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Zebra P630i

1. Loading Laminate Note In this description of loading laminate references to the lower Laminate Cassette apply only to the P640i Printer The P640i Printer can apply laminate to both surfaces of the card the P6307 Printer only to the upper surface The Laminate laminating film is loaded into cassettes to protect it from dirt or other contaminants See the figure below The Upper Laminate Cassette used on both the P6307 and P640 Printers has a label with the word UPPER and another label of a red dot The Lower Laminate Cassette used only on the P640 Printer has a label with the word LOWER and another label of a yellow dot Upper Lower Laminate Laminate Cassette Cassette P6301 and P6401 only P640 Removing the Laminate Cassette s Step 1 The Laminate Cassette s Upper only for the P630i Printer Upper and Lower for the P6401 are held in position by latch plates The Upper Cassette is freed by turning its Latch Plate counter clockwise to a full vertical position the Lower Cassette only present on the P640 Printer is freed by turning its Latch Plate clockwise Then pull the cassette straight out from its holder 980544 003 Rev A P630 P640 Card Printer User s Manual 17 Installation Installation Procedure Upper Laminate Cassette Latch Plate P630 and P640 Heater e Cores area Lower Laminate Cassette Latch P
2. P630 P640 Card Printer User s Manual 73 Troubleshooting Quality Problems e Toothed transport belt wrong length Poor color rendering Important Changes in contrast settings will not take effect until power is cycled 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 e Vary brightness and contrast controls in Preferences gt Image Adjustment Fine tune if necessary using Contrast Adjust in Properties Device Settings Color Calibration Faint non uniform image e Printhead pressure too low Adjust downward e Printhead not pivoting freely Gaps in image at edges and corners e Possible de lamination wear of platen s rubber surface Try cleaning platen If unsuccessful replace platen e Possible non uniformity of card thickness or card surface defects Continuous white or black stripes on card s longer dimension Before doing anything else clean the printing edge of the printhead with alcohol e White stripe means blown pixel non functioning heating element One or two blown pixels in isolation may be acceptable to some Otherwise replace printhead e Black stripe means non functioning circuit s on printhead If so replace printhead but first check that it is not the result of an image size change not followed by power cycling the printer 74 P630 P640 Card
3. Change ID Cade Kasi with the printer This prevents use of the printer with a Cuneo Code Shai Dabid PC not having the same ID Code The initial ID Code e a ere PESTE e is assigned at the factory during manufacture The password field factory assigned code is located on a sticker on the Dld Password underside of the ID Key To change this code select Start 5 Printers or Printers and Faxes Right click New Password Zebra P630i or Zebra P640i then select Properties DAA CU Device Settings gt Control gt Advanced Utilities In the Change ID Code window enter the old password from Help Cancel the underside of the ID Key in the Old Password field Enter a new password in the New Password field and enter the same password in the Confirmation field To disable the ID Code function leave the New Password and Confirmation fields blank When completed click the OK button Update Backup Config Most of the parameters affecting operation of the printer are set up using the printer driver and are then saved in the printer s flash memory as the current configuration The original factory configuration also resides in a separate backup memory allowing you to recover the as shipped settings The Update Backup Config command instructs the printer to replace the factory configuration with the current configuration but do not do this casually Once the current configuration replaces the factory configuration you can no
4. Zebra P630 P640 Card Printer User s Manual Y 980541 003 Rev A f Card Printer M4 JEN Solutions P630 P640 Card Printer User s Manual 980541 003 Rev A Foreword This manual contains installation and operation information for the Zebra P630 and P640i card printers manufactured by Zebra Technologies Corporation Copyright Notice 2006 ZIH Corp This document contains information proprietary to Zebra Technologies Corporation This document and the information contained within is Copyrighted by Zebra Technologies Corporation and may not be duplicated in full or in part by any person without written approval from Zebra Technologies Corporation While every effort has been made to keep the information contained within current and accurate as of the date of publication no guarantee is given that the document is error free or that it is accurate with regard to any specification Zebra Technologies Corporation reserves the right to make changes for the purpose of product improvement at any time Trademarks Zebra is a registered trademark of Zebra Technologies Corporation Windows and MS DOS are registered trademarks of Microsoft Corp All other trademarks or registered trademarks are marks of their respective holders 980544 003 Rev A P630 P640 Card Printer User s Manual Foreword Heturn Materials Authorization Product Disposal Product Disposal Information Do not dispose of this product in unsor
5. no gap between laminator patches Preventive Maintenance There is almost no preventive maintenance to be performed Dust and debris should be vacuumed out every 12 months or more frequently in adverse environments 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 Zebra Technical Support Before calling for technical support do the following Check all cable connections including power Check that the power switch is ON 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 ribbon laminate cleaning cassette 70 P630 P640 Card Printer User s Manual 980541 003 Rev A Troubleshooting Unusual Noises Unreported Events Unusual Noises Unreported 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 e Both ribbon cores not fully engaged on spindles e Ribbon not secured to takeup core e No ribbon type or wrong ribbon type specified in Printer Properties Reference Printing Preferences in Chapter 4 Settings and Adjustments ALARM light stays ON after error condition is cleared Not
6. Card Printer User s Manual Parallel Connector Optional 980541 003 Rev A 2 Installation Introduction Installation includes setting up the printer installing the printer driver in the computer s that will be sending print jobs to the printer connecting the interface installing the Cleaning Cartridge loading the cards ribbon and laminate and verifying that the printer can print a test card Loading the Printer Driver software is described in Section 3 Installation Procedure Important Execute the procedures that follow in the order given Remove the Printer from the Shipping Carton Step 1 Open and remove the plastic handle latches on either end of the shipping carton Step 2 Lift the upper part of the shipping carton off the lower part 980544 003 Rev A P630 P640 Card Printer User s Manual 7 Installation Installation Procedure Step 3 Remove the items from the cutouts in the foam block atop the printer Verify that the following items are included Printed Quick Start Guide Cleaning Cartridge Output Hopper Ribbon Take up Spool Two Power Cords Card Weight Documentation amp Driver CD USB Interface Cable P630 P640 Card Printer User s Manual 980541 003 Rev A Installation Installation Procedure Step 4 Remove the foam block from the top of the shipping carton Step 5 Lift the printer from the shipping carton Caution The printer weighs approximately 15
7. 34 Printer Driver Installation Installing the Printer Driver USB Step 6 If an older P6307 or P640 Printer and Driver is installed on your computer click on Uninstall Printers and Drivers to remove it Follow the screen prompts At the end of the uninstall process you will be asked to re boot your computer Before re booting exit from the Driver Installation program and remove the CD Then re boot your computer and start over with Step 1 If the computer enters the Found New Hardware Wizard at this time cancel this wizard Printer Setup Install a USB or Parallel Printer and Driver Install an Ethernet Printer and Driver Uninstall Printers and Drivers Install LIninstall IDPrint Lite a simple card printing application Mew Prnt lnstrictons Requires a PDF reader such as Adobe Acrobat Yew Print Release Notes Hequires a text reader such as Notepad Card Printer Solutions Click on Install a USB or Parallel Printer and Driver Printer Setup Install a USB or Parallel Printer and Driver Install an Ethernet Printer and Driver Uninstall Printers and Drivers Install Uninstall ID Frint Lite a simple card printing application Mew Prnt Instrictieng Requires a PDF reader such as Adobe Acrobat Yew Print Release Notes Requires a text reader such as Notepad s Card LU Printer Aw Solutions P630 P640 Card Printer User s Manual 98054 1 003 Rev A Printer Driver Installation In
8. 9 kg 35 Ibs Step 6 Remove the protective plastic bag from the printer Important Save all the packing material and the shipping carton in case the printer needs to be moved or shipped If the original material is lost or damaged a replacement Shipping Kit can be ordered from Zebra Step 7 Place the printer in a location that meets the following requirements Areasonably dust and dirt free environment will give better print quality e Flat surface at least 699 mm 27 5 in x 246 mm 9 7 in that can support the weight of the printer additional space preferred Vertical clearance at least 450 mm 17 in There should be easy access to all sides of the printer e Temperature within the range of 10 to 35 C 50 to 95 F Relative Humidity 20 to 80 non condensing AC power accessible 980544 003 Rev A P630 P640 Card Printer User s Manual 9 10 Installation Installation Procedure Remove Shipping Tape Step 1 Open the printer Main Cover Locate and remove the blue tape that secures the flip station in position P630 P640 Card Printer User s Manual 980541 003 Rev A Installation Installation Procedure Attach the Output Hopper Step 1 The Ou
9. A P630 P640 Card Printer User s Manual iii Foreword Icons Icons 3 gt Bb P gt Throughout this manual different icons highlight important information as follows Note Indicates information that emphasizes or supplements important points of the main text Important Advises you of information that is essential to complete a task or points out the importance of specific information in the text Electric Shock Caution Warns you of a potential electric shock situation Electrostatic Discharge Caution Warns you of a situation where electrostatic discharge could cause damage to electronic components Caution Advises you that failure to take or avoid a specific action could result in physical harm to you or could result in physical damage to the hardware Pinch Hazard Keep fingers away from printer cover hinges and back of cleaning cassette Hot Surface Danger of skin burns near laminator components P630 P640 Card Printer User s Manual 980541 003 Rev A Foreword P630i and P640i Printer Models P630 and P640 Printer Models The Zebra Product Number tells a story Model numbers include identifiers that specify options using the following conventions Part Number Base Printer P630i Dual Sided Color Card Printer w Single Linerless Laminator P6301S Dual Sided Color Card Printer w Single Linerless Laminator with Advanced ID Key Security Feature Base Printer P6401 Dual Sided Col
