TN1 General Information amp Zebra P640i Pro perties General Parts Advanced Color Management Al Automatic Windows will automatically select the
54. color uncompressed pixel maps The above elements may not always be sent to the driver as expected For example a bar code may be Sent as text a series of area fills or a monochrome bitmap Results will vary by application used to create the card design Another variable again controlled by the card layout application is the precedence stacking order of the various element types in the event that one or more of them overlap Any of the above five elements may be selected for black extraction when the ribbon is set up to apply YMC color and K black to the same surface of the card In this condition the driver generates an extracted K image by looking for true black features in the selected element types that is instances where all three YMC values are at the maximum full intensity Each such true black instance generates a corresponding cluster of black pixels in the extracted image which will be printed with the K black panel either on top of the YMC image or replacing it entirely your choice 64 P640i Card Printer User Guide Printing Preferences Magnetic Encoding Reference Technical Note 3 Magnetic Encoder amp Zebra P640i Printing Preferences Card Setup Image Adjustment YMC Color Printing K Black Panel Magnetic Encoding ID Log About Magnetic Data Format f SO SAMVA American Motor Vehicle Standard Bit By Bit on Track 1 Bit By Bit on Track 2 Bit By Bit on Track 3 Note Tr
55. connected hot has a faster data transfer rate and is the preferred port Power up the printer and start the computer If you do not see the following screen install the driver from Zebra s Printer Setup screen or use the Add a Printer procedure 74 P640i Card Printer User Guide Found New Hardware Wizard Welcom NY Found New oS oo oY vare for ate came with an installation CD aisk insert it now nat do you want the wizard to do Install the software automatically Recommended Install from a list or specific location Advanced Click Next to continue 1 Select Install from a list or specific location then click Next Found New Hardware Wizard Please choose your search and installation options a Y Search for the best driver in these locations Use the check boxes below to limit or expand the default search which includes local paths and removable media The best driver found will be installed Include this location in the search Cc zebra driver v Browse Don t search will choose the driver to install Choose this option to select the device driver from a list Windows does not guarantee that the driver you choose will be the best match for your hardware 2 If you have the Driver CD place it in the CD ROM drive If you are working instead with downloaded software or if you think the download may be more recent check Include this location in the s
56. cycling first then investigate specific issues e Printhead descends before card arrives Check horizontal offset Reference Technical Note 4 e Printhead stays down after card has gone away Check card presence sensor Reference Technical Note 2 e Laminate cutter s fails to operate see below and reference Technical Note 6 e Unusual media light indications Laminator spot check e Make sure the transfer roller toggle is in the operating position pointing right e Upper or lower laminate feed problems remove then replace transfer guides discarding laminate patches on transfer rollers Check for laminate where it shouldn t be Remove both laminate cassettes If out or nearly out load fresh laminate Wind laminate back in to eliminate overhang Reinstall cassettes latching securely Visually check path from cassette s through feed roller cutter and transfer guide e Check for misfeeding of laminate due to poor engagement of white plastic idler on cassette with drive roller Mark the upper core to check that it rotates no need to mark the lower core watch the notches on the laminate core Feed laminate by pressing the LAMINATE button e Laminate patch may be wrapped around the heated roller causing card feed problems and or poor lamination Turn printer OFF allow 10 minutes for cooling then remove heated rollers careful they will still be HOT Remove the rogue patch Do NOT use a metal knife or any tool that might damag
57. d LAMINATE buttons at the same time as you switch on the power 4 Release the three buttons when you see activity in the printer P640i Card Printer User Guide 33 Password Protection Not the same as D Code Password Protection blocks access to various low level printer adjustment screens including this one Check Use Password then enter a password of your choice Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Control gt Advanced Utilites gt Show Sensor data Sensor Data Fibber Tere share Hibben Pare Disiet Fr Prete 1am Piri Threabhclel Coria Baad Taa 29 Abben Ereid Care 5 Top Heater Ting Doar Heater Dac a Larras Tap Literate Sepa Lowen Siss Doiio Lamaresie Sarr Hopper Toor Lam Present heht 12 Uri Circe Lam dirion Threatened Traci Finan Hippi Trazi Hoar Prete Lit ig Stabs Cord Lom Ente Borer CadPisee ies 2 Prha Visio Cord Lam Eni AC Frequency hian AC Vadis artie reel precio Ribbon Panel Detect The current reading of the color ribbon sensor Panel Threshold The current value of the detection threshold for the color ribbon Above this value is termed black below this value is termed not black Laminate Sensors Reflective sensor that detect the presence of laminate on the transfer rollers below threshold laminate present above threshold laminate absent Card presence Sensor The reflective sensor to t
58. d meaning a permanent failure of one or more heating elements pixels can be caused by solid particles on the card surface even though the color ribbon affords some degree of protection The automatic card cleaning system in the P640 takes care of most issues but the operator should keep the inside of the printer clean by occasional vacuuming Also bear in mind that it is not a good idea to run the printer with the cover open by cheating the interlock switch except for test purposes Missing or blown heating elements show up as a white unprinted line This calls for a replacement print head Less seriously a faint line may be due to debris or contamination which can sometimes be corrected by cleaning the print head A faint line may also indicate a heating element on the verge of failure or a small piece of torn ribbon stuck under the head Examples of printhead problems The white line in the center of the black stripe suggests a number of blown pixels The wide black stripe means that a large number of pixels are fully on hot all the time Either of these problems may call for a replacement printhead but the black stripe may be caused instead by image handling issues between printer driver and the application that created the card layout Caution Do not touch the bottom edge of the print head Grease or other contaminants from the hands can attract particles that may in time dameage the head 4
59. djust The printer will then e Pick acard from the hopper f Mag encode it g Back up then run it under the read write head again to measure average maximum amplitudes of the recorded data displayed on the Mag Data Monitor below h Pause for a few seconds to allow adjustment i Back up again and repeat the read cycle continuously until the PRINT button is pressed after which the card is ejected through the laminator 6 Turn the adjusting screw first clockwise then counterclockwise in quarter turn increments while observing the data monitor With the bracket setup described in Step 2 above it is pos sible that there will little change in amplitude even with a full turn or two of the screw in either direction e If there is no appreciable change press the PRINT button to end the test then restore the default setup of Step 2 using the CR 80 card shim e eff the amplitude varies as you turn the screw tune for maximum values All three tracks should read at least 130 If there are track to track differences greater than 10 the head may be defective or skewed in the bracket If skewing is the problem loosen the lock nuts on the clamp screws diagram preceding page back out the screws a turn or two then carefully free the head which may have a light adhesive film on the surfaces mating with the bracket Position the head with its rim a hair below the edges of the bracket then retighten the clamp screws and lock n
60. e When the laminator heating is complete this dialog box will automatically disappear and the card will be laminated No operator intervention is required ou may initiate printing of more cards This dialog will close automatically once the laminator has reached temperature or you may click Close to close this dialog now Close Before calling for technician help do the following e Unless you hear noises suggesting a card jam condition try power cycling switch OFF wait 15 seconds then switch ON e Open the main cover then look for obvious problems such as a card where it shouldn t be media outages or misfeeds color rib bon laminate cleaning cassette e Check this section referring if necessary to the relevant Tech Note P640i Card Printer User Guide 980541 001 Rev A Troubleshooting Error messages What the Indicator Lights Tell You READY ALARM I i Bc Race BO GREEN a ves O h Laminator heating up but not yet at operating temperature po Laminator heaters in sleep mode when not in use the heaters cool at 10F per minute i 0 00 Printhead temperature error fy i A a No cards in magazine color ribbon out cleaning tape out laminator cassette s out a xe o Mag encoding write failure i Serious error conditions including MAIN COVER OPEN Laminator too hot card transport stalled card not seated properly mag encoding verification error head lift failur
61. e ribbon jam card jam any location card missing any location no gap be tween laminator patches L 50 light on ros o light flashing 1 gt 980541 001 Rev A P640i Card Printer User Guide 29 Technical Notes Restore printer configuration You can return the printer to its previous backup configuration be pressing the PRINT RIBBON and LAMINATE buttons on the front panel at the same time as the printer is powered up But first remove the color ribbon This is termed a three button reset page IN1 4 Flip station Any time you open the main cover for whatever reason be sure that the flip Station is fully down before the cover is closed Do this by gently pushing down at the back of the flip carrier Correction to this User Guide Most fasteners used in the P640i have U S standard threads Printers manufactured after October 2004 use Torx socket head screws in locations other than set screws on pulleys and gears In addition to a standard set of small hex drivers you will need the following Torx drivers T10 T15 T20 and T25 Other useful facts ID Key is an optional hardware key encoded with a serial number that is compared prior to every print job with a number in the printer s NVRAM If there is a mismatch the printer is disabled ID Code is a field alterable password stored by both the printer dirver and the printer itself It pre vents use of the printer with a PC not having the sa
62. e again to install this hardware then click Finish Installing the printer driver Note Only USB and Parallel versions are described here The optional internal Ethernet port is configured in a different way and may require technician help see page T N9 6 For more information contact Zebra tech support This section outlines the three ways of installing the P6401 driver 1 Direct from the Zebra Printer Setup screen page TN9 3 which comes up automatically from the Driver CD or from downloaded software see Download on this page 2 Using the Add a Printer procedure page TN9 5 and 3 Using the New Hardware Found Wizard procedure page TN9 2 No matter which way you select or allow Windows to select for you have the Driver CD or downloaded software on hand before you start Fa Note If you are using the parallel port to connect to your computer make sure the computer is set to ECP mode before installing the driver To do this you need to check the computer s BIOS For help refer to your computer manual or consult your technician You do not need to select ECP mode if you are using the USB port New Hardware Found Wizard Note The New Hardware Found message appears only if the P6401 printer has never been installed on the computer to which it is now connected If you plan to connect the P6401 Printer to the computer s parallel port shut down the computer then make the connection USB which can be
63. e carriage drives the card under the print head which transfers black characters and or bar code from the K panel onto the back sur face of the card 5 The carriage pushes the back printed card into the flip station which elevates the card then flips it through 1800 6 The card now face up is returned to the car riage which is then reversed into position for a second cleaning operation FRONT SURFACE NOW ON TOP 7 After its face cleaning the card is driven under the print head again this time to print a yellow Y dye image the first of three color passes P640i Card Printer User Guide 980541 001 Rev A 10 11 12 980541 001 Rev A Introduction INDICATOR LIGHT SUMMARY The carriage reverses the card into position for the second color pass magenta M fol lowed by another reverse and print cycle for the third color pass cyan C 4a ai Now fully printed the card re enters the flip station which this time acts only as an eleva tor no flipping to bring the card up to the laminator level CS ee il a arn mem e ee B a k Ear MIn o ue y sam at asar Si Far aih p ma pih oe 4 a a eei ee ee a N Perra a anann rman ace Se ee eee ee ee a ee 9 XJ An ejector arm propels the card into the lami nator infeed rollers which in turn drive the card between the two white transfer rollers p pper step 11 _ cassette Each transfer
64. e front the driver can extract a K image from the true black pixels of the YMC bitmap and also assign K to specific data types such as text if checked here Results depend on the card creation program in use Equal amounts of Y M and C dyes at maximum intensity deliver a near black image but one which is not machine readable For example a bar code printed from YMC color will be visible to the eye but will not be detectable by most bar code readers The remedy for this is to extract the black in other words to print the same bar code using the K black panel on top of the YMC bar code You can also choose to print only in K omitting YMC from that region The K black panel is not a dye It is more of a paint containing carbon black which is highly visible to infrared type readers P640i Card Printer User Guide 63 Depending on the application used to create the card layout elements of the design may be identified in different ways to the printer driver This printer driver recognizes and rasterizes five types of elements text lines and pixels area fills monochrome bitmaps and color bit maps e Text is text which is sent explicitly as such to the printer driver e Lines and pixels are lines and dots pixels sent as such to the printer driver e Area fills are color filled geometric shapes e Monochrome bitmaps are 1 bit bitmaps every pixel either black or white e Color bitmaps are full
