Zebra P520i
Contents
1. Only 30 mil cards should be used when the card is to be laminated Use 30 mil composite cards whenever possible to ensure compliance of the finished card to ISO flatness guidelines PRINT RIBBONS VS LAMINATIOR COMPAIBILITY PRINTING STATION LAMINATOR COMPATIBILITY Part Numbers Description Patch 1 mil Patch 0 6 mil Full Overlay 012 to 017 135 to 138 125 amp 131 800015 101 to 109 Monochrome Ribbon no yes yes 800015 440 amp 540 YMCKO no no yes 800015 445 amp 545 YMCK yes yes no 800015 448 YMCKOK no no yes 800015 450 Kdye O no no yes 800015 460 KO no no yes 800015 470 YMC yes yes no 800015 480 YMCKK yes yes no 800015 443 amp 543 YMCUvK nor no yes NOTE These ribbons can possibly be used without using the O Panel These ribbons can only be used with the full overlay Part Number 800015 125 and not with the 800015 131 e APPENDIX C AVAILABLE PATCH RIBBONS Part Number Description Patch 1 mil Carrier Based Rolls Cards roll 800015 012 clear patch for cards w mag stripe 100 800015 013 clear patch for smart cards 100 800015 014 clear full coverage patches 100 800015 031 clear full coverage alternating wWITH mag stripe 100 50 cards 800015 032 Genuine Secure Hologram Image Patches 1002. Da US rue uen DO 02 q 1 STROBE os 7 2 DO z 3 D1 m 4 D2 se 5 D3 AG En gt 6 D4 SL es 8 D6 GND 9 3 N a O PE SLCT AUTO FEED ERROR INIT SLCT IN 19 30 33 GND Note The printer pins number 15 16 18 30 34 35 are not connected B TECHNICAL SPECIFICATION APPENDIX Magnetic Card Stripe Encoder This section contains information on the additional operations of the P520 Printers with Magnetic Card Stripe Encoder See Chapter 2 for location INTRODUCTION Operation and maintenance requirements for the P520i Printer with the optional magnetic card stripe encoder See Chapter 2 for location The magnetic encoder can be set for either high or low coercivity APPENDIX A B A MEDIA LOADING ORIENTATION Note M1 Stripe Down HICO The magnetic encoder is a factory installed item with the read write head positioned below the card path available with HICO encoding or LOCO enco ding When loading cards into the Card Cartridge please ensure that the magnetic stripe is facing down and closest to the rear Also available are Printer models with the Magnetic Read Write head positioned above the card path with HICO encoding or LOCO encoding When loading cards please ensure that the magnetic stripe is facing up and closest to the rear M3 Stripe up HICO M2 Stripe Down LOCO M4 Stripe up LOCO approved HICO amp LOCO PVC cards are availabl
3. Except the character Including Start Stop and LRC characters Also note that these 3 characters are automatically managed by the magnetic encoder according to the ISO Standard norms NOTE Refer to the Card Printer Programmer s Manual for complete programming information APPENDIX A B Fas APPENDIX A APPENDIX Smart Card Contact Station This section contains information on the additional operations of the P520 Printers with Smart Card Contact Stations See Chapter 2 for location INTRODUCTION Your P520i may be equipped with an optional Smart Card contact station Smart Cards can store fingerprints voice recognition patterns medical records and other such data This printer model basically responds to commands that position the cards to the contact station where the printer connects the pins to the contacts connector on the Smart cards An external encoder reader is necessary for programming Smart Cards ISO 7816 All other printer operations remain the same as the standard P520 model APPENDIX B E A MEDIA LOADING ORIENTATION Position the cards with the Smart Card Chip at the top of the card and towards the printer B SMART CARD CONTACT STATION INTERFACE When a command to the parallel printer interface sends a card to the Smart Card Contact Station the printer connects the Smart Card Contact Station to the female DB 9 connector on the rear of t
4. Consult the dealer or an experienced radio TV technician for help The user may find the following booklet prepared by the Federal Communications Commission helpful How to identify and resolve Radio TV Interference Problems This booklet is available from the U S Government printing Office Washington D C 20402 Stock No 004 000 00345 4 Use of a shielded cable is required to comply within Class B limits of Part 15 of FCC Rules Pursuant to Part 15 21 of the FCC Rules any changes or modifications to this equipment not expressly approved by Zebra may cause harmful interferen ce and void the FCC authorization to operate this equipment INDUSTRY CANADA NOTICE This device complies with Industry Canada ICS 003 class B requirements INTRODUCTION Thank you for choosing the Zebra P520i Plastic Card Printer Zebra s P520i card printers offer a low cost high quality solution to those requiring computer controlled printing and encoding of credit card style plastic cards Card applications include personalized identification access control visitor membership badges and tags This manual guides you to efficient start up and operation of your new Card Printer P520 printer models The Zebra Product Number tells a story Here is a quick review of the Zebra Card Printer Series numbering and lettering system to help you The P520 Plastic Card Printer employs Dye Sublimation and Resin Thermal Transfer technologies Model numbe