10. Access Printer Sensor Data anaana aaa aaa 52 Printer Properties s 4 30 ao MG 68804 DOORS AKI KAWAL COTES qOP Ra SERGE SEES 54 C UTEUHEEERETERTTETCTURECOCEETIETTRTT E PEE 54 vicus AP AP AA 54 KOPA AA AA 55 nue raner WADE AG ANUMAN eh e a AGA E LANDO A 55 Color Management ee eee eee 56 DCCUINY 6 44224 seeded deteneeeeaea ss eee senaacdueee sew etes deni au bee oe 56 Device SettingS n nananana aa eee eee eee 57 Printing Preferences 0c hrs 59 ald et 2 4 4 eens AA 60 Image Adjustment DAN cen ecesseG cee ATE ess tees ees caus ooee anes 61 YMG Color NOs cg AKA RB Gt ate oes ee oo oe od ee Be Sees NAG ee ee oe 62 K Black Panels PC 62 Color Calibration 2 0 6 ee ee eee eee ees 64 Flip Station Routines ee RR eens 65 Laminator Station Adjustments aa 66 5 Troubleshooting 000 c eee ees 69 MOrWiCSSa0CSs lt paaa Hee NAA Cee ers bok bee Bea hoes 444 Hees loses eas 69 INnGICATOMLIGNUSIAINS sesed kA waaa ai suse ee ome eg ABG 2 a he TIT 70 Preventive Maintenance 1 0 0 0 a 70 Unusual Noises Unreported Events ce eee 71 Quality Problems RR RR rr 73 Laminate Problems l l rrr 15 Examples of Printhead Failures ce ee ees 15 System Related Issues 1 ee eee ees 76 INVA IP ACCESS uiu dm rcx RE mun dedos idee Re Sed Pals Hed ows eens 76 DHCP is enabled but the printer is n
11. Y offset 980544 003 Rev A P630 P640 Card Printer User s Manual 75 Troubleshooting System Related Issues Image missing at top or bottom of card e Ribbon folded over at edge Slacken ribbon by pulling more out of supply roll unfold edge then press RIBBON button to re sync 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 if available in Preferences or modify layout application Image loss at top of card e Could be on either edge Almost certainly due to ribbon fold over but could be a head non pivoting problem or an image size problem Consistent image defects card after card e Debris on platen or platen surface not flat Clean platen or replace if necessary Debris on platen Clean platen Random colored patterns on image Ribbon wrinkling Reduce takeup torque Check printhead pressure Too much heat being applied to YMC panels Try reducing gain offset and preheat separately for each color in the driver Device Settings Color Calibration 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 Random colored lines e Probably resulting from excessive takeup torque Scratches dings on long edges of card Look for a narrow band of abrasion
12. as your default printer this can always be changed in the Windows Printers or Printers and FA Xes control panel Then click Next gt 980541 003 Rev A P630 P640 Card Printer User s Manual 47 48 Printer Driver Installation Installing the Printer Driver Ethernet Add Printer Wizard Printer Sharing fou can share this printer with other network users IF you want to share this printer vou 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 Step 14 Specify whether or not you want to allow printer sharing then click Next gt Add Printer Wizard Print Test Page Aa To confirm that the printer is installed properly you can print a test page Cf Do you want to print a test page Step 15 Specify if you wish to print a test page note that card printers consider each card to be a page then click Next gt P630 P640 Card Printer User s Manual 980541 003 Rev A Printer Driver Installation Installing the Printer Driver Ethernet Add Printer Wizard Completing the Add Printer Wizard rau have successfully completed the Add Printer Wizard fou specified the following printer settings M ame zebra PbA4TII Share name Not Shared Port IP 10 1 3 104 Model zebra P640 Default Ma Test page es To close this wizard click Finish Cancel Step 16 Click Finish The following screen will appear Har
13. error condition on the host computer screen The sensors and iterlocks are shown in the following figure 980541 003 Rev A P630 P640 Card Printer User s Manual 51 Settings and Adjustments Sensors and Interlock Switches Cover Ribbon Printhead Motion Sensor Card interlock Motion Not Accessible Presence Sensor Sensor Truck Near Infeed Hopper Sensor Interlock Truck Outfeed Home Sensor Sensor 1080 CS SUC A 5 oT Cleaning Ribbon Sensor Flip Lower Laminator Sensor Not Accessible Sensor Present on P640i Only Access Printer Sensor Data To access the Sensor Data screen select Start Printers or Printers and Faxes Right click Zebra P630i or Zebra P640i then select Properties gt Device Settings gt Control gt Advanced Utilities gt Show Sensor data Ribbon Ribbon Panel Detect Temperature Printhead Temp Panel Threshold Controller Board T emp Ribbon Encoder Count Top Heater Temp Bottom Heater Temp Laminate Top Laminate Sensor Logic States Bottom Laminate Sensor Hopper Door 1 Lam Present Threshold Main Door 1 Lam Absent Threshold Truck Near Hopper 1 Truck Horne o lbpeJEmcete Printhead Lift 0 Card Presence Sensor 245 satel 1 Printhead Voltage 23 rb V pA n Card Lam E zit o AC Frequency E0 Hz Assumed AC Voltage 1104 0 unblacked not pressed open 1 blacked pressed clos
14. flex guide Replace cassettes in retention scaw 1 Open the front cover printer and close the cover 3 Hya parta 2 Load new ribbon or clear jammed ribbon For Card Jams T Tuin the printer on 2c Remove jammed card from the laminator Close the The card vall ba reprinted automatically 3 Close the front cover cover i 4 Press the Ribbon button on the printer front panel to If this error occurred while printing th d will b inted Thi k a printing the card will be reprinte zm ae Bis peres beam iti dE elt tall B re synchronize the ribbon automatically If this error occurred while printing the card will be reprinted automatically This dialog box will close automatically once the error is a cleared or you may click Close to close it now This dialog will close when the error is cleared or you may click Close to close it now Close Close 980541 003 Rev A P630 P640 Card Printer User s Manual 69 Troubleshooting Indicator Light Status Indicator Light Status xL Vlr po TATE TA 10003000 L LIGHT FLASHING PRINTER STATUS Laminator heaters in sleep mode when not in use the heaters cool at 1 F per minute Printhead temperature error or internal firmware problem 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
15. forces a ribbon synchronization whenever the door is closed or the printer is powered up is disabled 980544 003 Rev A P630 P640 Card Printer User s Manual 3 Introduction Controls and Indicators If you press and hold the PRINT button for more than two seconds the printer will continuously reprint the image in the buffer Stop this action by pressing the button momentarily while printing is in proces Note that pressing the PRINT button will have no effect if any of the following applies e Anerror condition exists e You have set up the print driver to print color on both sides of the card e The optional hardware lockout key ID Key is missing but this does not disable the checkerboard printout available after power up RIBBON button This button is used to synchronize the ribbon in other words to position it correctly under the print head If you hold the RIBBON button down and power up the printer it toggles on off the Ribbon Syncronization feature when the door is closed In typical applications the ribbon type is YMCK and the back of the card is printed first In such cases pressing the RIBBON button will advance the color ribbon to bring the leading edge of the next black panel under the print head If back side printing is not enabled the printer will synchronize on the next yellow panel when the RIBBON button is pressed LAMINATE button For the P640 Printer this applies to the Upper and Lower Laminato
16. 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 Laminate Allows you to choose whether laminate will be applied to the front side to both sides P6407 Printer only or to neither side Orientation Allows you to set up the front and back images independently for landscape or portrait orientation By checking the Rotate box you can also flip either image upside down Note The following combination is not available Front landscape and Back portrait 980541 003 Rev A Settings and Adjustments Printing Preferences Image Adjustment From the Image Adjustment screen the operator can adjust the brightness and contrast of the images printed on the cards To access the Image Adjustment 2 Zebra P640i Copy 1 Printing Preferences Card Setup YMC Color Frinting K Black Panel Image Adjustment Magnetic Encoding D Log Advanced About hn MU E 2 screen select Start gt Settings gt Printers UU UST on AA and Faxes Right click on the Zebra P630i or Zebra P640i printer listing i 7 Select Printing Preferences gt Image Reset Brightness Contrast to Defaults 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 Reference the Contrast and Brightness sample cards below for examples of the diffe
17. longer return the printer to the factory settings Restoring the Backup Configuration Settings Revert to Backup Config as follows Step 1 Power OFF Step 2 Remove the color ribbon 86 P630 P640 Card Printer User s Manual 980541 003 Rev A Printer Security Printer Parameters in the Driver Step 3 Press and hold the PRINT RIBBON and LAMINATE buttons at the same time as you switch on the power Step 4 Release the three buttons when you see activity in the printer Password Protection Password protection is not the same as ID Code Password protection blocks access to various low level printer adjustment screens On the appropriate screen check Use Password then enter a password of your choice 980544 003 Rev A P630 P640 Card Printer User s Manual 87 88 Printer Security Printer Parameters in the Driver P630 P640 Card Printer User s Manual 980541 003 Rev A Appendix D Worldwide Sales amp Support Sales and Support Locations Zebra Technologies Card Printer Solutions 1001 Flynn Road Camarillo CA 93012 8706 USA Phone 1 805 579 1800 Fax 1 805 579 1808 Toll free in US 800 452 4056 e mail cards zebra com Zebra Technologies Card Printer Solutions Europe Middle East Africa The Valley Centre Gordon Road High Wycombe Buckinghamshire HP13 6EQ England Phone 44 0 870 241 1527 Fax 44 0 870 241 0765 e mail eurosales zebra com Zebra Technologies
18. up to about 0 1 2 5 mm in from either or both of the long edges Card hopper base set too low System Related Issues Printer self test takes more than a few minutes to complete READY indicator LED is not lit on the panel Invalid IP address 76 P630 P640 Card Printer User s Manual 980541 003 Rev A Troubleshooting System Related Issues A valid static unique IP address must be assigned to the printer The default setting has DHCP disabled If you do not specify either the printer may incur an extended latency while being identified in your network Refer to your operating system networking configuration instructions to set up a unique static or DHCP selected IP address for your Ethernet enabled printer DHCP is enabled but the printer is not connected to your network Verify that the Ethernet cable is properly connected to the printer and to the Ethernet port on your computer or the network Valid host name has not been assigned to the printer If your client uses Windows 2000 a valid host name must be assigned to the printer Failing to do so may cause DHCP to register the IP address as the printer name in DDNS for clients that do not support dynamic updates Color differences may be attributable to the Windows operating system installed In a multi printer installation the colors printed on one unit do not match the colors from another even though the printer color settings are the same To ensure color cons
19. 541 003 Rev A Settings and Adjustments Flip Station Routines Black Panel Preheat 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 Note The printer must be power cycled for any Contrast Adjustments to take effect Contrast Adjust A subtle color printing control allows the user to shape the printer s lightness curve This means the ability to control how the printer resolves or differentiates the lighter and darker shades Between contrast settings of 0 and 100 the lightness curve transitions from linear to sinusoidal Linear 0 tends to result in a low contrast muddy looking image Sinusoidal 10096 gives mostly good results but tends to sacrifice the lightest and darkest shades For most purposes select 8096 and leave it there Flip Station Routines To access the Advanced Utilities screen select Start gt Printers or Printers and Faxes Right click on the Zebra P640i or Zebra P640i printer listing Select Properties gt Device Settings gt Control gt Advanced Utilites Advanced Utilities E X i E Flip Pause Flip Test 2 Eject Card Password Protection Use Password Set Password Move Carnage ID Lade Movel Home Position status Disabled uid Lalibration Disable