65. e same for each color Click Restore Defaults if you are not satisfied with adjustments made Offset Shifts the color curve up darker and down lighter Gain Adjusts steepness of the curve Lighter shades will remain unchanged but darker shades will get darker or lighter as the number is increased or decreased Prehea Adjusts how much the head is preheated before each print line every three hundredths of an inch A larger value darkens sharpens the leading edges of colored areas A lower value may result in feathering starting light then darkening over the following few pixels as the head heats up Black Panel Density Black Panel Preheat See K Black Panel Printing above Contrast Adjust A subtle color printing control allows the user to shape the printer s lightness curve roughly speaking the L in the color space called L a b In practical terms this means the ability to control how the P6401 resolves or differentiates the lighter and darker shades Between contrast settings of O and 100 the lightness curve transitions from linear to sinusoidal Linear 0 tends to result in a low contrast muddy looking image Sinusoidal 100 gives mostly good results but tends to sacrifice the lightest and darkest shades For most purposes select 50 and leave it there P640i Card Printer User Guide 49 Technical Note 5 Flip Station As the carrier descends the cam deflects Actuator A which i
66. e the front surface offset is consistently acceptable inspect the back surface patches of the last few cards to pass through the laminator Note the offset on the back surface When flipping the cards for inspection keep the mag stripe if present toward you ARON ED CARD i i Flip the cards left to right not front to back Correct for vertical offset in the lower laminator using the same procedure as in upper cassette vertical offset adjustment Laminator Parameters in the Driver Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Control gt Advanced Utilities gt Show Sensor Data Sensor Data is also available by this route Device Settings gt Status gt Advanced Information 58 P640i Card Printer User Guide Sensor Data r Ribbon Ribbon Panel Detect 220 Panel Threshold 130 Ribbon Encoder Count 504 Temperature Printhead Temp Fai AE Controller Board Temp 29 C Top Heater Temp Aze i E Bottom Heater Temp 29 C r Laminate Top Laminate Sensor m Logic States Hopper Door Bottom Laminate Sensor Lam Present Threshold Lam Absent Threshold Main Door Truck Near Hopper Truck Home Printhead Lift Flip Station Card Lam Enter Card Lam Exit 0 r Miscellaneous Card Presence Sensor 249 Printhead Voltage 23 760 Y AC Frequency 60 Hz S 0 unblocked not pressed open ATEA let us 1
67. e the heated rollers e Check upper and lower laminate sensor readings Reference Technical Note 6 with and without laminate present lt 20 if present gt 180 if absent numbers valid only if transfer guides installed Additional help For more information on specific printer functions print station flip station laminator etc refer to the appropriate Tech Note in the separate Tech Note Supplement to this Operator s Guide Error messages Most P6401 error conditions are identified by the printer itself and are reported by the computer as error messages with corrective actions Error messages are not further described in this section of the manual which deals only with fault conditions that are not reported automatically On this page are five examples of error messages Important Most problems can be prevented by careful handling of the media cards color ribbon and laminate see Section 2 Media Handling There is almost no preventative maintenance to do Dust and debris should be vacuumed out every 12 months or more frequently in adverse environments 980541 001 Rev A P640i Card Printer User Guide 27 28 Troubleshooting Error messages Most of the problems described in the following pages are correctable by the user but please note there is the potential for unexpected results if the procedures are not followed carefully If in doubt call for service assistance CARD STUCK IN LAMINATOR The pri
68. e to flip Reduce this value if the carrier hits the upper bracket holding the guide shaft If the flip station is not flipping reliably be sure it isa travel issue rather than anything else by opening x deue IZ printer Cover y then moving the flip station up by Laminator infeed rollers Ejector arm Card Insertion height adjustment 54 P640i Card Printer User Guide hand to activate the flip If it doesn t flip the mechanism itself is defective so adjusting the height parameter will have no effect If you overdo the height adjustment sending the carrier too high the U shaped azimuth adjust molding may be driven off the end of its track This causes the carrier to wobble as the U re engages on the way down 980541 001 Rev A Techncial Note 6 Laminator Accurate positioning of the laminate patch is important for practical and aesthetic reasons The patch must cover the entire image as printed by the P640 at the time of issuance thus protecting critical data with a tamper deterrent film Additionally because even the smallest amount of overhang can compromise the card s integrity the patch should be symmetrically positioned on the card Correctly positioned top front and bottom back laminate patches If there is no magnetic stripe on the underside a full width patch should be used Positioning of the patch is affected by three variables 1 S
69. earch then type in or browse to the download s default location c zebra driver unless you sent the unzipped files somewhere else Click Next 3 Following Step 2 the computer searches for a file named Atlprint inf If the search is successful the following screen appears This screen warns that installation of the driver software may destabilize your system The P6401 driver software has been exhaustively tested in many installations and has caused no problems of which Zebra is aware 4 Click Continue Anyway then Accept the License Agreement If you are using a USB connection the Browse Printers screen right displays the USB connected printers Highlight the printer serial number you are working on even if there is only one listed then click OK Browse Printers x Model Humber Serial Humber PB40i 0212077 Cancel Hescan 980541 001 Rev A 5 Click OK to accept the timeout defaults on whichever Configure screen appears USB or Parallel Configure USB Port Printer Info Model P40 0212077 Options 5000 5000 Write Timeout ms OF Read Timeout ms Cancel Note Compatibility Mode shold be enabled only if the P6401 printer is connected to the computer s parallel port through a third party dongle a hardware security device Configure Parallel Port Options AOD Read Timeout ms i mm mm Write Timeout ma Compatibility
70. ease the position parameter to correct Ribbon Torque Adjust Adjusts the current applied to the ribbon take up motor more current more torque thus controlling the ribbon tension between print head and take up Lowering the value default 100 can help reduce ribbon wrinkling but note that there are other factors see Ribbon Wrinkling inset below The downside of reducing the ribbon torque is an untidy loosely wrapped takeup roll That isn t important except aesthetically but low torque does matter if the ribbon fails to advance when it should see Ribbon Position left Printhead Position Adjust Adjusts the downward motion of the printhead The higher the number the greater the amount of overrun following sensor activation Ribbon Wrinkling Printhead Resistance Ohms This value should match what is written on the printhead Enter a new value if the printhead is changed If you enter a lower number than what is printed on the head itself the printed image will be lighter than expected and vice versa The printhead drive train comprises a stepper motor a gear quadrant and a crank arm directly coupled to the printhead bracket photos below In the down position the printhead spring is slightly compressed with the crank arm extended which means that the torque demand on the motor is at its lowest Increasing the printhead position parameter does not result in a mesurable increase in head pressure wh
71. eferences gt Card Setup Reference Technical Note amp e Card failed to flip Run Flip Test 3 to check flip action Reference Technical Note 5 MEDIA light ON steady but no obvious visual problem e Color ribbon not in ribbon sensor Section 2 e Color ribbon supply and or takeup cores not engaging properly on arbors Section 2 e Cleaning cassette not engaging properly on the takeup drive Section 2 e See Laminator spot check page 3 3 980541 001 Rev A P640i Card Printer User Guide 25 Troubleshooting Unusual Printer Lmainator Events Completely unexpected print results e Color ribbon out or nearly out Replace ribbon Section 2 e Main cover opened during a print job Open and close main cover then press RIBBON to re sync ribbon Reprint last job e Color ribbon panels out of sync see previous action e Color ribbon not advancing consistently Color ribbon supply and or takeup cores not engaging properly on arbors Section 2 e Front color side of card printed with black Open and close main cover then press RIBBON to re sync ribbon e Inconsistent color very faint printing Printhead not pressing on ribbon Reference Technical Note 4 e Color ribbon torn or jamming intermittently Clear jam Pull out more from supply roll and reattach to takeup roll Section 2 YMC color panels stick to card e Printhead running too hot Can happen after head replacement if head resistance incorrectly entered through printer driver
72. elements 300 to the inch each driven independently by the printer controller Sandwiched by spring pressure between the print head and the card being printed is the color ribbon usually a series of process color dye panels Y M and C for dye sub plus a panel of black resin K for mass transfer 2 P640i Card Printer User Guide 980541 001 Rev A Introduction Printing basics Printing basics This is the usual pattern for a P640i Printer ribbon Y M and C are the three dye sub process colors The K panel is for infrared readable bar codes and other data usually on J ane the back of the card A second K panel YMCKK is sometimes provided to allow black resin printing on both sides of the card C Y Cyan Yellow Dye Color Prnt ribbon As the ID card is driven through the print head station the color ribbon is metered out from the supply roll at the same speed Each color reqires a separate pass of the card The black dots at the bottom edge of the print head depict the heating elements in practice at 300 to the inch they are too small to be seen with the naked eye Color migrates from the dye ribbon onto the ID card the spread of the dye depending on the amount of heat applied by the print head element Each time it comes to a dye panel boundary the print head lifts to allow the card to back up then lowers again to print the next color The K black panel is a resin that mass transfers
73. ensor Data Flip Station Calibration Update Backup Config Upgrade Firmware Send Features File Set ID Code Disable Printer s Print Button Disable Printer s Other Buttons Status Disabled Status Polling Frequency Normal Reduced None Number of Times to Retry 13 Mag Position Adjust see Tech Notes TN3 Magnetic Encoder Mag Amplitude Adjust see Tech Notes TN3 Magnetic Encoder Flip Station Calibration see Tech Notes TN5 Flip Station Update Backup Config Most of the parameters affecting operation of the printer e g laminate station adjustments are set up using the printer driver and are then saved in the printer s flash memory as current configuration The original factory configuration also resides in a separate backup memory allowing you to recover the as shipped settings Update Backup Config instructs the printer to replace the factory configuration with the current configuration but DO NOT DO THIS CASUALLY On the same lines as System Restore in Windows XP you can re install the backup config by pressing PRINT RIBBON and LAMINATE buttons at the same time Upgrade Firmware Upgrades printer s flash memory with replacement printer firmware downloadable from the Zebra website Send Features File The features file is special software used to enable disable UV ultraviolet printing clear passwords and other items of a security sensitive nature Contact Zebra su
74. er 2 Click Next on the Add Printer Wizard welcome screen 3 Select Local Printer Make sure that Automatically Detect My Plug and Play Printer is unchecked then click Next 4 Select Use the following port and choose the port that the first printer is on In this illustration this will be ATLUSBOO1 5 In the printer list choose Zebra Technologies as the manufacturer then choose for this illustration Zebra P6401 Click Next 6 On the next screen choose Keep Existing Driver then click Next 7 Choose something meaningful for the printer name Pool for example Decide whether or not this is to be the default printer then click Next 8 Decide whether or not the pool is to be shared then click Next Shared means that other networked computers will be able to send jobs to the pool 9 Choose no test page then click Next 10 Click Finish 980541 001 Rev A In Printers and Faxes there should now be a printer called Pool or whatever you named it 11 Right click on Pool then click Properties 12 Click the Ports tab 13 Check the Enable Printer Pooling box 14 In the list of ports select the other ports that have printers connected to them remember that only one port was selected on the initial install For this illustration check the ATLUSBOO2 and ATLUSB003 ports then click OK The setup now is three printers Zebra P6401 1 Zebra P6401 2 and Zebra P6401 3 and one pool whi
75. er D To set up a network printer that is not attached to a print server J use the Local printer option 6 Local printer is the default selection Click Next The P640i is always a Local Printer even if it is connected by Ethernet to a network of several computers In such an installation the P640i printer driver would be separately installed on each of the connected computers so the P640i would not be a network printer as defined by Microsoft Important Compatibility Mode should be enabled only 1f the P6401 printer is connected to the computer s parallel port through a third party dongle a hardware security device 980541 001 Rev A 7 On the following screen click on the drop down arrow to view the options Select typically ATLUSBO01 for USB or PHID1 for Parallel then click Next Add Printer Wizard Completing the Add Printer Wizard You have successfully completed the Add Printer Wizard You specified the following printer settings Name Zebra P640i Share name lt Not Shared gt Pott ATLUSBOO1 Model Zebra P640 Default No Test page Nd To close this wizard click Finish 8 The next screen is a list of all printer drivers that came with the Windows operating system The P6401 is not one of them so click Have Disk even if you will be working with a downloaded driver instead of a disk This tells the system it has to look elsewhere for the driver Add Printer Wizard
76. er Temp Bottom Heater Temp Laminate Top Laminate Sensor Logic States Bottom Laminate Sensor Hopper Door Lam Present Threshold Main Door Lam Absent Threshold Truck Near Hopper Truck Home Printhead Lift Flip Station Card Lam Enter Card Lam Exit 0 Miscellaneous Card Presence Sensor 249 Printhead Yoltage 23 760 V AC Frequency 60 Hz 0 unblocked not pressed open iat ue 1 blocked pressed closed Close 46 P640i Card Printer User Guide Ribbon Encoder Count The pulse count from the motion sensor following page from start to finish of the most recent YMCK panel set paid out from the ribbon supply roll Printhead Voltage Should be about 24V Printhead Temperature Temperature ceiling 70 C above that temperature printing is stopped until the head cools Printhead Lift logic states 0 head raised head down see photos on following page Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Printer Adjustment Horizontal X Offset Pixels Moves the image along the length of the card Used to center the image on the card Vertical Y Offset Pixels Moves the image up and down Used to center the image on the card Print Station Adjustment Ofhpety oe lar i Horoma pI Oiza jpe Cancel Vertical 1 Offset pasts 2 5 Mep lack Para DO Dieja Dalai Aidai Hkk Fire Sid e PS Pista Fiction j
77. gure Ethernet Port x Printer Info Model Hame MAC Address Cancel Serial Number Configure Printer Browse Printer IP Address T 0 0 Timeouts 5000 Read Timeout ms 5000 Write Timeout ms 5 Note the serial number of the P6401 printer you are installing then look for that number on the Browse screen which may list more than one printer Click that number to highlight it then click OK P640i Card Printer User Guide 79 Browse Printers x IP Address MAC Address Model Number orettduunh g DK 11 11 11 111 O0 cf 52 72 05 05 Unknown 9610063 No En Cancel Hescan 6 When the Configure Ethernet Port screen reappears click Configure Printer Configure Ethernet Port x Printer Infa Model Name MAC Address 00 ct54 72 05 05 j Serial Number 9610063 Printer IF Address 5000 Read Timeout ms 5000 Write Timeout ma 7 Leave DHCP set to OFF Type in the IP address Netmask and Gateway codes provided by your network administrator then click OK Configure Printer MAC Address O0 cf 52 7205 05 Cannot be changed For manual configuration static IF turn off DHCP and enter desired values below Manual Configuration IP Address 1 11 fie 192 168 1 54 Netmask 255 255 255 Le 192 168 1 54 Gateway 0 0 O Le 192 768 17 5 4 Apply Changes To Printserver Cancel 80 P640i Card Pri
78. h the card print job was assigned in the Windows print spooler User Name Logs the username of the person submitting the card print job P630i P640i User Guide 61 Technical Note 8 Using the Windows Printer Driver The P6401 printer driver includes setup and diagnostic tools in two distinct groups These are Printing Preferences and Properties Generally speaking Properties screens are intended for use only by the trained technician This is because they can cause unexpected results if modified without the necessary experience The same applies to two of the Printing Preferences screens Magnetic Encoding and ID Log Some of the Preferences screens the operator may be asked to refer to and or modify Operator screens Printing Preferences Card Setup Printing Preferences Image Adjustment Printing Preferences YMC Color Printing Printing Preferences K Black Panel Technician only screens Printer Properties All screens Printing Preferences Magnetic Encoding Printing Preferences D Log To access the driver screens follow this sequence Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Printing Preferences or Properties Printing Preferences Printing Preferences Card Setup Image Size Sets the image area for both front and back of the card 1 inch 300 pixels Cards Specifies the type of card loaded in the hopper typically a PVC polyester PVC composite card for
79. he printer 82 does not function as expected refer to page 9 1 Uninstall then reinstall the printer driver using the Zebra Printer Setup screen You can NOT uninstall the driver by deleting its icon from the list of Printers and Faxes or by using the Add Remove Programs procedure in Windows If the second attempt at re configuration is unsuccessful please contact your reseller for technical support P640i Card Printer User Guide 980541 001 Rev A Technical Note 10 Printer Pooling Important n the P6401 many of the configuration variables are stored in the printer itself unlike the typical printer as defined by Microsoft All pooled P6401 printers must be set up similarly Set up the Printers individually For illustration we will establish a pool of three printers Install and setup the printers as outlined in Tech Note 9 The printers can have any names of your choosing here we will name them Zebra P6401 1 Zebra P6401 2 Zebra P6401 3 and we will assume they are attached to ports ATLUSBOO1 ATLUSBO02 ATLUSB003 respectively Before proceeding to pool the printers test them individually and be sure they are configured similarly Specifically check the following e Ribbon panel configuration ribbon type and what prints on which side of the card e Mag encoding configuration e Black extraction configuration if applicable Create the pool 1 Go to Start gt Printers and Faxes gt Add a Print
80. he right of the card hopper High no card Low card present Printhead Voltage Should be about 24V AC Frequency 50 or 60 Hz Assumed AC Voltage 110V assumed for 60 Hz If frequency and voltage are not correct see Laminate Station Adjust TN6 5 Printhead Temperatue Temperature ceiling 70 C above that temperature printing is stopped until the head cools Controller Board Temperature Should be about 5 above ambient Heater Temperature Temperatures at the top and bottom laminate heater cores Logic States Summarizes all two state interlocks and photosensors a very useful diagnostic tool Printer Properties Table 1 General Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt General amp Zebra P640i Properties Color Management Security Device Settings General Sharing Ports Advanced CA Zebra P640i Location Comment Model Zebra P640 Features Color Yes Paper available Double sided Yes CR 80 Standard CR 80 Oversize Staple No CR 80 Oversize Speed Unknown Maximum resolution 300 dpi Printing Preferences Print Test Page Printing Preferences brings up the preferences screen see Tech Note 8 Windows Printer Driver Prislidhest Rage prints the standard Windows test page cropped Printer Properties Table 1 Color Management Start gt Printers or Printers and
81. ial Port O FILE Print to File ATL Zebra USB Printer C USB Virtual printer port fo Zebra P640 e Add Port Delete Port Configure Port Enable bidirectional support C Enable printer pooling Specifies the computer port to which the P6401 is connected This will have been established at the initial installation of the printer and will not normally require attention An exception to this is if you wish to use printer pooling the ability to distribute print jobs to multiple printers To enable printer pooling check the Enable Printer Pooling box then check multiple ports Each port should have a single Zebra printer installed on it and all printers should be configured identically for example all with YMC front K back Now when you print to the main printer that is whichever printer you right clicked in Printers and Faxes to get to this screen this printer will get print jobs until it has buffered as many jobs as it can take Remaining jobs will then spill over to other printers until all printers in the pool are busy For more information see Tech Note TN10 P640i Card Printer User Guide 35 Printer Properties Table 1 Advanced Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Advanced amp Zebra P640i Properties Color Management Security Device Settings General Sharing Ports Advanced O Available from Priority
82. ich is more or less binary it is either under spring pressure firmly in contact with the card or not in contact at all 48 P640i Card Printer User Guide Keep in mind the following e The amount of ribbon drag exerted by the supply arbor is con trolled by a friction clutch This is set for a torque of approxi mately 5 oz ins 36 mN m and should not be adjusted unless you have a torque gauge e Ribbon drag exerted by the takeup arbor is controlled by varying the current applied to the motor Ribbon wrinkling can be caused by one or more of the following factors but always try adjusting ribbon torque first e Takeup torque too high e Supply torque drag too high Too much preheat ribbon sticking e Dense patches with sharp transitions text graphic elements on a dark image e Card thickness not uniform Printhead too hot because resistance value in flash memory higher than actual head resistance e Printhead angle adjust screwed down too far e Printhead not pivoting freely e Printhead rattling in frame e Printhead not right angled relative to card motion yaw adjust Wrinkle control is essentially a balancing act of several variables especially the balance between takeup and supply torques Example of ribbon wrinkling Note the random curved colored lines The cure in this case was reduction of takeup torque Adjustment procedure If the printhead doesn t press firmly on the card du
83. inly due to ribbon fold over but could be a head non pivoting problem or an image size problem P640i Card Printer User Guide 23 Troubleshooting Troubleshooting quality problems Consistent image defects card after card e Debris on platen or platen surface not flat Clean platen or replace if necessary Reference Technical Note 2 e This gross image artifact was caused by a tiny scrap of card less than 0 01 0 25 mm thick Random colored patterns on image e Ribbon wrinkling Reduce takeup torque Check printhead pressure Reference Technical Note 4 e Too much heat being applied to YMC panels Try reducing gain offset and preheat separately for each color in the driver Device Settings gt Color Calibration Reference Technical Note 4 and Technical Note 5 Typically the set of values should be the same for each color e Printhead running too hot Can happen after head replacement if head resistance incorrectly entered through printer driver Reference Technical Note 4 Printer Adjustment e Probably resulting from excessive takeup torque Scratches dings on long edges of card Look for a narrow band of abrasion up to about 0 1 2 5 mm in from either or both of the long edges e Card hopper base set too low Reference Technical Note 2 Laminate not centered on card e Vertical offset adjust mechanical adjustment Reference Technical Note 6 e Horizontal offset Properties gt Device Settings gt
84. k Ribbon Encoder Count The number of encoder pulses counted in one complete cycle of the color ribbon currently installed in the printer Laminate Sensors Reflective sensors that detect the presence of laminate on the transfer rollers below threshold laminate present above threshold laminate absent Card Presence Sensor The reflective sensor to the right of the card hopper High no card Low card present Printhead Voltage Should be about 24V AC Frequency 50 or 60 Hz Sensor Data Assumed AC Voltage 110V assumed for 60 Hz If frequency and voltage are not correct see Laminate Station Adjust TN6 5 Printhead Temperature Temperature ceiling 70 C above that temperature printing is stopped until the head cools Controller Board Temperature Should be about 5 above ambient Heater Temperatures Temperatures at the top and bottom laminate heater cores Logic States Summarizes all two state interlocks and photosensors a very useful diagnostic tool 980541 001 Rev A Back to Advanced Utilites Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Control gt Advanced Utilities Advanced Utilities Flip Pause Flip Test 2 Eject Card Flip Test 3 Password Protection Run Test C Flip No Flip Use Password Move Carriage ID Code Move Home Position X Calibration Mag Position Adjust Mag Amplitude Adjust Show S
85. k OK to accept Add Parallel Port x Choose Port To Add Zebra EnhancedLlPT1 Cancel Important Zebra Enhanced LPT is called PHID1 in the Add Printer Wizard P640i Card Printer User Guide 75 Configure Parallel Port x m Options gt 00 Read Timeout ma E00 Wite Timeout ms Compatibility Mode Using Dongle Cancel Important Compatibility Mode should be enabled only if the P6401 printer is connected to the computer s parallel port through a third party dongle a hardware security device S Note PHID1 is the alias for Zebra Enhanced LPT 1 E Printer Installation You have just installed port PHID1 Be sure to select this port From the list of ports the Add Printer Wizard will present Make a note of the port designation If you OK the above screen the Add Printer Wizard will complete the installation semi automatically USB Port If you selected USB Port the Browse Printers screen displays the USB connected printers Highlight the printer serial number you are working on even if there is only one listed then click OK Configure USB Port Printer Info Model P40 0212077 Options 5000 Read Timeout ms E000 Write Timeout ms Cancel E Printer Installation i You have just installed port PHID1 Be sure to select this port From the list of ports the Add Printer Wizard will present 76 P640i Card Printe
86. kew rotation 2 Horizontal offset left right 3 Vertical offset up down Horizontal offset is a software adjustment see Section 5 Skew and vertical offset are corrected by the following mechanical adjustments The cassette is held in place by two ears on the cassette latch Using a piece of 1 mil laminate as a feeler gauge set the front ear close to but not touching the cassette A hex head screw arrowed sets front back position of the latch Adjust the latch position using a 7 64 hex wrench 980541 001 Rev A Skew and vertical offset are adjusted by screws In the cassette pocket 7 64 hex wrench for skew flat blade screwdriver for vertical offset see diagram on next page Caution Before adjusting for skew or vertical offset remember that there is significant interaction between the latch and the adjusting screws in the pocket see diagram on next page AN Important Always adjust the latch after adjusting either of the screws in the pocket ome 1 E OR G aminate cutter gt gt et Uppa cassette ranster guide G P640i dual side laminator Transfer toggle Must be set to RUN horizontal for normal operation Rotate the toggle to open the rollers for jam Transfer roller P640i Card Printer User Guide 55 Laminate position adjustments Skew is caused by misalignment of the laminate cassette relative to the left right axis of the p