20. 630 P640 Card Printer User s Manual 980541 003 Rev A Installation Installation Procedure These are shown in the following figure 7 A BACK yy CARD A EANO RIESIA Step 1 Remove the Laminate Edge Guide from its storage location on the Laminator Frame it snaps out Laminate Edge Guide Step 2 For 1 3 in 33 mm laminate for use with magnetic stripe cards snap the Laminate Edge Guide into the inner hole and slot in the lower cassette as shown in the following pictures For 1 66 in 42 mm laminate for use with signature stripe cards use the outer hole and slot 980544 003 Rev A P630 P640 Card Printer User s Manual 23 Installation Installation Procedure Inner Hole and Slot Outer Hole and Slot Laminate Edge Guide in Inner Hole and Slot for 1 33 in 33 mm Laminate Used With Magnetic Stripe Cards 1 33 in 33 mm Laminate for Magnetic Stripe Cards Installing the Laminator Cassette s Step 1 Insert the cassette into its black molded pocket then close the cassette latch clockwise for the UPPER counterclockwise for the LOWER 24 P630 P640 Card Printer User s Manual 980541 003 Rev A Step 2 Clearing the If your Installation Installation Procedure 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
21. 7 information 980544 003 Rev A P630 P640 Card Printer User s Manual 81 Magnetic Encoder Magnetic Card Stripe Encoder AAMVA Standard Encoding Field Track Valid of Separator Density Characters characters Track Bits per inch f Including Start Stop and LRC characters Also note that these 3 characters areautomatically managed by the magnetic encoder according to the ISO Standard Norms Magnetic Encoder Cleaning Use the standard cleaning procedures This cleans the most important parts of the printer including the print Head Transport Roller and Magnetic Stripe Encoder Media Loading Orientation magnetic stripe cards The magnetic stripe must be flush to the surface of the card Caution ONLY USE cards that comply with ISO 7810 amp 7811 standards for AN to work properly Never use cards which have taped on magnetic stripes When loading cards with magnetic stripes into the card feeder please ensure that the magnetic stripe is face up facing the front of the printer Magnetic Stripe P630 P640 Card Printer User s Manual 980541 003 Rev A Appendix B Smart Card Contact Station Introduction This section contains information on the additional operations of a P6307 or P640i Printer equipped with the optional Smart Card Contact Station Smart Cards have a built in microcomputer and or memory chip which is used to store fingerprints voice recognition patterns medical r
22. 90 z m The Y M and C color curves can be separately modified by the Gain and mene Offset parameters Click Restore Defaults if you are not satisfied with adjustments made Magenta Gain Offset Preheat To access the Color Calibration screen select Start gt Printers or Offset x Printers and Faxes Right click on Preheat 950 X the Zebra P630i or Zebra P640i printer listing Select Properties gt Back Black Panel Dens fio y Device Settings gt Color Calibration pees mu um Offset Shifts the color curve up Front Black Panel Ders 100 z darker and down lighter Contrast Adjust i0 amp 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 Note Typically the set of values should be the same for each color Preheat 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 This controls 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 64 P630 P640 Card Printer User s Manual 980
23. Card Printer Solutions Latin America 9800 NW 41st Street Suite 220 Doral FL 33178 USA Phone 1 305 558 8470 Fax 1 305 558 8485 e mail latinsales card com 980541 003 Rev A P630 P640 Card Printer User s Manual 89 Worldwide Sales amp Support Corporate Headquarters Zebra Technologies Card Printer Solutions Asia Pacifique Sims Lane 06 11 387355 Singapore Phone 65 84 20 322 Fax 65 84 20 514 e mail asiasales zebra com Corporate Headquarters Website 90 Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills IL 60061 3109 USA Phone 1 847 634 6700 Fax 1 847 913 8766 e mail sales zebra com www zebracard com P630 P640 Card Printer User s Manual 980541 003 Rev A
24. EC Directive 1999 5 CE R amp TTE Directive EN300330 2 V1 1 1 Radio Frequency Interferences For a formal certificate please contact the Compliance Office at Zebra s Camarillo facility EUROPE Norway Only This product is also designed for IT power system with phase to phase voltage 230V Earth grounding is via the polarized 3 wire power cord FI Laite on liitett v suojamaadoitus koskettimilla varustettuun pistorasiaan SE Apparaten skall anslutas till jordat uttag NO Apparatet m tilkoples jordet stikkontakt FCC DECLARATION OF CONFORMITY Models P630 and P640i have been tested and found to comply with the limits for a Class A device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and operated in accordance with the P630 P640i User s Manual this document may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense INDUSTRY CANADA NOTICE This device complies with Industry Canada ICES 003 class A requirements Cet equipement est conforme a l ICES 003 classe A de la norm Industrielle Canadian 980541 003 Rev
25. Manual 15 Installation Installation Procedure Step 6 Re open the printer cover to inspect the ribbon path for wrinkles and folds Correct if necessary then close the cover If you do not then hear the ribbon motor advancing the ribbon press the RIBBON button Installing the Cleaning Cassette Before being printed each surface of the card is cleaned by a soft tacky roller that is itself cleaned periodically by adhesive tape in the Cleaning Cassette Typically the roller is cleaned every 10 cards The printer driver software allows the card count to be modified By cleaning the roller every 10 cards the Cleaning Cassette contains sufficient tape for 3 000 cards This matches the other components of the standard Zebra media pack 3 000 cards 3 000 color ribbon images Step 1 Open the main cover of the printer Step 2 Remove the Cleaning Cassette from its packaging Step 3 Remove the protective foil from the Cleaning Cassette Avoid touching the exposed tacky surface Step 4 Install the Cleaning Cassette on the printer by locating the rectangular pin on the cleaning mechanism in the receptacle on the cassette Push the cassette gently home ensuring that the internal grooves on the upper spool engage the teeth on the takeup drive you will hear a click when it is fully engaged 16 P630 P640 Card Printer User s Manual 980541 003 Rev A Installation Installation Procedure
26. Printer User s Manual 980541 003 Rev A Troubleshooting Laminate Problems Laminate Problems Laminate not centered on card e Vertical offset adjust mechanical adjustment Horizontal offset Properties Device Settings Printer Adjustment Laminate Station Adjust Laminate not parallel with card edges e Skew adjust mechanical adjustment e If using partial width laminate edge guide not properly installed one of two positons Transfer guide not properly installed Laminate patch wrapped around heated roller 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 Examples of Printhead Failures White line across length of the card The white line is a sign of a blown pixel The adjacent black stripe is a printhead driver problem components on the head itself These are independent problems not necessarily co located that may require replacement of the printhead Random occurrences of white unprinted spots e Possible card quality problem Run IDPrint Lite with graytone bmp on cards from a different batch Check platen surface for specks of debris Image not centered on card Properties Device Settings Printer Adjustment Horizontal Vertical Offset Image offset on card e Correct this by increasing horizontal X offset decreasing vertical
27. Printer s Print Button Mag Position Adjust Mag Amplitude Adjust Disable Printer s Other Buttons Show Sensor Data Flip Station Calibration Statue Polling Frequency Smart Card Calibration Set Ribbon OEM Oh Misael tallest M ss Update Backup Contig Upgrade Firmware Number of Times to Retry f Send Features File 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 Test2 Picks up a card runs 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 980541 003 Rev A P630 P640 Card Printer User s Manual 65 Settings and Adjustments Laminator Station Adjustments Eject Card Picks up a card runs it to the flip station raises 1t 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 Laminator Station Adjustments 66 Accurate positioning of the lam
28. Status Contral The control screen allows manual control over the printer These functions are similar bo the buttons on the front of the printer Control OK Cancel Apply Settings and Adjustments Printer Properties The Device Settings screen allows you to access various adjustment and calibration screens Printer Adjustment The following procedures can be performed from the Printer Adjustment screen 980541 003 Rev A Printer Adjustment X Laminate Station Adjust Flip Station Adjust Advanced Adjust Card Hopper OF L ancel Heb Help Pick Position Adjust Piwels o E Cleaning Station Clean Frequency Every 10 I Cards Print Station Adjustment Laminate Station Adjustment Flip Station adjustment o Ic Advanced Adjustments a Magnetic Encoder Position b Smart Card Position 5 Card Hopper Pick Position 6 Cleaning Frequency P630 P640 Card Printer User s Manual of 58 Settings and Adjustments Printer Properties Color Calibration The following procedures can be performed from the Color Calibration screen 1 Yellow a Gain b Offset c Preheat Color Calibration 2 Magenta a Gain b Offset c Preheat z EN 3 Cyan a Gain b Offset c Preheat 4 Black Panel Density 5 Black Panel Preheat 6 Contrast Adjustment T 8 BRE Status The Status screen displays the current state of the printer and provides
29. TUXRqgPPSSECUATA A bERbeEpaeeds eee euEese 90 980541 003 Rev A P630 P640 Card Printer User s Manual Contents P630 P640 Card Printer User s Manual 980541 003 Rev A 1 Introduction Thank you for choosing the Zebra P630i or P6407 Card Printer This manual guides you to efficient start up and operation of your new Card Printer The Zebra P630 and P640i Card Printers provide high speed full color dual sided card printing A micro positioning card transport system provides enhanced color photos A range of interface encoder reader and security options allow ordering the specific configuration suitable for a particular application The difference between the P6307 and the P6407 is that the P630 has a single sided laminator 1 e it lays down and seals a laminating film on the top surface of the printed card while the P640 has a dual sided laminator 1 e it lays down and seals laminating film on both surfaces of the printed card References in this document that refer to either or both of the models will be in the form of the printer or the P630i P640 Printer references that are specific to one or the other will be in the form of the P630i Printer or the P640 Printer 980544 003 Rev A P630 P640 Card Printer User s Manual 1 Introduction Printer Features Printer Features The following figure shows features of the P630i P640i Printer Cleaning Cassette Ribbon Ribbon Take Up Spool Flip S
30. 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 ar 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 P630 P640 Card Printer User s Manual 39 Printer Driver Installation Installing the Printer Driver USB Wait while the Wizard installs the software Found Hew Hardware Wizard Please wait while the wizard installs the software Cancel Step 18 When software installation is complete the following window will display Click Finish Found New Hardware Wizard Completing the Found New Hardware Wizard The wizard has finished installing the software for Zebra P640 a Click Finish to close the wizard Cancel Step 19 This completes software driver installation To use the P6301 or P6401 Printer you would select it just like you would any other printer connected to a Windows system 40 P630 P640 Card Printer User s Manual 980541 003 Rev A Printer Driver Installation Installing the Printer Driver Ethernet Installing the Printer Driver Ethernet Note To install the USB driver see the procedure starting on page 32 Important The Ethernet Network must be configured correctly with the Printer and the host computer on the same subnet
31. ack pixels of the C bitmap and also assign K to specific data types such as text if checked here Results depend on the card creation program in use eed dme Printing Elements Settings and Adjustments Printing Preferences 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 Equal amounts of Y M and C dyes at maximum intensity deliver a near black image but one that is not machine readable A bar code printed from YMC 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 which means printing the same bar code using the K panel on top of the YMC bar code You can also choose to print only in K omitting YMC from that region The K panel is not a dye It is more of a paint containing carbon black which is highly visible to infrared type readers 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 Text Text which is sent explicitly as such to the printer driver Lines and Pixels Lines and dots pixels sent as such to the printer driver Area Fills Colo
32. al Offset mils Adjusts laminate placement on the card Caution Do not set the temperature ABOVE 180 C or BELOW room temperature 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 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 Caution Running the printer at 220V 60Hz in Auto mode may cause premature failure of the heaters Running the printer at 110V 50Hz in Auto mode may cause abnormally long heat up time and poor temperature control 980541 003 Rev A P630 P640 Card Printer User s Manual 67 68 Settings and Adjustments Laminator Station Adjustments P630 P640 Card Printer User s Manual 980541 003 Rev A Troubleshooting Error Messages Most error conditions are identified by the printer itself and are reported by the computer as error messages with corrective actions listed The following are typical computer reported error messages FLIP STATION JAM The printer is reporting that the flip station is jammed To 1 Open the front cover and remove any obstructions from MEDIA JAM the
33. arkway Veron Hills Ilinois 60061 United States of America This EULA is a legal agreement between you either an individual or a v Reject Step 6 This brings up the Configure Ethernet Port screen Click the Browse button Configure Ethernet Port x Printer Info Model Mame MAC Address Cancel Serial Humber Configure Printer Printer IP Address HEN Browse Timeouts 5000 Read Timeout ms 5000 Write Timeout m 980541 003 Rev A P630 P640 Card Printer User s Manual 43 44 Printer Driver Installation Installing the Printer Driver Ethernet Step 7 Any Zebra printers will be located Select highlight the desired printer for this procedure it is a P640i but the steps would be the same for a P6307 and click the OK button Note If the Printer is not found check to make sure the Printer is powered on and the Ethernet connector is engaged Also the Ethernet Network must be configured correctly with the Printer and the host computer on the same subnet mask If you are not sure how to verify d this or change the configuration consult someone knowledgeable on Ethernet Networks Browse Printers x IP Address MAC Address ModelNumber SerialNumber Configured OK 10 1 3 104 00 07 4d 00 00 00 P640 9405056 LU Cancel Rescan Step 8 The Configure Ethernet Port screen will reappear but now the information for the P640i printer selected in step 7 will be displayed Configure Ether
34. cannot rotate upward to disengage from the cleaning roller Pivot arm screw too tight or too loose Unusual events In any of the following cases and all other unusual events try power cycling first then investigate specific issues e Printhead descends before card arrives Contact Zebra Customer Service e Printhead stays down after card has gone away Contact Zebra Customer Service Laminate cutter fails to operate Unusual media light indications 72 P630 P640 Card Printer User s Manual 980541 003 Rev A Troubleshooting Quality Problems Laminator spot check o Note Remember the P640 Printer includes upper and lower laminators the P630 Printer y 7 has the upper laminator only Make sure the transfer roller toggle is in the operating position pointing to the right 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 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 p
35. d dme K Black Panel The printer 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 1s 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 When the Card Setup screen is set for YMC and K on the same side of a card a process called Black Extraction is enabled The K Panel screen displays available options for Black Extraction P630 P640 Card Printer User s Manual 980541 003 Rev A amp ebra P640i Copy 1 Printing Preferences 980541 003 Rev A Image Adjustment Magnetic Encoding ID Lag Advanced About Card Setup ME Color Printing F Black Panel To enable these selections the printer must be configured in Card Setup to print Frant F Element Selection Lines and Pixels Area Fille Monochrome Bitmaps Color Bitmaps Black Portions Only Print Dye Black Under K Black C Do Not Print Dye Black Under E Black Use K Black for machine readable data The back surface is typically a K only image For the front the driver can extract a K image from the true bl
36. d Printer User s Manual J9 Printer Driver Installation Installing the Printer Driver USB Step 9 This brings up the Browse Printers window shown below If your P640i P630i Printer is listed select highlight it and click OK If your printer 1s not listed make sure the printer is powered on and check the USB cable connections then click Rescan When it appears select highlight it and click OK Browse Printers x Model Humber Serial Number 1 P640 9405056 Cancel Hescan Step 10 This brings up the Configure USB Port window If your printer is not listed in the Printer info area click Browse Leave the two timeout values alone Click OK Configure USB Port x Printer Into Model Pb40i 5405056 Options 5000 Read Timeout mz 5000 Write Timeout ms Cancel Step 11 This will bring up the Printer Installation window Note the value shown on the first line ATLUSBOOI for the screen shown here then click OK E Printer Installation 1 You have just installed port ATLLISBOOH Be sure to select this port From the list of ports Ehe Add Printer Wizard will present 36 P630 P640 Card Printer User s Manual 980541 003 Rev A Printer Driver Installation Installing the Printer Driver USB Step 12 This opens the Add Printer Wizard welcome window Click Next gt Add Printer Wizard Welcome to the Add Printer Wizard This wizard helps you install a printer or make print
37. dware Installation The software you are installing Far this hardware Printers has not passed Windows Logo testing to verify its compatibility with Windows F Tell me why this testing ts 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 Step 17 Click on Continue Anyway You will see files being copied to the Windows folder When the file copying is complete your printer is ready to use Copying Files Eg AtlLangMon2 dll To CAWINDOW S systems2 HO aan AMANG GG 980541 003 Rev A P630r P640 Card Printer User s Manual 49 50 Printer Driver Installation Installing the Printer Driver Ethernet P630 P640 Card Printer User s Manual 980541 003 Rev A 4 Settings and Adjustments Introduction This section describes settings and adjustments that can be made to the P630 and P640 Printers Sensors and Interlock Switches These are of several different types of sensors and interlock switches but they have one thing in common they tell the printer s control 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
38. e There is a delay after closing the cover before the ALARM light goes out e Some alarms require recycling power in order to clear e Main cover interlock switch may not have actuated when cover closed e Alarm condition not corrected Card has both front and back images printed on same side e Check selections made in Printing Preferences gt Card Setup in Chapter 4 Settings and Adjustments e Card failed to flip Run Flip Test to check flip action Reference Chapter 4 Settings and Adjustments MEDIA light ON steady but no obvious visual problem e Color ribbon not in ribbon sensor e Color ribbon supply and or takeup cores not engaging properly on spindles Cleaning cassette not engaging properly on the takeup drive Completely unexpected print results e Color ribbon out or nearly out Replace ribbon 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 spindles e Front color side of card printed with black Open and close main cover then press RIBBON to re sync ribbon Inconsistent color very faint printing Printhead not pressing on ribbon Contact Zebra Customer Service 980544 003 Rev A P630 P640 Card Printer User s Manual 71 Troubleshooting Unusual Noises Unrepor
39. ebra P640i Properties 2 x e a preferences screen Reference Printing Color Management Security Device Settings General Sharing Ports Advanced Preferences below j X Print Test Page Prints the standard Windows test page Location Comment Model zebra P640 Features Color Yes Paper available Double sided Yes CR 80 Standard 578x852 pixels CR 80 Oversize 600x957 pels Staple Mo CR 80 Oversize 670x968 pixele Speed Unknown Maximum resolution 300 dpi Printing Preferences Print Test Page Sharing eae Coram a Windows definition In a network Color Management Security Device Settings General Shang Pos Advanced environment it allows other computers to NN You can share this printer with other users on your network To send jobs to the printer that s connected to ga enable sharing for this printer click Share this printer Windows Firewall is already configured to allow the sharing of printers with your computer other computers on the network C Share this printer Share name FT List in the directory r Drivers 34 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 Cancel Ap
40. ecords or other types of data The printer may be equipped with an optional contact station for programming Smart Cards ISO 7816 This printer model responds to commands that position the card at the contact station where the printer connects to the contacts on the Smart Card All other printer operations remain the same as the standard model Media Loading Orientation Orient the cards with the gold plated Smart Card contacts at the bottom surface of the card and facing to the right Contacts on Bottom Surface of Card 980541 003 Rev A P630 P640 Card Printer User s Manual 83 Smart Card Contact Station Laminating Smart Cards 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 Loading procedure for smart card laminate is exactly the same as for standard laminate as shown in Chapter 2 INDEX MARKER CUT LINE 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 After loading the Smart Card laminate in the upper cassette trim the laminate along the cut line as shown 84 P630 P640 Card Printer User
41. ed P630 P640 Card Printer User s Manual 980541 003 Rev A Settings and Adjustments Sensors and Interlock Switches 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 the 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 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 Temperature Temperatures at the top and bottom laminate heater cores Logic States Summarizes all two state interlocks and photo sensors a very useful diagnostic tool 980541 003 Rev A P630 P640 Card Printer User s Manual 59 Settings and Adjustments Printer Properties Printer Properties To access the various Printer Properties select Start gt Printers or Printers and Faxes Right click Zebra P630i or Zebra P640i then select Properties General Printing Preferences Brings up the amp z