87. laminate patch on the transfer roller Never re use 3 Re install the Transfer Guide with its top edge above the laminate cutter guide It s easier if you pull back the retaining spring while re inserting the guide then release the spring as you push the guide into position it will click into place with its far leg against the back plate of the laminator Press the LAMINATE button to load the transfer roller s ae Laminate cutter guide 980541 001 Rev A P640i Card Printer User Guide 19 20 Media Handling Laminating Station Cut line in center of in dex hole Caution Improper replacement of the transfer guide will cause laminate skewing and misfeeding Be sure the transfer toggleis set to RUN Take care not to damage the transfer roller ribs when replacing the transfer guide Laminating smart cards The laminating patch on the top surface of a smart card has a rectangular aperture to expose the card s electrical contacts In all other respects the laminating process for smart cards is the same as for ordinary cards The special laminate for the top cassette is punched with a repeated pattern Index hole The smaller hole is an index marker that tells the printer where to cut the laminate exactly splitting the index hole the printer driver allows adjustment of the cut location Loading procedure for smart card laminate is exactly the same as for standard laminate P640i Card Printer Use
88. llel rails Card transport knob Allows you to move the truck to left or right by hand When the printer cover is lifted there is no power applied to the transport stepper motor Removing the platen Using the card transport knob move the truck back to Take care of the platen its home position stopping when the right hand edge of the platen is even with the right hand inner sufrace of the hopper Push the platen to the left against its spring then pry the platen out using a CR 80 card 980541 001 Rev A P640i Card Printer User Guide 37 Truck home sensor Determines the truck s end stop position Activated by a vertical flag on the left edge of the truck photo above Card presence sensor Located behind the mag encoder Do not lose the spring It holds the platen tight against the right hand end of the truck and is essential for good print registration Truck interlock arrowed If there are no cards present in the hopper and a hot load is attempted while the truck is elsewhere the cavity under the hopper is exposed and potentially i F as TER Mah i ails ae Te Pa mi el ry dangerous Active when the hopper cover is open the truck interlock prevents the truck from driving to its home position 38 P640i Card Printer User Guide 980541 001 Rev A Cleaning cassette TOP As the drive motor begins to turn the drag caused by stickiness of the cleaning tape on the supply roll creates a clockwise turning
89. ly 1 equivalent to 0 03 6 Using a 7 64 hex wrench turn the skew adjust screw in 1 4 turn increments as directed in the diagram below 7 After each movement of the skew adjust screw do the following three actions a Adjust the cassette latch screw in the same direction by the same amount b If you have not already done so remove and discard the laminate patch on the upper transfer roller close the printer cover then press the LAMINATE button to run out a fresh patch from the upper cassette c Print atest card and inspect for skew 8 Re install the cassette Lower cassette skew adjustment procedure Once the front surface skew is consistently acceptable inspect the back surface patches of the last few cards to pass through the laminator Note the direction of skew on the back surface Don t worry about vertical offset at this stage unless the laminate overhangs grossly in which case proceed to the Vertical offset adjustment procedure below When flipping the cards for inspection keep the mag stripe if present toward you Flip the cards left to right not front to back Correct for skew in the lower laminator using the same procedure as the upper cassette but note that the reel in direction will be clockwise for the lower cassette as it sits in the printer 980541 001 Rev A P640i Card Printer User Guide After each movement of the lower cassette skew adjust screw perform exac
90. me ID Code Check the ID Code if the printer fails to function and everything else looks fine Reference Technical Note 8 Password protection blocks access to some of the lower level printer adjustment screens Not to be confused with ID Code Reference Technical Note 8 Interlock cheating is not something the operator should do but as a technician you will need to run the P640i with the main cover open Cut a narrow strip of plastic from a used CR 80 card fold it then push it into the interlock slot in the center wall When the ALARM light goes out the interlock switch is closed 980541 001 Rev A P640i Card Printer User Guide 31 Technical Note 1 General Information Model P640i with card receiver The cover at left gives access only to the card hopper which may be hot loaded while the printer is powered up and operating unlike the main cover right opening the card hopper cover does not disable the printer Dimensions in inches and italicized millimeters lt sss SS P640 Specifications Card size ISO CR 80 2 125 x 3 385 30 mil thick Card hopper 150 cards Throughput 120 cards hour YMC on front K on back Print system Single printhead with flip station for front and back printing Dye sublimination for YMC colors and thermal mass transfer for K and Uv panels K opaque black resin Uv clear ultraviolet visible resin Printhead resolution 300 dpi Image size typical 952 pixels 3 17
91. me to the Add Printer Wizard This wizard helps you install a printer or make printer connections e If you have a Plug and Play printer that connects 1 through a USB port or any other hot pluggable port such as IEEE 1394 infrared and so on you do not need to use this wizard Click Cancel to close the wizard and then plug the printer s cable into your computer or point the printer toward your computer s infrared port and turn the printer on Windows will automatically install the printer for you To continue click Next Cancel From this point on the only difference relative to the Zebra Printer Setup is that in Add a Printer you now have to select a port In the Printer Setup procedure port configuration is the first thing you do Add Printer Wizard Select a Printer Port Computers communicate with printers through ports Select the port you want your printer to use If the oe ed you can create a new port gy al printer Use the following port Note Most comput KO RG Teen RON Q Qe Sn Wr ps Sa ree Create a new port Select Parallel port LPT1 or USB port USBOO1 You do not have to use these default numbers but note that the Parallel port number relates to a specific physical port USB does not Note that you are not offered here the Zebra PHID1 parallel or ATLUSBOO1 ports as you were previously These are custom port designations that will be made automatically as you proceed
92. mer PlODCIICS E 6 62 boned Geen eh bose oon t he EE Geers sees 64 OPUS 442456 Saree dab eee ested ane an bes oe hea bee bore eae ee os 70 Card SCUD e errean ee ee eee aA Eta eR RSE OEE OR ea ON Re EERE ES ra eR 72 Technical Note 9 Installing the Windows Printer Driver 0000000 73 FIPS UNOS WSC 2a oe oo Sop ow bored eeees Oe oe on ee ee oh eee ee ee bee 73 Driver OD ee we te dew st he ms oe hk es te are Be pee Setar ae A ee a ee ieee E eee ve 73 DOWO ces ctccedeou vend aase Gh uees cep eae ER eeu b oe cence 73 Uninstalling the printer driver 2 0 0 cee 73 Windows file MISSING 00 cc eee ee es 73 Installing the printer driver 0 0 ee eee ees 74 New Hardware Found Wizard 0 00 cece eee 74 Install using Zebra s Printer Setup Screen 2 0 ee ee 75 Install using Add a Printer 0 0 ee ee ee ees 78 Firewall issues 24 4200i54 4e0bhnen ge bee eeee hed Ss ear oksane ons oon aaa Rar 79 Configuring the Ethernet option 0 0c ee eee 79 Technical Note 10 Printer Pooling 0 00 cece ees 83 Set up the Printers individually 0 0c cc ee eee 83 P640i Card Printer User Guide 980541 001 Rev A 10 15 2004 Introduction Main cover Interlock actua 7 7 Card hopper cover Transfer toggle Rotate clockwise to separate trans Laminating station ID Key option N N N Cleaning Print Flip Card Push Indicator
93. n the flip arms or it may drag the card an inch or two toward the print Station then jam Flip Sation Adjustment 0 gt Fip Station Man Height Ardent oa e lt HEIGHT F Fa MERTON i HEIGHT ADAST A EEE WT POSTEN ANST e feo position F abit e in al l ea mai a ut J reigns Haai Audie rel Fiert Pooition idut B Card Position Adeni Pres Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Control gt Advanced Utilites gt Move Truck to Flip Station In 1 the card should drive smoothly to rest almost touching the right hand edge of the flip station base molding It must not rebound off the edge To move the card further to the right increase make less negative the Card Adjust parameter and vice versa Now click Oe Flip Test 3 sh E _ with Flip enabled The card should land as 2 with a gap of between 0 04 and 0 1 1 to 2 5 mm The exact gap isn t critical but it has to be visibly there Rest Position Adjust Adjusts how far down the carrier drives This parameter is the number of motor steps more or less relative to the Edge A event at the photo sensor diagram Card Flip arm PRE FLIP Yo Flip station base molding Post FLip 53 on preceding page If the truck fails to pull the card out of the flip station after the flippi
94. n the printer driver go to Printing Preferences gt Image Adjustment then set both Brightness and Contrast to 50 default condition 1 Run IDPrint Lite Tech Note 8 then select Graytone bmp as Image 1 2 Print two or three cards with the graytone image 3 If you are satisfied with the overall appearance and uniformity of the image you might wish to leave well alone If you feel some improvement could be achieved proceed to Step 4 4 Referring to the photo on the preceding page mark the head angle adjust button head with a fiber tip pen to serve as a reference Loosen screw 3 just enough to allow sliding movement of the printhead bracket 5 Unlock the angle adjust button head screw turn it a quarter turn counterclockwise then re lock it This will have the effect of rotating the head counterclockwise a fraction of a degree when you snug the button head against the printhead frame Tighten screw 3 6 Print another graytone card for comparison If there is a noticeable improvement try another quarter turn adjustment then print again 7 If the print quality is seen to deteriorate rather than improve return to the as shipped setting of the head angle screw then try rotating it clockwise in quarter turn increments P640i Card Printer User Guide 45 8 When you are satisfied with the graytone image quality print one or two cards with Wedge_1 bmp to test for ribbon wrinkling This image is the densest possible pr
95. n turn drives the flip stop to the right Now when the next flip is called for the cam strikes the left The flip station performs two independent functions projection of the flip stop flipping the card in the 1 It lifts the card in process clear of the carriage flips opposite direction Actuator B moving in parallel it upside down then returns it to the carriage so that with A is then set to return the flip stop to the left its other side may be printed 2 It lifts the fully when the carrier heads downward on completion of printed card clear of the carriage raising it to the point the flip action where it lines up with the laminator s infeed path An ejector arm then propels the card into the laminator infeed rollers Note that the flip action alternates in consecutive cycles between clockwise and counterclockwise How the flip station works As the motor driven carrier rises taking with it the flip arms and card the cam is forced to rotate by the projection on the right side of the flip stop The actuators do nothing at this time Actuator B The cam Actuator A is driven over Flip stop center by the flip oO stop at which point the flip spring takes over fully inverting the card ActuatorA Actuator B Shown here at its upper limit of travel the carrier is about to descend One end of the flip spring locates in a cavity in the rear flipper arm the other in a hole in the rear
96. nate Cassettes 0 0 ee tee eee een ees 15 Main components of the laminating system 2 00 00 cece eee 16 Removing the cassettes 0 0 cc eee e eae 16 Loading the cassetteS 0 eee e eens 17 Installing the cassettes 0 0 0 eee eens 18 Clearing the Laminate Channels 0 0 00 ee eens 19 Laminating smart CardS 0 0 cc eee eee ees 20 980541 001 Rev A P640i Card Printer User Guide vil Table of Contents SSALGUDIESHOOING pisces eeee teense de eee edna sbheh cae eden eet 21 Image AGMUISIMeR ec acedaa scence nna sree oe a crew e aca wanes 21 Troubleshooting quality problems 002 cece ees 22 Poor color registration ss sesse ens ee eee eens 22 Examples of color mis registration 0 anaa anaana 22 POO Color renden eseon ericae Gases 4 bea eeroseds6 55 seers eneens as 22 Faint non uniform image 2 ee eee eens 22 Gaps in image at edges and corners 0 0 cc a eee 22 Continuous white or black stripes on card s longer dimension 23 Random occurences of white unprinted spots 000 0c eee eee 23 Image not centered ON Card 1 eee ees 23 Image missing at top or bottom of card 1 eee 23 Consistent image defects card after card 0 0 ccc eee 24 Random colored patterns on image n naana eee 24 Scratches dings on long edges of Card 1 nananana 24 Laminate not centered ON Card 2 eee eee
97. nections refer to Technical Note 9 in Section 4 of this Guide for instructions on driver installation P640i Card Printer User Guide WARRANTY INFORMATION Printers All Zebra Card Printers are warranted against defects in material or workmanship for twelve 12 months from the purchase date Proof of purchase or shipment date is required to validate the warranty period The warranty becomes void if the equipment is modified improperly installed or used damaged by accident or neglect or if any parts are improperly installed or replaced by the user Note Products must be packaged in the original or comparable packaging and shipping container In the event equipment is not so packaged or if shipping damage is evident it will not be accepted for service under warranty Surface transportation charges for return to customers in the continental Unit ed States is paid by Zebra Otherwise Zebra pays CPT carriage paid to nearest airport customer pays customs duties taxes and freight from airport to destination If Zebra determines that the prod uct returned for warranty service or replacement is not defective as herein defined the customer will pay all handling and transportation costs Printheads Since printhead wear is part of normal operation the original printhead is covered by a twelve 12 month warranty Warranty period begins on purchase date To qualify for this warranty the printhead must be returned to the factory or to