42. el option 10 100 Mbps Ethernet option Windows drivers Plug and Play 2000 XP 980541 003 Rev A P630 P640 Card Printer User s Manual 79 80 Technical Specifications P640i Specifications Security features ID Key option a hardware lockout an ID Code and a printer to PC password lockout Compliances FCC Class A UL IEC EN 60950 1 Power requirements 110 220 VAC 50 60Hz 4 2 A Environment Operating 50 to 95 F 10 to 35 C 20 to 8096 RH non condensing Storage 4 to 158 F 20 to 70 C 5 to 90 RH non condensing Dimensions see drawing i Net weight 35 Ib 15 9 kg net Shipping weight 43 Ib 19 5 kg P630 P640 Card Printer User s Manual 980541 003 Rev A Appendix A Magnetic Encoder Magnetic Card Stripe Encoder This section contains information on the additional operations of the P630i or P6407 Printer with Magnetic Card Stripe Encoder The magnetic encoder uses high coercivity ISO Standard Encoding Track Field Track Valid of Separator Density Characters characters 1 210 BPI Alphanumeri 791 c ASCII 2 75 BPI Numeric ASCII EE 210 BPI Numeric ASCII 48 62 Bits per inch T Except the character f Including Start Stop and LRC characters Also note that these 3 characters areautomatically managed by the magnetic encoder according to the ISO Standard Norms o Note Refer to the Card Printer Programmer s Manual for complete programming y
43. er connections IF you have a Plug and Play printer that connects AJ thraugh a USB port for any other hot pluggable port such as IEEE 1334 infrared and sa 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 an Windows will automatically install the printer for you To continue click Nest Cancel Step 13 This brings up the Add Printer Wizard Local or Network Printer window For a typical USB installation select Local Printer attached to this computer and check the box to detect a Plug and Play printer Then click Next gt Add Printer Wizard Local or Network Printer A The wizard needs to know which type of printer to set up cf Select the option that describes the printer you want to use Automatically detect and install my Plug and Play printer CO A network printer ar a printer attached to another computer i To set up a network printer that is niat attached to a print server Y use the Local printer option 980541 003 Rev A P630r P640 Card Printer User s Manual 37 Printer Driver Installation Installing the Printer Driver USB Step 14 This brings up the Found New Hardware Wizard welcome window In general select Yes this time only and then click Next gt Found Hew Hardware Wizard Welcome to the Found New Hardware Wiza
44. error or major internal control problem requiring power cycling of the printer OFF pause then ON a X LLIGHT ON LIGHT FLASHING PRINTER STATUS a Laminator heating up but not yet at operating temperature ENMLZ heaters in sleep mode when not in use the heaters cool at 1 F per minute Ke xt a Printhead temperature error or internal firmware Printhead temperature error or intemal firmware problem o Magnetic encoding write failure LN error conditions including Main cover open Laminator too hot card transport stalled card not seated properly magnetic encoding verification error head lift failure ribbon jam card jam any location card missing any location no gap between laminator patches 980544 003 Rev A P630 P640 Card Printer User s Manual 5 Introduction Controls and Indicators Rear of Printer The Power Connector Power Switch and Interface Connector s are located on the rear of the printer as shown below CE Power Switch CE g E 8 amp AC Power Connector DB9 Serial Interface USB Ethernet Connector for Contact Connector Connector Smart Card Contact Optional Station Optional P630 P640
45. f Printer 2oc3a 4 h56e 4586 RES SE nee SUE EUREN d Ede ESSE 6 ASI EET TTE ee ee MAA ee ee ee TET 7 faniga eloled e p nas aaa IMG KAMA NAE ccuecs INENG GT AA nt see th E ORANG T instalation Procedure suec arat bets DAANG ceo etr o8 heck ba dn Geese aoe ee T Remove the Printer from the Shipping Carton 0 aaa T Remove Shipping Tape 2 ns 10 Attach the Output Hopper ee ee eens 11 Attach the Ribbon Take Up Spool 0 0 0 0 0 eee 11 Connecting Power aaaea eaa ee ee hrs 12 Ribbon Installation 22k awa NGA b44244R84 HOE E Cbd DOC RES SEER EGE ER 12 Installing the Cleaning Cassette nananana anaa eee 16 Loading LamInale cise em xdi ede tate RR URGE dd nose ae D d oa 17 Loading the Laminate Cassette s naana 20 980541 003 Rev A P630 P640 Card Printer User s Manual vii Contents Using Partial Width Laminate llli 22 Installing the Laminator Cassette s a 24 Clearing the Laminate Channels 0 0 0 0 cece eee ene 25 LoadMg Cards AA cee ese cam ede SEE Sees boa eeu een eee bee eee 26 Connecting the Interface eee ne 29 3 Printer Driver Installation 0 31 OVENVIEW AA 31 Installing the Printer Driver USB 2 32 Installing the Printer Driver Ethernet cc ccc eee eee 41 4 Settings and Adjustments ee 51 IMOOUCIION PD 51 Sensors and Interlock Switches aaa 51
46. flip station path Do not try to manually force the flip The printer is reporting a media jam The problem might be lt ts zie a ribbon jam laminate out of position laminate not 2 Close the front Cover The printer will automatically try to advancing properly or a card jammed in the laminator To CARD STUCE IN LAMINATOR lower the flip station correct The printer is reporting that the card is stuck in the If this error occurred during printing the card may need to 1 Open the cover and determine the cause of the jam laminator be reprinted Select Reprint to reprint the card or and clear the problem reck Cancel to cancel the print job rin and the lani m kes For Ribbon Jams a a Ass handling E emper atule o Cancel 2a Remove the jammed or broken ribbon and reinstall the 2 Open the printer cover ribbon into the printer Close the cover if ribbon does 4 Unscrew the heated De mb Carino not automatically resynchronize press the Ribbon REOR hane Tha satis CEPI ES ees button to resynchronize the ribbon moved removed to provide access to the lammation For Laminate Jams RT av Oe RIBBON OUT 2b Remove both cassettes and check reset the laminate 4 Carefully remove card stuck in laminator The printer is reporting a Ribbon Out The problem position to the end of the cassette Make sure to clear 5 Replace heated roller azzermbly cartidge and tighten might also be that the ribbon is jammed To correct laminate from the
47. inate is important for practical and aesthetic reasons The laminate 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 f VA AE A NO 4 PA Note If there is no magnetic stripe on the underside a full width laminate should be used To access the Laminate Station Adjustment screen select Start gt Printers or Printers and Faxes Right click on the Zebra P630i or Zebra P640i printer listing Select Properties gt Device Settings gt Printer Adjustment gt Laminate Station Adjust Laminate Station Adjustment 4 X E rm Length Adjust mil 35 EX 5 2 Cancel 3 Horizontal Offset mils EL __ Cancel Top Laminate LEHGTH ma He 2 elp Heater Temperature E 160 ne Eal Line Voltage Bottom Laminate OFFSET I LEHGTH 1 Auto Length Adjust mile zo C 0v Horizontal Offset mils 3U I U 300v Heater Temperature C 160 EX P630 P640 Card Printer User s Manual 980541 003 Rev A Settings and Adjustments Laminator Station Adjustments Length Adjust mils This is the length of the laminate patch If the patch is too long decrease this number and vice versa Horizont
48. istency it is recommended that the identical operating system and settings be used on all computers generating print jobs 980541 003 Rev A P630 P640 Card Printer User s Manual Zr 78 Troubleshooting System Related Issues P630 P640 Card Printer User s Manual 980541 003 Rev A Technical Specifications 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 sublimation 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 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 Laminating system P640i Separate laminators for front and back surfaces of card P6301 Single laminator for front surface of card 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 Parall
49. l an Ethernet Printer and Driver Uninstall Printers and Drivers Install Uninstall ID Print Lite a simple card printing application Yew Print Instructions Requires a POF reader such as Adobe Acrobat Yew Print Release Mates Requires a test reader such as Notepad N9 Card IN Printer Sec Solutions P630 P640 Card Printer User s Manual 980541 003 Rev A Printer Driver Installation Installing the Printer Driver Ethernet Step 5 This will bring up the End User License Agreement To proceed with the installation click Accept End User License Agreement License Agreement END USER LICENSE AGREEMENT FOR ZEBRA TECHNOLOGIES SOFTWARE AMD OR FIRMWARE IMPORTANT READ CAREFULLY Be sure ta carefully read and understand all of the rights and restrictions described in this zebra Technologies End User License Agreement EULA You will be asked to review and either accept or not accept the terms of the EULA This software and or firmware will not install on your computer unless or until you accept the terms of this EULA Tour click of the ves button is a symbol of your signature that vau accept the terms of the EULA For your reference You may refer ta the copy of this EULA that can be found in the Help for this software andor firmware You may also receive a copy of this EULA by contacting the ebra Technologies subsidiary serving your country or write Zebra Technologies 333 Corporate Woods P
50. late P640 only Hot Surface If the printer has been in use the Heater Cores area of the Laminator may be hot Important If either Latch Plate is opened even unintentionally the corresponding Cassette must be removed and the Laminate reeled in 18 P630 P640 Card Printer User s Manual 980541 003 Rev A Installation Installation Procedure Caution If you feel resistance when 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 the cassette which will come free with a short tail of laminate Step 2 Temporarily remove the corresponding Transfer Guide to be sure there are no scraps of laminate remaining If there are any remove them Then slide the Transfer Guide back in until it is held in place by the Retaining Clip 1 Push the Retaining Clips A to the Left 2 Slide the Transfer Guides B Straight Out Step 3 Open the Cassette like a clam shell by separating its two halves Grasp the two halves firmly with your fingers then pull it apart Do NOT use tools Upper Cassette shown 980544 003 Rev A P630 P640 Card Printer User s Manual 19 20 Installation Installation Procedure Step 4 If there is an empty laminate core in the Cassette remove it Loading the Laminate Cassette s Important If you are using partial width laminate in the Lower Cassette of a P640 Printer read the followi
51. mask If you are not sure how to verify this or change the configuration consult someone knowledgeable on Ethernet Networks Step 1 Connect the printer power and connect the Ethernet Port on the rear of the printer to an Ethernet Network Port Turn the Printer on and let it initialize until the READY LED on the front panel is lit Step 2 Insert the User Documentation Drivers and Training CD into the CD drive of the host computer The Select Language window will open WA ra Please Select Language rd e i Solutions Exit Step 3 From the Select Language window click on the appropriate language for your system The Main Menu will open in the selected language English shown below 980541 003 Rev A P630 P640 Card Printer User s Manual 41 42 Printer Driver Installation Installing the Printer Driver Ethernet 4 Card z GG ini Security Line N41 TE8 Solutions Printer Driver Documentation Support Install Printer Driver User s Manual Register Your Product gt Install Adobe Acrobat gt Warranty gt Media List gt Sample Card Images gt Web Site User Training Exit Requires Acrobat Requires active internet connection 2005 2006 ZIH Corp Step 4 From the Main Menu click Install Printer Driver The Printer Setup window will open Click Install an Ethernet Printer and Driver Printer Setup Install a USB or Parallel Printer and Driver Instal
52. ned on and the READY LED is lit then click Next gt Then click Next gt This will bring up the Add Printer Software Wizard as shown on the next page 46 P630 P640 Card Printer User s Manual 980541 003 Rev A Printer Driver Installation Installing the Printer Driver Ethernet Add Printer Wizard Install Printer Software The manufacturer and model determine which printer software to use N A Select the manufacturer and model of your printer IF your printer came with an installation Ka disk click Have Disk IF pour printer is not listed consult pour printer documentation for compatible printer software Manufacturer Printers Atlantek Zebra P amp 20 Zebra Technologies Zebra PAO Zebra P640i Zebra PE3lI ity This driver is not digitally signed Windows Update Tell me why driver signing is important Select the Manufacturer Zebra Technologies and the printer model number then click Next gt Step 13 This brings up the Name Your Printer screen Add Printer Wizard Mame Your Printer Tou must assign a name to this printer Type a name for thiz printer Because some programs do not support printer and server name combinations of more than 31 characters itis best to keep the name as short az possible Printer name Do you want to use this printer as the default printer Q Yes 9 Ng Verify that the printer name is correct Specify if you want to use this printer
53. net Port x Printer Info DK Model Mame P640 MAC Address 00 07 4d 00 00 00 Cancel Serial Number 405056 Configure Printer Printer IP Address 10 1 3 Timeouts 5000 Read Timeout ms 5000 Write Timeout m Then click OK P630 P640 Card Printer User s Manual 980541 003 Rev A Printer Driver Installation Installing the Printer Driver Ethernet Step 9 This brings up the Add Printer Wizard Click Next gt Add Printer Wizard Welcome to the Add Printer Q Wizard This wizard helps vou install a printer or make printer connections i If You have a Plug and Play printer that connecte through a USB port or any other hot pluggable port such as IEEE 1384 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 pour computer or point the printer toward your computer s infrared pork and turn the printer an Windows will automatically install the printer Far you To continue click Hert Cancel Step 10 The next screen lets you specify the type of printer to set up Select Local printer attached to the computer Automatically detect and install my Plug and Play printer should be un checked Then click Next gt 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 printe
54. ng section Using Partial Width Laminate before proceeding with this procedure Partial width laminates are frequently used on the bottom surface of cards that have a signature panel or a magnetic stripe Important The Upper and Lower Laminate Cassettes the lower one only used on the P6401 Printer the upper one used on both printers are loaded differently even though the Cassettes appear virtually the same Note Handle the laminate by the ends of the spools only to avoid contaminating the laminate Step 1 Remove the new roll of laminate from its packaging Step 2 Carefully following the guidelines in the following figure place the laminate in the Cassette P630 P640 Card Printer User s Manual 980541 003 Rev A Laminate Unrolls d O a Under Spool ma Sg N 4 Installation Installation Procedure Upper Cassette Used on Both P630 and P640 White Roller Up Notched End of Spool to Left Ng UL h Laminate Unrolls Over Spool Tak Step 3 Step 4 Step 5 Step 6 980541 003 Rev A Notched End of Spool to Right White Roller Down Lower Cassette Used on P640 Only Pull out an inch or two of laminate past the lip of the cassette Close the cassette by firmly pressing the clamshell together You will hear a click and feel a detent when the halves of the cassette seat together Pull out a little more laminate between the lips of the cassette If it suddenly stops resis
55. ngs General Color Management Group or user names FT CREATOR OWNER n Everyone rr Power Users DT W PTBURTON Power Users Add Remove Permissions for Administrators Allow Deny Print Manage Printers Manage Documents O O O O O Advanced coed Special Permissions For special permissions or for advanced settings click Advanced 56 P630 P640 Card Printer User s Manual Color Management settings allow you to associate color profiles on the printer based on the type of media being used and printer configuration The Add button allows the operator to add additional profiles to the color profile list Automatic Allows Windows to select the best color profile Manual Allows the operator to select the desired profile from the list shown in the Color Profile Window 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 printer 980541 003 Rev A Device Settings General Sharing Ports Advanced Device Settings Color Management Security Maintenance These maintenance screens are used primarily to calibrate the printers at the Factory Madifying these values could cause undesirable results Printer Adjustment Status The status screen displays the current state of the printer which is updated every few seconds
56. nt of the Transfer Guide can cause laminate skewing and misfeeding Be sure the Transfer Toggle is set to RUN Take care to avoid damaging the Transfer Roller ribs when replacing the Transfer Guide Loading Cards The P6301 and P6401 Printers use standard ISO CR 80 PVC Composite cards Do not use cards with a paper or peel off adhesive backing e Size 54 x 86 mm 2 125 x 3 375 in 10 Thickness 75 mm 03 in 10 frequently referred to as 30 mil cards Important Do not bend cards or touch the print surfaces as this can reduce print quality The surface of the cards must remain clean and dust free Always store cards in an enclosed container Ideally use cards as soon as possible Step 1 Open the Card Feeder Cover 26 P630 P640 Card Printer User s Manual 980541 003 Rev A Installation Installation Procedure Step 2 Remove all wrapping from the card deck A Caution Do not touch print surfaces of the cards this can reduce print quality Step 3 Holding the card deck by the sides hold it vertically against a flat surface such as a desktop If the deck is too thick for your hand to hold it comfortably use about half a deck at a time i A Tma Step4 Push the stack back and forth to an angle of about 45 from vertical so as to separate all of the cards Important Static charges and edge burrs from the card die cutting process can render individual cards stuck toge
57. of laminate onto the transfer roller If laminate does not feed automatically press the LAMINATE button on the printer control panel Laminate Channels scissor cuts were neat enough to pass for machine made cuts continue with printing cards If not don t waste a print cycle Instead remove the hand cut patch es from the Transfer Roller s as follows Note Clearing procedures for the upper and lower laminate channels are similar The upper channel is shown here Removal of the Transfer Guide gives access to the Transfer Roller Step 1 Step 2 Step 3 Step 4 Step 5 980541 003 Rev A Retaining Springs Transfer Guides Transfer Toggle Shown in Normal RUN Position Set to OPEN Only When Specified OPEN J Push the Retaining Spring to the left pull the Transfer Guide straight out toward you Remove and discard the laminate patch on the Transfer Roller Never re use Turn the Transfer Toggle to the OPEN position Remove any laminate between the Transfer Rollers Return the Transfer Toggle to the RUN position P630 P640 Card Printer User s Manual 25 Installation Installation Procedure Step 6 Re install the Transfer Guide with its top edge above the laminate cutter guide Pull back the retaining spring while re inserting the guide then release the spring as you push the guide into position Press the LAMINATE button to load the Transfer Roller s Important Improper replaceme
58. olor Management Security Device Settings i f re face aea Poe Advanced relative to the most recent job Printing aao o r Defaults allows the system administrator to C Available from 12004M To i200 M establish default settings such as print Priority E quality Driver Zebra PE4Ui New Driver Spool print documents so program finishes printing Faster C Start printing after last page is spooled Start printing immediately C Print directly to the printer Hold mismatched documents v Print spooled documents first Keep printed documents v Enable advanced printing features Printing Defaults Print Processor Separator Page 980541 003 Rev A P630 P640 Card Printer User s Manual 59 Settings and Adjustments Printer Properties Color Management zixl Ports Advanced Security Device Settings General Sharing Color Management Al These settings let you associate color profile s with your color printer Color profiles control the color on your printer based on the type of media being used and the printer configuration C Manual Manually select the default color profile for all output from this device from the list of associated color profiles Default color profile Manes Color Profiles currently associated with this printer Remove Set oe Default Security zixl Sharing Forts Advanced Security Device Setti
59. or Card Printer w Dual Linerless Laminator P640iS Dual Sided Color Card Printer w Dual Linerless Laminator with Advanced ID Key Security Feature Smart Card Options None Contact Encoder Contact encoder amp MIFARE contactless Contact Station MIFARE contactless Magnetic Encoder None Yes select defaults below Magnetic Encoder Defaults None otripe Up HiCo Interface USB Standard Configuration USB amp Built InEthernet 10 100T USB and Parallel Minimum Printer Order Applies Power Cords 120V A C US amp 230V A C European U K and Australia Windows Drivers and User Documentation Training Windows Driver CD Win 2K and XP amp User Documentation amp Training CD RoHS Compliant 980544 003 Rev A P630 P640 Card Printer User s Manual V vi Foreword P630 and P640i Printer Models P630 P640 Card Printer User s Manual 980541 003 Rev A Contents Fe oc eo ee a a ee AA i Copyright Notice 0 0 0 RR Rh i TrademarkS s cx aaa iezzes ues ERR UE cae obs Sum LAHAR des baw EGO UR LANA Rr m ORA NG i Return Materials Authorization naaa aaa RR RR iI Declarations of Conformity aaa ii les 2 Sn Gee AA AA IV P630i and P640i Printer Models a V LEi rae e i eie AA AA AP ORE QR CIE AA 1 Fite E ARA 2 Controls and Indicators lle RR RR RR rer 3 Control Panel Buttons RR RR RR RR RR rn 3 Control Panel Indicators RR RR IRR Rc 5 Rear o
60. ot connected to your network TI Vill P630 P640 Card Printer User s Manual 98054 1 003 Rev A Contents Valid host name has not been assigned to the printer l l 77 Color differences may be attributable to the Windows operating system installed 77 6 Technical Specifications 0 0c ees 79 P640i Specifications 0 0 ee ee ee eee eee 79 Appendix A Magnetic Encoder slllleenlnne 81 Magnetic Card Stripe Encoder 0 0 a 81 ISO Standard Encoding 0 aa 81 AAMVA Standard Encoding a 82 Magnetic Encoder Cleaning aa 82 Media Loading Orientation ccc eee eens 82 Appendix B Smart Card Contact Station es 83 IUOGUCHON cT 83 Media Loading Orientation aaa aaa aaa eee eee ees 83 Laminating Smart Cards eee eee ees 84 Appendix C e Printer Security 0 000 eee eee 85 OKC P 85 Replacing a Lost ID Key 0 0 0 aa 85 Printer Parameters in the Driver aaa 86 ID COde PARA PP AA AA AA 86 Update Backup Config cc ee eh 86 Restoring the Backup Configuration Settings AA 86 Password Protection aaa 87 Appendix D Worldwide Sales amp Support 89 Sales and Support Locations 0 0 0c e 89 Corporate Headquarters 1 0 ke aaa 90 WED ds pha BG LEG NAWA TT