98. ng its tip flush with the bottom surface of the bracket Check how the head sits in the bracket Look for symmetry with the upper rim of the head surrounding the potted wires almost even with the bracket just a hair below Install the encoder assembly taking care that the shoulder screws do not clamp either end of the bracket or the washer at the right hand end Check that the assembly is free to move up and down at both ends Adjust the mag encoder using Mag Amplitude Adjust and Mag Position Adjust utilities in the Windows printer driver see below Magnetic Encoding Functions in the Driver Mag Position and Amplitude For this procedure you will need to cut a feeler gauge about 14 wide 6 mm from a standard CR 80 card which should be 0 03 0 75 mm thick Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Control Advanced Utilities Flip Pause Flip Test 2 Eject Card Flip Test 3 Password Protection Run Test C Flip No Flip Use Password Move Carriage ID Code Movel Home Position Calibration Mag Position Adjust Mag Amplitude Adjust Show Sensor Data Flip Station Calibration Update Backup Config Upgrade Firmware Send Features File Set ID Code Disable Printer s Print Button Disable Printer s Other Buttons Status Disabled Status Polling Frequency Normal Reduced C None Number of Times t
99. ng action chances are 1 The card position is wrong see above or 2 The carrier is not coming down all the way repeat the Flip Station Calibration routine in Advance Utilities preceding page Another test for this power down the printer then power up listening for the flip station reset action Open the main cover then push gently down on the carrier at the back close to the guide shaft If there is any downward travel increase the parameter make it less negative but don t overdo it because this will increase the reset noise and potentially damage the carrier drive Insertion Height Adjust Insertion height is the intermediate non flipping elevation to which the card is driven for insertion into the laminator The Insertion Height Adjust parameter is the number of motor steps more or less relative to the Edge B event at the photo sensor diagram on preceding page Adjust the parameter if the ejector arm misses the card Raise the insertion height by increasing the parameter making it less negative and vice versa Flip Station Max Height Adjust The card carrier needs to move high enough to actuate the flipping mechanism but should not over travel excessively The Max Height Adjust parameter is the number of motor steps more more or less relative to the Edge C event at the photo sensor diagram on preceding page Increase this parameter make it less negative only if there is an occasional failur
100. ns it to the flip station flips it returns it to the platen then backs it out to the card sensor by the mag head The sequence repeats until the PRINT button is pressed and released Flip Test 3 See Flip Station Adjustment Procedure preceding page Exercises the flip station by raising and lowering the flip station carrier one cycle per click The radio buttons select Flip or No Flip cycles Eject Card Picks up a card runs it to the flip station raises it to the laminator infeed then ejects it through the laminator Like Flip Test 1 but done once only and without flipping Flip Pause Picks up a card runs it to the flip Station raises it to the laminator infeed then holds this position termed the Insertion Height in the flip station dialog until the user presses the PRINT button at which point the flip carrier descends and the truck returns the card to the hopper 980541 001 Rev A Flip station calibration This routine determines the number of motor steps it takes for the carrier to descend from the rest position datum Edge A in the diagram to the real rest position that being the carrier s physical end stop This stored number is used to drive the carrier down to the rest position before each and every flip station action Calibraton is a one time setup routine but is also a useful starting point when diagnosing flip station problems Power OFF Lift the cover then push the carrier down
101. nt and Back Disable Laminator Sleep Mode Orientation Front Back C Portrait pS ky Landscape Li Landscape Rotate Image 180 l Rotate Image 180 Back Orientation Same as Front Uv File ed Printing Preferences YMC Color Printing The P6401 accepts 24 bit color images meaning that each of the colors Y M and C is represented by 8 bits per pixel In High Quality the default setting all 24 bits are processed In Low Quality the printer driver transmits a smaller amount of color information the effect being a slight degradation of the printed image The advantage of low quality is increased transmission speed which can be helpful if the connection is through a conventional parallel port With a USB connection there will be no noticeable difference Printing Preferences Image Adjustment amp Zebra P640i Printing Preferences Image Adjustment Magnetic E ncoding ID Log About Card Setup YMC Color Printing K Black Panel err rrr td C Low Quality 16 bits per pixel 980541 001 Rev A The Brightness and Contrast controls here have same effect on the printed image as do similar controls on typical office color printers Click Reset to restore default conditions amp Zebra P640i Printing Preferences Card Setup YMC Color Printing K Black Panel Image Adjustment Magnetic Encoding ID Log About Brightness Contrast 50 Reset Brightness Co
102. nter User Guide 8 Check the Static IP address reported on the Configure Ethernet Port screen If correct click OK If not click Configure Printer again to repeat the process Note The IP address shown below is for illustration only Configure Ethernet Port x Printer Info Model Name MAC Address Serial Number ok Cancel Configure Printer Printer IF Address 152 166 0 245 Browse Timeouts 5000 Read Timeout rs 5o00 write Timeout ms 00 ct 54 72 05 05 5610063 9 This screen reminds you to select the correct port when it is asked for by the Printer Wizard W Printer Installation j You have just installed port ENETOO1 Be sure to select this port from the list of ports the Add Printer Wizard will present 10 From this point on the Add Printer Wizard will complete the installation semi automatically Check each screen to be sure the checked items are correct before moving on to the next Add Printer Wizard Welcome to the Add Printer Wizard This wizard helps you install a printer or make printer connections a If you have a Plug and Play printer that connects J through a USB port or any other hot pluggable port such as IEEE 1394 infrared and so on you do not need to use this wizard Click Cancel to close the wizard and then plug the printer s cable into your computer or point the printer toward your computer s infrared port and turn the printer
103. nter is reporting that the card is stuck in the laminator To Correct 1 Turn off the printer power and allow the laminator to cool to a safe handling temperature 2 Open the printer cover 3 Unscrew the heated roller assembly cartridge retention screw The cartridge can then be moved removed to provide access to the lamination path 4 Carefully remove card stuck in laminator 5 Replace heated roller assembly cartridge and tighten retention scew 6 Close the printer cover 7 Turn the printer on The card will be reprinted automatically This dialog will automatically disappear once the error is cleared or you may click Close to close it now MEDIA JAM The printer is reporting a media jam The problem might be a ribbon jam laminate out of position laminate not advancing properly or a card jammed in the laminator To correct 1 Open the cover and determine the cause of the jam and clear the problem For Ribbon Jams 2a Remove the jammed or broken ribbon and reinstall the ribbon into the printer Close the cover if ribbon does not automatically resynchronize press the Ribbon button to resynchronize the ribbon For Laminate Jams 2b Remove both cassettes and check reset the laminate position to the end of the cassette Make sure to clear laminate from the flex guide Replace cassettes in printer and close the cover For Card Jams 2c Remove jammed card from the laminator Close the cover If
104. ntrast to Defaults STATE DRIVER S LICEMSE STATE DRIVERS LICEMSE STATE DRIVER S LICENSE SLATE DRIVERS LICENSE 980541 001 Rev A Printing Preferences K Black Panel When the Card Setup screen page TN8 1 is set for YMC Color and K Black on the same side of a card a process called Black Extraction is enabled see inset panel right The K Black Panel screen below displays available options for Black Extraction Before you make any modifications to the K Black Panel display take a few minutes to under stand what Black Extraction does Although quite subtle in concept it can have a dramatic effect on image quality and machine readability What is black extraction Black extraction has to do with the way the printer driver handles the K black panel It applies only to surfaces of the card on which both YMC color and K black are to be printed amp Zebra P640i Printing Preferences Image Adjustment Card Setup Magnetic Encoding _ID Lo About YMC Color Printing K Black Panel To enable these selections the printer must be configured in Card Setup to print Front K Element Selection Lines and Pixels Area Fills Monochrome Bitmaps l Color Bitmaps Black Portions Only Print Dye Black Under K Black C Do Not Print Dye Black Under K Black Use K Black for machine readable data The back surface is typically a K only image For th
105. o Retry 3 gt Advanced Utilities gt Calibration 1 If you have not already done so see Replacing the read write head above back off the adjust ment screw counterclockwise until the head bracket is fully down P640i Card Printer User Guide 41 42 Adjustomg screw 3 82 hex wrench Shim The shim is a narrow strip of CR 80 card It must be removed before running the printer Using the manual card transport knob drive a card under the head and leave it there With the card under the head make sure it s there turn the adjustment screw to elevate the left end of the head bracket to the point where your CR 80 feeler gauge just slides under the bracket Test the mechanical setup by running the card back to the hopper then slowly out again There should be a barely perceptible upward movement of the bracket as it rides up over the tapered pick edge of the truck see diagram on preceding page Load a few cards with magnetic stripe Click Mag Position Adjust The printer will then a Pick acard from the hopper b Mag encode it c Back up then run it under the read write head again to determine the position at which the mag encoding begins d Eject the card through the laminator The starting position is stored in firmware and is used for all subsequent mag operations Mag Data Monitor Track 1 Amplitude 138 Track 2 Amplitude 139 Track 3 Amplitude 110 Close 5 Click Mag Amplitude A
106. ocess black meaning that on all three passes Y M and C one end of the printhead is fully on while the other end is off a sure way to induce wrinkling if there is the slightest tendency Wrinkling may be a head angle issue more clockwise than it should be but it may equally result from too high a ribbon torque page TN4 x Check the torque before readjusting the head 9 When you are satisfied that ribbon wrinkling is under control print one or two cards with Wedge_2 bmp this being the same triangle flipped so that its black area starts full width 10 As a final test run Portraits bmp to test for skin tone realism etc Print Station Parameters in the Driver Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Status gt Advanced Information See also Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Control gt Advanced Utilities gt Show Sensor Data Ribbon Panel Detect The current reading of the color ribbon sensor High black Low not black Panel Threshold The current value of the detection threshold for the color ribbon Above this value is termed black below this value is termed not black Sensor Data Ribbon Temperature Ribbon Panel Detect 220 Panel Threshold 130 Ribbon Encoder Count 504 Printhead T emp Controller Board Temp Top Heat
107. ock Caution Make sure AN power is disconnected before working on the print head Also note that the head will likely be destroyed if power is reapplied while you are in porcess of reconnecting the cable or if the plug is not seated properly Replacing the print head 1 Open the main cover then power OFF 2 Remove the color ribbon 3 Unplug the cable from the print head 4 Remove only the fasteners 1 2 and 3 in the photo on the preceding page then lift the print head clear 5 Make a note of the resistance entered on the replacement printhead s label should be between 2400 and 3600 U 6 Connect the cable to the replacement printhead making sure it is seated properly see STOP above Install the print head securing it with shoulder bolts 1 and 2 fully tightened then loosely with socket head cap screw 3 with plain washer through the slot in the bracket 980541 001 Rev A 7 Pivot the head assembly forward to bring the angle adjust button head in contact with the print head frame then tighten screw 3 8 Make sure the cable is not inhibiting free rotation of the print head about its pivot 9 Power ON then check print quality as follows 10 Enter the printhead resistance in the driver Properties Print Station Adjustment screen page TN4 4 Print quality tests and adjustments The objective in the following is to find the best compromise between image quality and ribbon wrinkling I
108. oe Black Panal Compensation at Ribbon Teequt Adit 2 Cleverley Fused Overlay Fard Spoed jmmr 4 Pirie Printhead Flevistance Chea 2050 po Drel Paii Conpenibtoi itt T Porthaed Position Adit Black Panel Speed The printer was characterized in manufacture at a specific speed Changing this speed will force the printer to use estimated energy values and is not recommended 980541 001 Rev A K Black Panel Printing Black Panel Compensation Unlike YMC color printing which is required only to deliver realistic portraits and pleasing graphics the K panel serves a more quantifiable purpose namely machine readability In practically all instances of K panel usage there is a requirement both for bar codes and well defined text and sometimes for signatures which can be ispideryi in appearance unless compensated for Unfortunately these requirements are in opposite corners The P6401 provides three controls for K panel printing these are 1 Black panel compensation Adjustment screen this page TN4 x Ifa line of black dots is printed along the card motion axis the heating element pixel in question doesn t cool down completely between adjacent dots Without compensation the steadily increasing residual heat would cause the printed dot to increase noticeably in size bloom below left Properly compensated the dot size is reasonably constant below right BREE BERR
109. of printhead problems aana aaa aa ee ee eee 44 Cleaning the printhead 0 eee ees 44 Print head attachment hardware 0 0 0 ccc ee ee eee 45 Replacing the printhead 0 eee eens 45 Print quality tests and adjustments 0 0 00 ccc eee 45 Print Station Parameters in the Driver 2 0 0 0 ccc ee ees 46 K Black Panel Printing 0 e eens 47 Technical Note 5 Flip Station 00 02 ce es 50 How the flip station WOrkS 00 cee 50 Flip station adjustment procedure 0c eee 51 Flip Station Routines in the Driver 0 0 ee eee 52 Carrier Motion n a a oe ont ace sae tp at aeincew ah dere lnm gests ed Bona ce cea p ae NO AL He ee ROL A 53 980541 001 Rev A 10 15 2004 P640i Card Printer User Guide Table of Contents Techncial Note 6 Laminator 2 00 cee es 55 Laminate position adjustments 0 ccc ee eee eee 56 Laminator Parameters in the Driver 0 0 00 ccc eens 58 Correcting Laminator Problems 0 0 0 cc cece a 59 Technical Note 7 ID LOog iis ciescccad ct eeew ese ew eit bee dees see ad eee ees 61 Technical Note 8 Using the Windows Printer Driver 005 62 OPE OIOF SCIONS pic kh ae en be os tobe SR ee EE r Agnes ES Bebo OTe eae 58 ae eee aah Oa 62 Printing Preferences ccc cud2 accbawe oo bu betwee aes 64s hag Ewa ohe eS eS 62 What is black extraction 0 0 ee ee eens 63 Pri
110. on Windows will automatically install the printer for you To continue click Next 11 Select Local printer 980541 001 Rev A Add Printer Wizard Local or Network Printer The wizard needs to know which type of printer to set up Select the option that describes the printer you want to use C Automatically detect and install my Plug and Play printer A network printer or a printer attached to another computer i To set up 4 network printer that is not attached to a print server LD use the Local printer option The P6401 is always a local printer even if it is connected by Ethernet to a network of several computers In such an installation the P6401 printer driver would be separately installed on each of the connected computers so the P6401 would not be a network printer as defined by Microsoft 12 Click the drop down arrow to view the port options then select then select typically ENETOO1 Add Printer Wizard Select a Printer Port Computers communicate with printers through ports Select the port you want your printer to use If the port is not listed you can create a new port Use the following port EEA iv Note Most computers use the LPT1 port to communicate with a local printer The connector for this port should look something like this wre Create a new port 13 Select Zebra Technologies and P6401 then click Next Add Printer Wizard Install Printer Softw
111. ons in the printer s host computer ID Log records data encoded on the card s magnetic stripe together with date time and the printer s serial number The data set can be uploaded at any time to a central archive thus providing a means for security officers to validate the card by comparing it with tamper proof real data To access the D Log screen in the Windows printer driver follow this sequence Start gt Printers or Printers and Faxes gt _Right click Zebra P6401 gt Printing Preferences gt D Log amp Zebra P640i Printing Preferences Card Setup Image Adjustment YMC Color Printing K Black Panel Magnetic Encoding ID Lag About V Enable Logging Log File Definition Create New Log File Each Day File l Delete Existing Log Files Separator Character Log File Contents Time l Date Printer Serial Number Static Text Max 16 characters IP Address Magnetic Track 1 Data Magnetic Track 2 Data E Magnetic Track 3 Data Application will send data with L xxx TextOut F Spooler Job Number User Name NOTE EIN Readback must be enabled in order to log EIN data EIN Readback Enable can be found on the Magnetic Encoding tab Enable Logging When checked logging is active Create New Log File Each Day Check the File box then type in a directory path to a folder of your choosing If a non valid path is entered a default path will be created The file generated b
112. ontrol logic what s happening and where enabling it to continue with the process or if a malfunction occurs to light the appropriate indicator light and report a specific error condition on the host computer screen ID Key Theoptional ID Key is a hardware dongle that is tied to a specific P6401 printer It is intended to prevent unauthorized use of the printer Like a camera battery in appearance the ID Key has a non alterable memory containing a unique 64 bit serial number that is compared prior to each print job with a serial number stored in the printer s nonvolatile RAM If the serial numbers fail to match or if no ID Key is detected the printer is disabled If the ID Key is removed during a card printing session the printer will cease to operate after the current batch of cards 1s printed The ID Key is carried in a 2 x 34 plastic fob that plugs into a receptacle to the right of the card hopper Typically at the end of each work session the ID Key is removed from the printer and stored in a secure location such as the key safe Replacing a lost D Key The recovery procedure requires a special computer file obtainable only from Zebra product support This file is downloaded to the printer following which the replacement ID Key is inserted The printer is then power cycled off then on at which point the key s serial number is recorded in NVRAM 980541 001 Rev A Printer Parameters
113. ould perform the following tests before replacing components 1 Power OFF Remove all cards from the hopper then close the hopper cover Disable the main cover interlock so that the printer will function with the cover open Power ON 2 On the host computer follow this sequence Start gt Printers or Printers and Faxes gt Right click Zebra P640i gt Properties gt Device Settings gt Control gt Advanced Utilites 3 Click Move Truck to Flip Station 4 With the flip arms horizontal click Flip Test 3 No_ Flip a few times noting what happens as the carrier begins to elevate at the start of the flip cycle This is a test for clearance between flip arms and platen If the arms touch the platen even lightly there will be tendency for one or both of them to rotate a little as the carrier rises The arms must be parallel to the platen with a few thousandths of an inch clearance each side Using a flashlight check the gap by inserting a 0 004 0 01 mm feeler gauge between each arm and the platen A narrow strip of regular copier paper can be used instead but a long metal feeler gauge is better P640i Card Printer User Guide 51 If you detect that either of the arms catches at one end of the platen but is free at the other the carrier needs Azimuth adjustment see below Always correct for azimuth error before adjusting the gap between arms and platen If there is no azimuth error but insufficient clearance bet
114. pport for more information Password Protection Not the same as ID Code Password Protection blocks access to various low level printer adjustment screens including this one Check Use Password then enter a password of your choice P640i Card Printer User Guide 67 Set ID Code Sends an ID Code password of your choice to the printer synchronizing the driver printer ID Code This is a security lock out linking a specific printer to a specific computer In other words it prevents use of the printer with a PC not having the same ID Code Change ID Code Current ID Code Status Disabled To disable the ID Code Feature clear the password field Old Fassword Help Cancel Disable Printer s Print Button New Password Confirmation In regular on line use the PRINT button reprints the last image downloaded from the computer to the printer s buffer memory If Disable is checked the PRINT button has no effect except after power cycling when power is restored but only until the first print job is received from the computer the printer will print a checkerboard test card each time the PRINT button is pressed Disable Printer s Other Buttons If Disable is checked the RIBBON and LAMINATE buttons have no effect after the first downloaded job from the computer Status Polling Frequency Determines how often the PC polls the printer for status e Normal Default mode fo
115. r Guide 980541 001 Rev A Troubleshooting Image Adjustment Start gt Printers or Printers and Faxes gt Right click Zebra P640i gt Printing Preferences gt Image Adjustment Brightness and Contrast controls on the image Adjustment screen have same effect on the printed image as do similar controls on typical office color printers Click Reset to restore default conditions ontras Brightness 50 ontras l ontras Contrast 50 Brightness 25 Brightness 50 lt a Brightness 75 a Contrast 75 Contrast 75 p Contrast 100 Brightness 50 Brightness 50 Brightness 50 980541 001 Rev A P640i Card Printer User Guide 21 Troubleshooting Troubleshooting quality problems Troubleshooting quality problems Poor color registration e Minor mis registration of Y M and C color passes may be due to printhead angle adjust screw not in firm contact with printhead frame Reference Technical Note 4 e For gross mis registration of Y M and C suspect card not firmly against left hand pick edge of truck on one or more passes Spring at left end of platen may be missing or bound up Reference Technical Note 2 e Check printed card for damage on corners or edges Example the card may be scraping along the underside of the hopper base molding Reference Technical Note 2 e Printhead pressure too light Reference Technical Note 4 e Printhead may be running hot Will occur if head resistance incorrectly entered in driver software
116. r Parallel and USB Polls the printer for errors for as long as it is busy printing cards e Reduced Default mode for Ethernet Polls the printer for errors sends a print job polls twice more then disconnects This allows computers to connect to the printer and print a card while the previous card is printing desirable in a network environment e None No error polling Not a recommended option 68 P640i Card Printer User Guide Number of Times to Retry Determines how many retries the driver will execute in the event of a communications failure The default is 3 retries A higher number may be desirable if Communications Failure messages occur frequently Printer Adjustment Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Printer Adjustment Device Settings Printer Adjustment Print Station Adjust Laminate Station Adjust Flip Station Adjust OF Cancel Help Advanced Adjuzt Card Hopper Fick Position Adjust Fivela o Cleaning Station Clean Frequency Every Print Station Adjust see Tech Notes TN4 Print Station Laminate Station Adjust see Tech Notes TN6 Laminator Flip Station Adjust see Tech Notes TN5 Flip Station Pick Position Adjust Pixels see Tech Notes TN2 Card Transport Clean Frequency see Tech Notes TN2 Card Transport Advanced Adjust see Tech Notes TN3 Magnetic En
117. r User Guide Click OK to accept the timeout defaults on the Configure USB Port screen Make a note of the port designation If you OK the above screen the Add Printer Wizard will complete the installation semi automatically see Step 6 and following Important From this point on the screens for Parallel and USB are similar the only difference being the port description Only USB screens are shown Add Printer Wizard Welcome to the Add Printer Wizard This wizard helps you install a printer or make printer connections If you have a Plug and Play printer that connects 1 through a USB port or any other hot pluggable port such as IEEE 1394 infrared and so on you do not need to use this wizard Click Cancel to close the wizard and then plug the printer s cable into your computer or point the printer toward your computer s infrared port and turn the printer on Windows will automatically install the printer for you To continue click Next i Cancel 5 On the next screen select the default Local printer with the Auto Plug and Play box unchecked then click Next Add Printer Wizard Local or Network Printer The wizard needs to know which type of printer to set up Select the option that describes the printer you want to use Local printer attached to this computer C Automatically detect and install my Plug and Play printer A network printer or a printer attached to another comput
118. rd below generated by the driver this is not the test card printed Dina Eigi Pir Contin Repini Lact Cani Copier 1 Z ra Mafii Count Mecere Print Advanced Uien 66 P640i Card Printer User Guide Run Clean Cycle Decontaminates the card cleaning roller by activating the cleaning cassette One clean cycle per click Clear Error This clears error reporting on the screen but note that the underlying cause of the error may still be present Reprint Last Card This reprints the last card printed as many times as specified in the Copies box Zero Buffer Count Click Receive or Print as desired to set the related buffer to zero 1f no job is in process the buffer values will already be zero Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Control gt Advanced Utilities Advanced Utilities Flip Pause Flip Test 2 Eject Card Flip Test 3 Password Protection Run Test C Flip No Flip Use Password Move Carriage Move Home Position v Calibration Mag Position Adjust Mag Amplitude Adjust Show Sensor Data Flip Station Calibration Update Backup Config Upgrade Firmware Send Features File ID Code Status Disabled Set ID Code Disable Printer s Print Button Disable Printer s Other Buttons Status Polling Frequency Normal Reduced C None Number of Times to Retry 3 Flip Test 1 see Tech Notes TNS
119. ring the printing swipe there is nothing to stop uncontrolled advancement of the ribbon due to the takeup drive To correct this increase the adjust parameter to the point where the ribbon ceases to advance freely then add 40 more to the number 980541 001 Rev A DN Printhead spring Head raised Print head bracket clear of sensor arrowed The quadrant is driven by a pinion on the print head stepper motor shaft Head lowered Print head bracket activates sensor Motor continues to drive a few more steps see Printhead Position Adjust compressing the spring to deliver Color Calibration Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Color Calibration Color Calibration Yellow Gain Offset Preheat Magenta Gain Offset Preheat Cyan Gain Offset Preheat Black Panel Density Black Panel Preheat c in x fim x __ pk j mk fw x host _ i 100 _ x Contrast Adjust 980541 001 Rev A Cancel Help Reset to Defaults en o Be p g o E Color rendering in the P6401 can be described in terms of a curve which determines how much power is put into the printhead for a given shade The Y M and C color curves can be separately modified by the Gain and Offset parameters shown here Note Typically the set of values should be th