61. ply 54 P630 P640 Card Printer User s Manual 980541 003 Rev A Settings and Adjustments Printer Properties Ports NG Specifies the computer port to which the Color Management Security Device Settings P630i or P640i connected This will have General Sharing Pots Advanced been established at the initial installation of the printer and will not normally require S MD attention Print to the following ports Documents will print to the first free checked port An exception to this is if you wish to use ot Ipe lp de printer pooling the ability to distribute C COM1 Serial Port print jobs to multiple printers To enable na nig printer pooling check the Enable Printer C COM4 Serial Por Pooling box then check multiple ports mga ABALA aa PA Each port should have a single Zebra printer e UNTERE TRETEN installed on it and all printers should be Ee SS configured identically for example all with M Enable bidirectional support YMC front K back Now when you print to Lt ees ES 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 Cancel Aer take Remaining jobs will then spill over to other printers until all printers in the pool are busy Advanced zx Determines the spooling queuing of print jobs and how spooled jobs are handled C
62. r Optional Optional 980544 003 Rev A P630 P640 Card Printer User s Manual 29 30 Installation Installation Procedure P630 P640 Card Printer User s Manual 980541 003 Rev A Printer Driver Installation Overview Each computer that will use the P630 or P6407 Printer must have the Printer Driver installed A common Printer Driver serves both P630 and P640i Printers To install the Printer Driver insert the User Documentation Drivers and Training CD included with your printer into the host computer and the InstallShield Wizard will walk you through the required installation steps The InstallShield Wizard will e Automatically install the User Interface when the driver CD is inserted e Start the installation process when the Install Printer Driver menu item is selected from the Main Menu Allow you to install either a local printer and driver or a networked printer and driver e Detect previous versions of the driver and clean up any unnecessary Windows registry entries You must select Uninstall Printers and Drivers in the Printer Setup window to remove any previous driver versions e Install the new driver files e Reboot your computer 980541 003 Rev A P630 P640 Card Printer User s Manual 31 Printer Driver Installation Installing the Printer Driver USB Installing the Printer Driver USB Note To install the Ethernet driver see the procedure starting on page 41 Step 1 Connec
63. r the P630i Printer has only the Upper Laminator If either or both of the laminate transfer rollers is not loaded with a laminate patch then pressing the LAMINATE button will correct the condition provided the cassette is not out of laminate and if the cassette latch is closed locked If both transfer rollers are already loaded the LAMINATE button has no effect If you hold the LAMINATE button down and power up the printer it toggles on off the Ribbon Syncronization feature when the printer is powered up A typical use of the LAMINATE button is in reloading a transfer roller after removing the first hand cut patch of laminate following installation of a fresh roll P630 P640 Card Printer User s Manual 980541 003 Rev A Introduction Controls and Indicators Control Panel Indicators Depending on the condition they are reporting the three indicator lights READY MEDIA and ALARM can be in one of three states Off On steady or Flashing o Note The READY indicator is bi colored Its two color channels green and yellow y 7 function independently READY Indicator Steady Ready to print Flashing Printer busy Yellow Steady Laminator s in sleep mode Flashing Laminator s not at operating temperature MEDIA Indicator Normal Steady Any media outage Flashing Magnetic encoding failure ALARM Indicator Normal Steady Error condition requiring intervention Flashing Printhead temperature
64. r attached to this computer CO A network printer or a printer attached to another computer 4 To set up a network printer that is nat attached to a print server J use the Local printer option Click Next gt 980541 003 Rev A P630 P640 Card Printer User s Manual 45 Printer Driver Installation Installing the Printer Driver Ethernet Step 11 The Add Printer Wizard Select a Printer Port screen will now appear Add Printer Wizard Select a Printer Port Computers communicate with printers through ports Select the part you want pour printer ta use If the port iz nat listed you can create a new pork 3 Use the following port Note Most computers use the LPT1 part to communicate with a local printer The connector for this port should look something like this O Create a new port Step 12 Click on Use the following port scroll to ENETxxx Zebra Ethernet internal where xxx is the number of the port any Zebra Ethernet port number can be used Add Printer Wizard Select a Printer Port Computers communicate with printers through ports Select the port you want pour printer to use IF the port is not listed vou can create a new port Use the following port SSSR E EE NE ETT Note Most computers use the LPT1 port to communicate with a local printer The connector for this port should look something like this CO Create a new port Check that the printer is tur
65. r filled geometric shapes Monochrome Bitmaps 1 bit bitmaps every pixel either black or white Color Bitmaps Full 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 1s the precedence stacking order of the various element types in the event that one or more of them overlap P630 P640 Card Printer User s Manual 63 Settings and Adjustments Color Calibration 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 1s 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 Color Calibration xj Color rendering in the printer can be ET described in terms of a curve which OR NM a HOD z determines how much power is put DE TN Cancel into the printhead for a given shade peade mx 3
66. rd Windows will search for current and updated software by looking on your computer on the hardware installation CD or on the Windows Update Web site with your permissian Can Windows connect to Windows Update to search for software CO Yes now and every time connect a device CO No not this time Click Nest to continue Step 15 The next window helps install the software driver Select Install the software automatically Recommended and then click Next 5 Found New Hardware Wizard This wizard helps you install software Far ZEBRAPBALI If your hardware came with an installation CD g3 on floppy disk insert it now What do you want the wizard to do CO Install from a list or specific location Advanced Click Nest to continue Step 16 The Wizard will search for the Printer The screen that appears while searching appears on the next page 38 P630 P640 Card Printer User s Manual 980541 003 Rev A Printer Driver Installation Installing the Printer Driver USB Found Hew Hardware Wizard Please wait while the wizard searches a ZEBRAPEADI Cancel Step 17 When the Wizard finds the Printer it may display a window referring to 980541 003 Rev A compatibility as shown below If so click Continue Anyway Hardware Installation The software vou are installing for this hardware Printers has not passed Windows Logo testing to very its compatibility with Windows sP
67. rent settings available Click the Reset Brightness Contrast to Defaults button to restore default conditions eed dme Ee DRIVER S LICENSE No 123 32 4321 Exp 11 30 2005 ag STATE DRIVER S LICENSE Contrast 25 Brightness 50 Contrast O Brightness 50 Contrast 50 a gt Brightness 25 STATE DRIVER S LICENSE Operator No 123 32 4321 Exp 11 30 2005 Lic No 123 32 4321 Exp 11 30 2005 Caroline T Thomas 12 Brown Street Kingston ST 02222 SS 987 00 1234 Wt 112lbs Ht 5 2 Sex F Hair Brown Eyes Blue Class A Restrictions B CDL N A Date Of Birth 12 02 71 Contrast so MNEEEEENM Brightness 75 Eyes Class A Restrictions B CDL N A 12 02 71 Contrast75 Brightness 50 aa Contrast 50 a Brightness 50 eae STATE DRIVER S EE Qum T gt ear 12 Brown Street Kingston ST 02222 SS amp 987 00 1234 Wt 112lbs Ht 5 2 Sex F Hair Brown Eyes Blue Class A Restrictions B CDL N A Date Of Birth 12 02 71 Contrast 100 Brightness 50 free 980541 003 Rev A P630 P640 Card Printer User s Manual 61 62 Settings and Adjustments Printing Preferences YMC Color Printing A xl Image Adjustment Magnetic Encoding ID Lag Advanced About Card Setup YMC Color Printing K Black Panel l3 Zebra P640i Copy 1 Printing Preferences C Low Quality 16 bits per pisel ee
68. ressing the LAMINATE button 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 damage the heated rollers Check upper and lower laminate sensor readings with and without laminate present 20 if present gt 180 if absent numbers valid only if transfer guides installed Quality Problems Important Operator should contact Zebra Card Printer Solutions Customer Service before changing any factory settings within the printer Poor color registration 980541 003 Rev A 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 For gross mis registration of Y M and C suspect that the card not firmly positioned against left hand pick edge of truck on one or more passes Spring at left end of platen may be missing or bound up Check printed card for damage on corners or edges Example the card may be scraping along the underside of the hopper base molding Printhead pressure too light Printhead may be running hot Will occur if head resistance incorrectly entered in driver software Toothed transport belt pulley may be slipping on drive shaft Tighten set screws make sure the screws bear on flats on the shafts
69. s Manual 980541 003 Rev A Appendix C Printer Security The optional ID Key is a physical security key that is programmed for each specific P630i or P640i printer It is intended to prevent unauthorized use of that printer 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 1s detected the printer is disabled 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 a key safe Replacing a Lost ID Key Important If the ID Key is removed during a card printing session the printer will cease to operate after the current batch of cards is printed 980541 003 Rev A P630 P640 Card Printer User s Manual 85 Printer Security Printer Parameters in the Driver 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 Printer Parameters in the Driver ID Code The ID Code or password synchronizes the driver
70. stalling the Printer Driver USB Step 7 This will bring up the End User License Agreement To proceed with the installatiion click Accept End User License Agreement License Agreement END USER LICENSE AGREEMENT FOR ZEBRA TECHNOLOGIES SOFTWARE AMD OR FIRMWARE IMPORTANT READ CAREFULLY Be sure ta carefully read and understand all of the rights and restrictions described in this zebra Technologies End User License Agreement EULA ou will be asked to review and either accept or not accept the terms of the EULA This software andor firmware will not install on your computer unless or until you accept the terms of this EULA Tour click of the ves button is a symbol of your signature that vau accept the terms of the EULA For your reference You may refer ta the copy of this EULA that can be found in the Help for this software andor firmware You may also receive a copy of this EULA by contacting the ebra Technologies subsidiary serving your country or write Zebra Technologies 333 Corporate Woods Parkway Veron Hills Ilinois 60061 United States of America This EULA is a legal agreement between you either an individual or a v Reject Step 8 This will bring up the Add Zebra Printer Port window Select the USB Port and then click Next gt gt Add Zebra Printer Port x Please choose your printer s interface t Parallel Port Ethernet External Converter 980541 003 Rev A P630 P640 Car
71. standard printer information and sensor data which is updated every few seconds Printer Information E E P630 P640 Card Printer User s Manual 980541 003 Rev A Settings and Adjustments Printing Preferences Control The following procedures can be performed from the Control screen Printer Control X i Close Advance Laminate Help Run Clean Cycle Print Test Card Clear Error Print Control Reprint Last Card Copies ero Buffer Count Receive Print Advanced Utilities Printing Preferences Advance the Ribbon Advance the laminate Run a cleaning cycle Print a test card Clear an Error Reprint the last card and select number of copies Zero the buffer Select advanced utilitles such as a 0 nc oOo C O O E C Flip Test 1 Flip Test 2 Flip Pause Move carriage Calibration Update the backup configuration Upgrade the firmware Send the features file Control the Password Control the ID Code k Disable the control panel buttons Set the printer status The Preferences screens the operator may be asked to refer to and or modify are Card Setup Image Adjustment YMC Color Printing and K Black Panel To access the Printing Preferences screens select Start gt Printers or Printers and Faxes then right click Zebra P630i or Zebra P640i printer and select Printing Preferences or Properties 980541 003 Re