120. rint Test Page To confirm that the printer is installed properly you can print a test page Do you want to print a test page O Yes No P640i Card Printer User Guide 81 17 Click Next to bring up the Completing the Add Printer Wizard screen Add Printer Wizard Completing the Add Printer Wizard You have successfully completed the Add Printer Wizard You specified the following printer settings Name Zebra P640i Share name lt Not Shared gt Pott ENETOO1 Model Zebra P640i Default Test page To close this wizard click Finish 18 The next screen warns that installation of the driver software may destabilize your system The P6401 driver software has been exhaustively tested in many installations and has caused no problems of which Zebra is aware Click Continue Anyway to complete the printer driver installation Hardware Installation The software you are installing for this hardware Printers has not passed Windows Logo testing to verify its compatibility with Windows XP Tell me why this testing is important Continuing your installation of this software may impair or destabilize the correct operation of your system either immediately or in the future Microsoft strongly recommends that you stop this installation now and contact the hardware vendor for software that has passed Windows Logo testing Continue Anyway STOP Installation 19 The Ethernet port is now configured If t
121. rinter looking down on the printer from above The skew adjust screw causes the pocket to rotate relative to the left right axis The vertical offset adjust screw controls the depth of the cassette in the pocket Note that the front ear of the latch must be in close contact with the cassette without changing its position Cassette latch adjust Skew adjust J Pi fd l I fl f GARD HOFFER IL Gl j LEFT RIGHT AXIS OF PRINTER Cassette latch Front ear Cassette pocket ail Reset the cassette pocket If the pocket has been replaced or if the laminate is grossly misaligned Back off the vertical offset adjust screw skew adjust screw and cassette latch adjust screws Using three CR 80 cards total thickness 0 090 2 3 mm as a feeler gauge in the gap between the pocket and back plate adjust for skew and vertical offset until the gap is an even 0 090 across the width of the pocket With a cassette in the pocket adjust the latch screw so that the latch s front ear is snug to the cassette but doesn t shift it out of position see page 6 1 The pocket is now in its default position as assembled in production before adjustments in final test 56 P640i Card Printer User Guide Making sense of the skew adjustment Turning the skew adjust screw clockwise rotates the cassette itself clockwise looking down on the printer On the face of it that Laminate patch should worsen
122. rinters Atlantek Zebra P620 Zebra Technologies Zebra P640i Windows Update A This driver is not digitally signed Tell me why driver signing is important After selecting the P6401 go to Step 11 10 If you don t have the CD Browse to the location folder containing the unzipped downloaded driver files default location is c zebra driver If necessary double click the file named AtlPrint inf Install From Disk Insert the manufacturer s installation disk and then OK H make sure that the correct drive is selected below LK Copy manufacturer s files from D v Browse 11 On the following screen type in a name for the printer This can be anything you like such as Printer A Typically check No don t make this the default printer If asked you do NOT want to share the printer Add Printer Wizard Name Your Printer You must assign a name to this printer Type a name for this printer Because some programs do not support printer and server name combinations of more than 31 characters it is best to keep the name as short as possible Printer name Zebra P640i Do you want to use this printer as the default printer O Yes No 12 If you select Yes Print Test Page the printer will do just that when the installation is completed and the various media are loaded The test page is a clipping from the top left corner of the standard Microsoft Printer Driver report P640i
123. sers do not have to find the print driver when they connect to the shared printer Additional Drivers This is sharing according to the Microsoft Windows definition In a network environment it allows other computers to send jobs to the printer that s connected to your computer Table 1 Security Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Security Printer Properties amp Zebra P640i Properties Advanced Device Settings General Sharing Ports Color Management Security Group or user names fi CREATOR OWNER 8 Everyone 8 Power Users O5L PMCARON Power Users Permissions for Administrators Allow Deny Print Manage Printers Manage Documents Special Permissions For special permissions or for advanced settings click Advanced This is the standard Windows security screen showing user access to various printer control options Both Print and Manage printers must be checked for full functionality of the P6401 980541 001 Rev A Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Ports amp Zebra P640i Properties Color Management General Security Device Settings Sharing Ports Advanced de ZebraP640i Print to the following ports Documents will print to the first free checked port Port Description Printer CJ COM1 Serial Port O COM2 Serial Port O COM3 Serial Port O COM4 Ser
124. t One or two blown pixels in isolation may be acceptable to some Otherwise replace printhead Reference Technical Note 4 Black stripe means non functioning circuit s on printhead If so replace printhead Reference Technical Note 4 but first check that it is not the result of an image size change not followed by power cycling the printer These are independent problems not necessarily co located Random occurences of white unprinted spots Image not centered on card Possible card quality problem Run DPrint Lite with graytone bmp on cards from a different batch Check platen surface for specks of debris White spots like these may be caused by card surface imperfections Properties gt Device Settings gt Printer STATE DRIVER S LICENSE Adjustment gt Horizontal Vertical Offset Correct this by increasing horizontal X offset decreasing vertical Y offset Caroline T 12 Brown Street ST SS 987 00 1234 Wt 112lbs Ht 5 2 Image missing at top or bottom of card 980541 001 Rev A Ribbon folded over at edge Slacken ribbon by pulling more out of supply roll unfold edge then press RIBBON button to re sync Reference Technical Note 4 Bottom edge and or right hand edge of image missing could be card layout application sending wrong image size should be 952 x 578 pixels Select appropriate image size 1f available in Preferences or modify layout application Could be on either edge Almost certa
125. t Security See Tech Notes TN1 General Information amp Zebra P640i Properties General Advanced Sharing Parts Color Management Security Device Settings Group or user names g Administrators 0O5L PMCARON Administrators fi CREATOR OWNER gi Everyone gi Power Users 05LXPMCARON Power Users Permissions for Administrators Allow Deny Print Manage Printers Manage Documents Special Permissions For special permissions or for advanced settings click Advanced Printer Properties Ports Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Ports See Tech Notes TN1 General Information amp Zebra P640i Properties Color Management Security Device Settings General Sharing Ports Advanced Ps b Zebra P640i Print to the following port s Documents will print to the first free checked port Port Description Printer O COM1 Serial Port O COM2 Serial Port O COM3 Serial Port O COM4 Serial Port C FILE Print to File ATL Zebra USB Printer Zebra P640i OO USB Virtual printer port fo Enable bidirectional support C Enable printer pooling 70 P640i Card Printer User Guide Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Advanced See Tech Notes TN1 General Information amp Zebra P640i Properties Color Management Security Device S ettings General Sharing Ports Advanced
126. t click Zebra P6401 gt Properties gt Device Settings gt Control gt Advanced Utilities gt Show Sensor Data P640i Card Printer User Guide 65 Sensor Data Ribbon Ribbon Panel Detect 220 Panel Threshold 130 Ribbon Encoder Count 504 Temperature Printhead T emp Controller Board Temp Top Heater T emp Bottom Heater Temp Laminate Top Laminate Sensor 10 Logic States Bottom Laminate Sensor 18 Hopper Door Lam Present Threshold 124 Lam Absent Threshold 140 Main Door Truck Near Hopper Truck Home Printhead Lift Flip Station Card Lam Enter Card Lam Exit 0 Miscellaneous Card Presence Sensor 249 Printhead Voltage 23 760 Y AC Frequency 60 Hz Assumed AC Voltage 110 0 unblocked not pressed open 1 blocked pressed closed Close Ribbon sensors see Tech Note TN4 Print Station Laminate sensors see Tech Note TN6 Laminator Card presence sensor see Tech Note TN2 Card Transport Printhead temperature see Tech Note TN4 Print Station AC frequency Assumed AC voltage see Tech Note TN6 Laminator Laminate Station Adjust Temperatures see page TN8 5 Logic states see page TN8 5 Device Settings Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Control Printer Contral These buttons mimic the from panel buttons lean Cycle Pratt Tai Cad Prints a data sum mary ca
127. te roller otherwise it won t feed Caution If the end of the laminate is crinkled or uneven cut it as square as you can with scissors then reel it in Important Check for overhang any time the cassette latch is opened or the cassette isremoved 1 Make sure the laminate is even with the lips of the cas sette 2 Insert the cassette into its black molded pocket then close the cassette latch clockwise for the UPER counterclock wise for the LOWER 3 Close the main cover If there was a laminate error before you replaced the cassette laminate will automatically feed from the just loaded cassette followed by a cutting action to free a patch of laminate onto the transfer roller If laminate does not feed automatically press the LAMI NATE button 18 P640i Card Printer User Guide 980541 001 Rev A Media Handling Laminating Station Clearing the Laminate Channels If your scissor cuts were neat enough to pass for machine made cuts continue printing cards in the usual way If not don t waste a print cycle Instead remove the hand cut patch es from the transfer roller s as follows Important Clearing procedures for the upper and lower channels are similar The upper channel is shown here Removal of the Transfer Guide gives access to the transfer roller 1 Pull back the retaining spring at the same time pulling the Transfer Guide straight out toward you 2 Remove and discard the
128. ted te withstand 760 000 flexures ecurity gray on gray micro printing covert UW printing amp Automatic self cleaning optional holagrams OVI orn 1 mil system for blemish free printing sit Wakebeld Ri 2S79 U 5 A ggaadg g0ng Demo exhibitor badge landscape format Flower_Show_Front bmp Flower_Show_Back bmp Print test 2 Graytone bmp Test for uniformity blown pixels card flatness etc Print test 4 Wedge_1 bmp Test for ribbon wrinkling Using IDPrint Lite Assuming IDPrint Lite is stored in its default location launch it by going to the Windows Start menu then All Programs then to Zebra Technologies followed by ID Print Lite fi ji Pergam Fileritntes echnokepe Ldn Limi ample Fiem Siow Fothep Cram e Terrin Lie Saepled Fle Show Back beg Typically Image 1 is for the front of the card and Image 2 the back If a five panel ribbon is used such as YMCKK or YMCUVK Image 2 is typically printed on the front of the card with the K or Uv panel following C and Image 3 is printed on the back of the card with the final K panel Image 4 is not used at this time To assign a file to Image 1 click the little square box to the right of Image 1 then click the dotted button at right of the Image 1 window The Select Image File screen below displays the sample files included with IDPrint Lite Highlight the file you want to be Image 1 then cli
129. tem is activated every 10 cards the cleaning cassette contains sufficient tape for 3 000 cards This matches the other components of the standard Zebra media pack 3 000 cards 3 000 color ribbon images gt Note In dusty environments clean the roller more frequently The driver y 7 allows you to select any frequency from card to 20 cards Loading the color ribbon When the color ribbon is exhausted a warning message appears on the monitor and the MEDIA light on the printer turns on Important Opening of the main cover elevates th for easy ribbon loading 980541 001 Rev A P640i Card Printer User Guide 13 Media Handling Loading the color ribbon P6401 color ribbon left and empty core right The flange end with internal grooves goes to the back Important Are both the new ribbon and takeup cores fully home on the arbors as far back as they will go You should hear a click 1 Install an empty ribbon core on the right takeup arbor Push the core back as far as it will go making sure the internal grooves on the core engage the teeth on the takeup arbor 2 Pull out more ribbon then bring the free end of the ribbon up to the right of the takeup core 3 With the ribbon centered on the takeup core attach its free end to core with Scotch tape or the adhesive label that came with the fresh roll Take up slack by reversing the supply roll don t try to rotate the takeup arbor Caution Make
130. ters the power supply can handle any voltage from 110V to 230V so an incorrect setting here will cause no immediatedamage Correcting Laminator Problems Laminate Station Adjustment Top Laminate Length Adjust mils 0 H Cancel Help Line Yoltage a Horizontal Offset mils AME H f LENGTH i Heater Temperature C 180 Bottom Laminate OFFSET f LENGTH i Auto o Horizontal Offset mils 115 4 Length Adjust mils C 10y C 220V Heater Temperature C 150 H Problem Laminate bunches up outside the cutter assembly having missed the feed slot This can happen to either upper or lower laminates It is probably a cassette installation problem such as 1 Failing to latch the cassette 2 Out of square scissor cut on the leading edge of the laminate 3 Leading edge of laminate not reeled in even with the lips of the cassette Reference Section 2 Media Handling P640i Card Printer User Guide 59 Cutter feed slot transfer rollers and relieve pres Sa sure on the card Corrective action Turn off the printer then allow it to cool for about 10 minutes Unscrew the heater assembly fastener ar rowed then partially withdraw the assembly together with the card Pull the card out of the heater inspect Corrective action the rollers for laminate scraps and other foreign matter then re install the assembly Do NOT use metal Unlatch the cassette
131. the condition motion shown in diagram A It doesn t do so because the laminate patch is reversed in the transfer process Laminate patch motion Transfer roller N lt gt motion Upper cassette skew adjustment procedure The following procedure assumes that the horizontal offset has been software corrected as described in Section 5 1 Check the action of the cassette latch If necessary adjust its fore aft position so that its ears smoothly engage the cassette without nudging the cassette 2 Print and laminate a few test cards in the usual way noting the direction of skew Don t worry about vertical offset at this stage unless the laminate overhangs grossly in which case proceed to the Vertical offset adjustment procedure below yy D FRON TAF CARD FRONT F CARD IID 980541 001 Rev A 3 Referring to Section 2 Media Handling unlatch and remove the upper cassette from its pocket Rotate the laminate core counterclockwise reeling in the laminate to bring it even with the lips of the cassette VERY IMPORTANT Set the cassette aside 4 Remove the upper transfer guide then discard the laminate patch on the upper transfer roller If you don t do this the next patch to be applied will not reflect the skew adjustment you are about to make 5 Using a fibertip pen mark the skew adjust screw head for reference Note One full turn of the screw de skews the laminate by approximate
132. tlined in this guide The cassettes are differentiated by color coded dots Red UPPER Yellow LOWER 980541 001 Rev A P640i Card Printer User Guide 15 Media Handling Laminating Station Main components of the laminating system The laminating system comprises two separate independent units one for the front of the card one for the back A ya fe ranster gt guide a Tz lt p gt Vee Transfer toggle Must be set to RUN horizontal for normal oper Transfer ation Rotate the toggle to open roller the rollers for jam clearance Removing the cassettes 1 Open the latch plate by flipping it to the full vertical posi tion until you feel some resistance Turn the UPPER latch counterclockwise the LOWER clockwise Caution If either of the latch plates is A opened even unintentionally the cassette affected must be removed and the laminate reeled in see page 2 6 16 P640i Card Printer User Guide 980541 001 Rev A Media Handling Laminating Station 2 Grasp the cassette and pull it straight toward you clear of the printer Caution If you feel resistance when AN removing the cassette the laminate has likely run out leaving one end attached to the core and the other end under the cutter Keep tugging on cassette which will come free with a short tail of laminate Caution Remove the transfer guide to be sure there are no scraps of laminate remaining 3 Open the cassette like
133. tly READY indicator Green Ready to print or printer busy Yellow Laminator not at operating temperature MEDIA indicator Normally Off On Any media outage ALARM indicator Normally Off What the Indicator Lights Tell You are me x I o eeo za pe pea ero 35 r ri ian sly le F gt F gt s A 0 No cards in magazine color ribbon out cleaning tape out laminator cassette s out lf le XOQ Mag encoding write failure Serious error conditions including MAIN COVER OPEN Laminator too hot card transport stalled card not seated properly mag encoding verification error head lift failure ribbon jam card jam any location card missing any location no gap be tween laminator patches se we Q light on 70 light flashing p gt 980541 001 Rev A P640i Card Printer User Guide 7 Introduction INDICATOR LIGHT SUMMARY A typical card production sequence Several variations are possible such as multi pass color printing on the back surface instead of the black only printing shown here 1 Blank cards are loaded face down in the hop per with the mag stripe if any toward the front 2 The carriage pushes the bottom card out of the deck carrying it under the mag encoder 3 After passing under the encoder the card sur face 1s cleaned by a tacky roller which is itself decontaminated periodically by adhe sive tape in the cleaning cassette 4 Th
134. tly the same three actions described in step 7 of the upper laminator Y EJ Upper cassette vertical offset adjustment The following procedure assumes that the horizontal offset has been software corrected and that skew has been adjusted as outlined above 1 Check the action of the cassette latch If necessary adjust its fore aft position so that its ears smoothly engage the cassette without nudging the cassette 2 Print and laminate a few test cards in the usual way noting the vertical offset front to back position of the laminate patch on the front of the card 3 Unlatch and remove the upper cassette from its pocket Rotate the laminate core counterclockwise reeling in the laminate to bring it even with the lips of the cassette Set the cassette aside 4 Remove the upper transfer guide then discard the laminate patch on the upper transfer roller If you don t do this the next patch to be applied will not reflect the vertical offset adjustment you are about to make 5 Using a fibertip pen mark the vertical offset adjust screw head for reference Sy Note One full counterclockwise turn of the screw pushes out the cassette and therefore the laminate patch by approximately 0 03 Gust under 1 mm o7 6 Using a flat blade screwdriver turn the vertical offset adjust screw in 4 turn increments YW FRON FRONT 7 Re install the cassette Lower cassette vertical offset adjustment Onc
135. to its physical end stop Push at the back of the carrier near the guide shaft Do NOT force Click Flip Station Calibration This elevates the carrier until Edge A just clears the photo sensor at which point the motor stops and the step count is saved in flash memory The motor then drives the carrier back down to the rest position Carrier Motion Vertical motion of the carrier is detected by a single photo sensor activated by two tabs at the back of the carrier molding The carrier is positioned by counting a specific number of motor steps from the instant the sensor s optical path is opened or closed by edges A B and C Flip station components The two halves of the sensor arrow are contained in cavities in the molded back wall of the flip station The sensor tabs are integral with the carrier molding Edge C is hidden by the card ejector arm Flip Station Parameters in the Driver Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Printer Adjustment gt Flip Station Adjust 980541 001 Rev A P640i Card Printer User Guide Card Position Adjust Pixels Adjusts how far the truck drives into the flip station Should be set so that the card is centered in the flip arms if it isn t centered the truck may have difficulty removing the card after the flipping action If the card position is incorrect the truck can depart leaving the card i
136. tore the file temporarily the Desktop is a convenient location 2 Navigate to that location then launch the Printer Installer by double clicking the downloaded file Printer Installer This will install the Zebra Parallel Printer drivers Cancel 3 Click OK This brings up the WinZip Self Extractor which will put the unzipped decompressed files in their default location c zebra driver unless you choose a different location Click Unzip The Self Extractor will then announce that it has successfully unzipped a number of files Win ip Self Extractor w kp _09_15 exe X To unzip all files in wekp2 09 75 exe to the Unzip epecitied folder press the Unzip button Run winzip Unzip to folder Ic Webrasdriver Browse Close W Overnarite files without prompting ABOU ke When done unzipping open setup exe Ts elp 980541 001 Rev A 4 Navigate to c zebra driver or to the alternate location you specified then double click setup exe This displays the Zebra Printer Setup screen You are now at the same stage as if you had inserted the Driver CD Important If the computer you are working on has ever run a Zebra Atlantek printer uninstall all previous versions of the driver before installing the new one You can NOT uninstall a printer driver using the Add Re move Programs procedure in Windows or by deleting a printer icon from the list of Printers and Faxes Uninstalling the printer driver
137. tum 52 P640i Card Printer User Guide Because it is easily accessible and doesn t require removal of the rear cover try to correct the problem with the front flipper adjustment Mark the bushing for reference with a fiber tip pen Using a 4 open end wrench adjust in very small increments such as 1 8 of a turn A full clockwise turn of the screw moves the bushing in by about 0 03 34 mm Note Inserting a CR 80 card into the flipper arms to check for grip is easier if you remove the color ribbon If you are starting from scratch set the nose of bushing about 0 02 1 2 mm proud of the inner surface of the carrier You can estimate this by comparison with a CR 80 card which is 0 03 thick After adjusting the gap Check operation of the flip station by running Flip Test 3 with Flip both with and without a card in the flipper arms The rear flipper arm is different You need to remove the rear cover for access Also it s not possible to adjust the bushing without first removing the cam Flip Station Routines in the Driver Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Control gt Advanced Utilites Flip Test 1 Picks up a card runs it to the flip station flips it raises it to the laminator infeed then ejects it through the laminator The sequence repeats until the PRINT button is pressed and released Flip Test 2 Picks up a card ru
138. uts 7 Complete the procedure by re running Mag Posi tion Adjust as in Step 4 above P640i Card Printer User Guide 980541 001 Rev A Horizontal Offset Override Defaults This is to prevent accidental modification of the offset number which should not need attention in regular use Horizontal X Offset Pixels Adjusts where the printer starts looking for a mag stripe It is a manual fine tuning of the value determined by the Mag Position Adjust routine It is intended only for testing and diagnosis Start gt Printers or Printers and Faxes gt Right click Zebra P6401 gt Properties gt Device Settings gt Printer Adjustment gt Advanced Adjust Advanced Adjustments WARNING Changing these settings may be detrimental Cancel Help to the operation of the printer Do not change them unless you know what you are doing Override Defaults Magnetic Encoding Horizontal gt lt Offset Pixels 4 Magnetic Encoding Preferences Start gt Printers gt Right click Zebra P6401 gt Printing Preferences gt Magnetic Encoding amp Zebra P640i Printing Preferences YMC Color Printing K Black Panel Magnetic Encoding ID Log About Card Setup Image Adjustment Magnetic Data Format f SO C AAMVA American Motor Vehicle Standard Bit By Bit on Track 1 Bit By Bit on Track 2 Bit By Bit on Track 3 Note Tracks not selected for Bit By Bit will default to ISO AAMYVA selection
139. ween arms and platen see Gap adjustment below Azimuth adjustment The flip station carrier is held in alignment with the platen by a U shape molding that rides along a fixed rail in the motor housing behind the carrier Using a fiber tip pen mark the screw for reference then adjust it in very small increments such as 1 8 of a turn A full turn of the screw moves the U shape molding about 0 08 2 mm rotating the carrier almost 3 To fine tune the azimuth adjustment run Flip Test 3 with flip selected If the gap between the rear flipper arm and the platen is to spec 0 004 at the arm s mid point and if neither end of the arm snags after repeated flip cycles you can be sure the azimuth adjustment is good Flip carrier sensor tabs This view is from left to right along the center wall of the printer ockwise rotation of the azimuth adjust screw causes clockwise rotation of the carrier assembly viewed from above Example if the platen tugs down the right hand end of front flipper arm as the carrier elevates the carrier needs clockwise rotation Gap adjustment The flipper arms must be separated so that they clear the platen but not so far that they lose their grip on the card There is a fine line between too tight grabbin g the platen and too loose failing to hold the card securely Rest position datum Photo sensor Carrier motion insertion height datum Max height da
140. x 578 pixels 1 93 Magnetic stripe encoder option Hi Co type 3 track ISO and AAMVA compatible Custom formattable through Windows printer driver Cleaning system Both card faces cleaned by high tack roller Roller is refreshed automatically by transfer tape at selectable intervals typically 10 cards 32 P640i Card Printer User Guide Laminating system Waste free design with built in cutters Continuous mil 0 025 mm thick polyester film in reloadable cassettes Controls Print Ribbon advance Laminate advance Indicators Ready to print Media outage Alarm Data interface USB Parallel option Ethernet option Windows drivers Plug and Play 2000 XP Security features ID Key option a hardware lockout and a printer to PC password lockout Compliances FCC Class A UL IEC EN 60950 1 CSA C22 2 Power requirement 105 125 Vac 60Hz 3A 190 260Vac 50Hz 1 5A 980541 001 Rev A Environment Operating 50 to 95 F 10 to 35 C 20 to 80 RH non con densing Storage 4 to 158 F 20 to 70 C 5 to 90 RH non con densing Dimensions see above drawing Net weight 35 lb 15 9 kg net Shipping weight 43 Ib 19 5 kg Sensors and interlock switches in the P6407 You cane learn a lot about how the P6401 functions by spending a few minutes thinking about its various sensors and interlocks These are of several different types but they have one thing in common they tell the printer s c
141. y D Log is of the type MMDDYYYY log File This is either a folder into which all daily files will be sent Create New Each Day or a single file that will accumulate data day after day Separator Character By default the pipe character is used to separate data resulting in lines looking like this 07 06 3004110 14 051031 204 OIIIIIM 2 jsmith If this is not to your liking a different separator may be specified 980541 001 Rev A Time Logs the time a which the card was sent to the printer in the HH MM SS format The 24 hour clock is used so 13 00 1 00 pm and 05 00 5 00 am Date Logs the date on which the card was sent to the printer in the MM DD YYYY format Printer Serial Number Logs the serial number of the printer which printed the card Static Text Adds to the record text in the box at right Enter no more than 16 characters IP address Logs the IP address of the PC which sent the card to the printer Magnetic Track 1 2 3 Data Logs the data sent to the printer to be encoded on the card s magnetic stripe EIN Data from Mag Track 2 Logs the Embedded Inventory Number pre encoded on Track 2 Note that EIN Readback must be enabled for this action see Tech Note 3 Magnetic Encoder Application will send data with L xxx TextOut Allows third party applications to send data to be logged in much the same way as they would send magnetic data Spooler Job Number Logs the number whic

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