72. t power cord could cause equipment damage result in an electrical fire or possibly cause injury Step 3 Plug the power cord into the printer s power connection and a grounded AC power source connection Step 4 Turn the printer on by setting the Power Switch to ON D Ribbon Installation Note In normal printer operation when the ribbon is exhausted a warning message appears on the monitor and the MEDIA indicator on the printer lights P630 P640 Card Printer User s Manual 980541 003 Rev A Installation Installation Procedure Step 1 Open the printer Main Cover The printhead will raise for easy ribbon loading Step 2 Remove the ribbon from its packaging Remove the tape that holds the end of the ribbon save this tape it will be used shortly Step 3 Install the Ribbon on the left supply spindle with the free end of the ribbon coming from the roll pointing down to your right Note that the flanged end of the ribbon spool is toward the rear of the printer and make sure the internal grooves on the core engage the teeth on the supply spindle 980544 003 Rev A P630 P640 Card Printer User s Manual 13 14 Installation Installation Procedure Step 4 Route the Ribbon as shown in the figure below The Ribbon Supply Spindle is free wheeling pull ribbon off it as needed If the tape removed from the new ribbon in step 2 is undamaged use it to attach
73. t the printer power and connect the USB port on the rear of the printer to the computer s USB port Turn the Printer on and let it initialize until the READY LED on the front panel is lit Step 2 The Windows Found New Hardware screen will appear at this time Click Cancel Step 3 Insert the User Documentation Drivers and Training CD into the CD drive of the host computer The Select Language window will open WU te Card MA Printer Please Select Language AMAL Solutions an Exit Step 4 From the Select Language window choose the appropriate language for your system The Main Menu will open in the selected language English shown below 32 P630 P640 Card Printer User s Manual 980541 003 Rev A Printer Driver Installation Installing the Printer Driver USB 4 Card GG inia Security Line N41 TE8 Solutions Printer Driver Documentation Support Install Printer Driver User s Manual Register Your Product gt Install Adobe Acrobat gt Warranty gt Media List gt Sample Card Images gt Web Site gt User Training Exit Requires Acrobat Requires active internet connection 2005 2006 ZIH Corp Step 5 From the Main Menu click Install Printer Driver The Printer Setup window will open Printer Setup Install a USB ar Parallel Printer and Driver Card Printer Solutions 980541 003 Rev A P630 P640 Card Printer User s Manual 33
74. tation Security Key Optional Card Feeder Output Control o Hopper Panel oS libo C E Print Head Laminator Station P640 Magnetic Encoder Optional Laminator Station P6301 O OO O 6 Q B e 9 nan O CO NETO e l 175 KYUN 9 5 o rp 9 TD ES CS O Power Switch AC Power Connector 2 P630 P640 Card Printer User s Manual 980541 003 Rev A Introduction Controls and Indicators Controls and Indicators Control Panel Buttons A limited amount of control and status information is available at the Control Panel on the front of the printer Additional control functions and status information is available via the host or networked computer s Buttons Indicators 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 nasus WR i i E Ww wi 8 mma os a E i In regular on line use the PRINT button reprints the last image downloaded from the computer to the buffer memory If you hold the PRINT button down and power up the printer the Ribbon Syncronization feature which normally
75. ted Events e Color ribbon torn or jamming intermittently Clear jam Pull out more from supply roll and reattach to takeup roll YMC color panels stick to card e Printhead running too hot Can happen after head replacement if head resistance incorrectly entered through printer driver Contact Zebra Customer Service e Color gain and offset too high Contact Zebra Customer Service Check ribbon takeup and supply torques Contact Zebra Customer Service K Black panel sticks to card e Printhead running too hot Can happen after head replacement if head resistance incorrectly entered through printer driver Contact Zebra Customer Service Black panel density and or preheat set too high Contact Zebra Customer Service Check ribbon takeup and supply torques Contact Zebra Customer Service e Color image printing with K black panel Check selections made in Printing Preferences Loud rattling screeching from card transport e Card 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 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 Rattling noise every 10 cards Cleaning cassette not firmly engaged Cleaning cassette broken or cassette halves separated Cleaning cassette
76. ted municipal waste This product is recyclable and should be recycled according to your local standards For more information please see our web site at http www zebra com environment Return Materials Authorization Before returning any equipment to Zebra Technologies Corporation for in warranty or out of warranty repair contact Repair Administration for a Return Materials Authorization RMA number Repack the equipment in the original packing material and mark the RMA number clearly on the outside Ship the equipment freight prepaid to the address listed below e For USA Latin America and Asia Pacific Zebra Technologies Corporation Zebra Card Printer Solutions 1001 Flynn Road Camarillo CA 93012 8706 USA Phone 1 805 578 5001 FAX 1 805 579 1808 e For Europe and Middle East Zebra Technologies Corporation Zebra Card Printer Solutions Pittman Way Fulwood Preston PR2 9ZD Lancashire U K Phone 44 1 772 797555 FAX 44 1 772 693000 P630 P640 Card Printer User s Manual 980541 003 Rev A Foreword Declarations of Conformity Declarations of Conformity 80 336 EEC EMC Directive EN 55022 1998 RF Emissions control modified by EMC Directive EN 301489 3 V1 4 1 RF Emissions and Immunity for radio 92 31 EEC and equipment 93 68 EEC EMC Directive EN55024 2001 Immunity to Electro Magnetic Disturbances 73 23 EEC modified Low voltage EN 60950 1 2001 Product safety by 93 68 E
77. the end of the ribbon to the Take Up Spool otherwise use other adhesive backed tape Important When the end of the ribbon is attached to the Take Up Spool any slack in the ribbon can be taken up by rotating the Ribbon Supply Spool do not try to turn the Take Up Spool Bg P630 P640 Card Printer User s Manual 980541 003 Rev A Installation Installation Procedure 4 Attach Ribbon to Take Up Spool 2 With Tape y 1 Pass Ribbon l o Over the Round SR Z z 7 Guide Bar E 6 O O UESN Fore si 2 Ribbon Goes Through the Ribbon Sensor Step 5 Close the printer main cover then press the RIBBON button on the Control Panel to initialize the color ribbon If the MEDIA light fails to go out check the ribbon sensor A Important Color ribbon wrinkling and fold over can seriously affect print quality 980541 003 Rev A P630 P640 Card Printer User s
78. ther with significant adhesion force These cards must be physically separated from each other before inserting into the Card Feeder if not separated feeding or printing problems may occur Step 5 Restore the card stack to its original squared off condition and place the cards in the input hopper The input hopper can hold up to 150 cards Note Cards with a Magnetic Stripe should be loaded with the stripe up and toward the front of the printer as shown in the figure below 980544 003 Rev A P630 P640 Card Printer User s Manual 27 Installation Installation Procedure stack Step 6 Place the Card Weight on top of the card Step 7 Close the Card Feeder Cover 980541 003 Rev A P630 P640 Card Printer User s Manual 28 Installation Installation Procedure Connecting the Interface The P630i and P640i Printers have a USB interface as standard As options must be specified at time of order the printer can additionally have a 10 100T Ethernet port for connection to an Ethernet Network or a parallel Centronics port Normally only one interface at a time will be connected 6 USB Ethernet Parallel Connector Connector Connecto
79. ting further pulling a spring detent on the cassette has probably snagged a notch on the end of the core This means that the core was installed the wrong way Open the cassette and re install the laminate If the exposed end of the laminate is uneven or crinkled cut it as square as you can with scissors P630 P640 Card Printer User s Manual 21 22 Installation Installation Procedure NON NA Step 7 Holding the cassette 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 1s even with the edge of the lips of the cassette Important Check for overhang any time the cassette latch is opened or the cassette is removed Using Partial Width Laminate o Note Since partial width laminates are only used for the back 1 e lower surface of the y 7 card this section only applies to the P640 Printer Laminate come in three widths Full Width laminate is 2 in 51 mm wide Full width laminate is used on the front i e upper or back 1 e lower surface of the card Partial Width laminate is available in two widths e 1 66 in 42mm wide laminate is used for cards with a writable signature panel e 1 33 in 33 mm wide laminate is used for cards with a magnetic stripe If there is no signature panel or magnetic stripe on the back of the card full width laminate would generally be used P
80. tput Hopper is positioned on the right side of the printer to receive the printed cards Install the Output Hopper by inserting the tab on the side of the Output Hopper into the slot on the right side of the printer Attach the Ribbon Take Up Spool Step 1 Attach the Ribbon Take Up Spool by sliding it onto the Ribbon Take Up Spindle and pressing it straight back until in clicks into place Important Make sure that the Ribbon Take Up Spool is attached with its toothed end toward the rear of the printer 980544 003 Rev A P630 P640 Card Printer User s Manual 11 12 Installation Installation Procedure Connecting Power The AC Power is connected and turned on so that in the next procedure Ribbon Installation when the printer s main cover is opened the Print Head will raise automatically i Power Switch Step 1 Verify that the printer s Power Switch is set to OFF O Step 2 Select the proper power cord for the local ac power source from the accessories that are shipped with the printer Caution If you do not have the proper power cord for your local power source or if the power cord appears frayed or damaged in any way or if the power cord will not securely plug into the printer s power connection or the source outlet STOP Use of a damaged or incorrec
81. v A P630 P640 Card Printer User s Manual 59 Settings and Adjustments Printing Preferences Card Setup From the Card Setup screen the operator can adjust the following settings l3 Zebra P640i Copy 1 Printing Preferences 2 xl Image Adjustment Magnetic Encoding ID Lag Advanced About Card Setup YMC Color Printing Image Size CR 20 Standard 578x552 pixels Cards zebra Card YMC Color K Black FF ir fe C Off amp Front Front and Back v Disable Laminator Sleep Mode s Portrait ET Ka Portratt Landscape Landscape Rotate Image 180 Back Orientation Same as Front Rotate Image 180 K Black Panel eed dme P630 P640 Card Printer User s Manual 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 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

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