5. The two most important factors that will increase your print quality are cleanliness and card stock To diagnose and fix print quality problems follow the troubleshooting procedure below e Small spots appear on the printed card with a non printed area or a different color Possible Cause m o YY A Contamination on the card surface B Dust inside the printer and or dirty Cleaning Roller gt gt Solution A1 Check that cards are stored in a dust free environment A2 Use a different supply of cards B1 Perform a Cleaning of the printer see Cleaning section B2 Replace Cleaning Roller see Cleaning section e There are non printing horizontal lines white on the card surfaces UL _ gt gt Solution Possible Cause A Ribbon is not correctly positioned B e Print Head may be dirty C Print Head elements may have been damaged e g scratched or burnt A1 Open cover and press down the Print Head Unlock Lever to open the Print Head carriage The Print Head will move up A2 Check that the ribbon is properly rolled onto the ribbon cores and there are no wrinkles in the ribbon A3 Push down on the Lock Lever until an audible click signals the locked down position A4 Ribbon will automatically synchronize A5 Print again B1 Perform a Cleaning of the Print Head see 4 2 Cleaning the Print Head C1 Call service for Print Head replacement information TROUBLESHO
6. 8000 15 033 World Globe Hologram Image Patches 100 Zebra TrueSecure Varnish Overlays 800015 131 Clear 350 Zebra TrueSecure 0 6 mil Carrier Based Rolls 800015 135 clear full coverage patches 170 CARDS FOR PRINTING AND LAMINATION Part Number Description Card pack thickness 104523 111 Premier grade PVC 100 30mil 104523 112 Premier grade PVC LoCo 100 30mil 104523 113 Premier grade PVC HiCo 100 30mil 104524 101 Premier plus grade composite 100 30mil 104524 102 Premier plus grade composite LoCo 100 30mil 104524 103 Premier plus grade composite HiCo 100 30mil CARDS SUITABLE FOR PRINTING ONLY Part Number Description Card pack thickness 104523 110 Premier grade PVC w adhesive back 200 10mil 104524 101 Premier plus grade composite 100 30mil 104524 102 Premier plus grade composite LoCo 100 30mil 104524 103 Premier plus grade composite HiCo 100 30mil APPENDIX C B ACCESSORIES Accessories available for P520 printers appear below Always refer to the part num ber when placing an order Printer supplies Part Number Description 300320 001 Centronics Parallel cable 36 pins 206851 001 Additional Card Output Hopper 105909 112 Replacement Print Head Kit Cleaning Supplies Part Number Description 105909 169 Premier Cleaning Kit 25 swabs 50 cards 105912 003 Adhesive Cleaning Roller Kit set of 5 105912 002 Cleaning Cartridge complete 104531 0
7. a location that allows easy access to all sides The printer should never be operated while resting on its side or upside down 2 Place the printer s power switch in the OFF O position 3 Insert the power cable to the printer power socket and attach to grounded electrical socket of the proper voltage and type CAUTION Intermittent or unpredictable operation may occur from unsecured connectors If damaged the power cable must be replaced by an exact equivalent Use only Parallel Cable under 3 Meters in length 4 Attach and secure the interface cable to printer and computer Note In printers with two connectors use the USB or the Parallel Ethernet never both 5 Switch power on Parallel Computer Connector Option E a USB Computer Connection Ethernet Computer Connector Option o Ol OPERATION E Ethernet Indicators The following shows the function of the switch and indicators found on P520i Printers that use Ethernet Computer Interfaces LED Action Status Being Signaled Red Flashing Power On Self Testing Red Solid gt 30 sec Failure of Power On Tests Red Green Flashing Alternately Firmware Download mode Green Solid gt 30 sec Proper Hardware Operation Network Found Green Rapid Flashing 9 sec Network not Found Green Slowly Flashing 1 sec Print Job in Progress Ethernet Push Button Press the Ethernet Push button with the printer ON to to get a Test Ca
8. first card or choose the sample card available during driver installation 7 Go to the Microsoft Word Software O If the printer was not selected as the default printer go to the file menu and Select Printer and choose Zebra P520i Card Printer in the printer names list Then Close the print dialog box O Come back to file menu and choose Page Setup O Select Paper Size tab and in Paper Size choose Card Then select the orientation landscape O Go to Margins tab Set the Top Bottom left and right margins to O zero values O Press OK to close Page Setup window O The card appears on the screen Design a card with 2 sides similar to the following Front side If found return to Http artworld com DLL O Once you are ready to print go to File and point Print O The printer will feed in a card and start printing the data download time will vary depending on the complexity ofthe card design and the processing speed of the computer O Once the printing job is achieved the card is ejected from the printer PRINTING A SAMPLE CARD B 6 PRINTING A SAMPLE CARD CLEA PROTECT YOUR FACTORY WARRANTY The recommended maintenance procedures must be performed to maintain your factory warranty Other than the recommanded cleaning procedures described in this manual allow only Zebra authorised technicians to service the P520 Printer NEVER loosen tighten adjust or bend etc a part or cable inside the p
9. free or that it is accurate with regard to any specification Zebra reserves the right to make changes for the purpose of product improvement at any time TRADEMARKS P520i is a service mark and Zebra is a registered trademark of Zebra Technologies Corporation Windows and MS DOS are registered trademarks of Microsoft Corp All other trademarks or registered trademarks are marks of their respective holders PRODUCT WARRANTY STATEMENT Printers All Zebra Card Printers are warranted against defects in material or workmanship for twelve 12 months from the purchase date Proof of purchase or shipment date is required to validate the warranty period The warranty becomes void if the equipment is modified improperly installed or used damaged by accident or neglect or if any parts are improperly installed or replaced by the user Note Products returned must be packaged in the original or comparable packing and shipping container In the event equipment is not so packaged or if shipping dama ge is evident it will not be accepted for service under warranty Surface transporta tion charges for return to customers in the continental United States is paid by Zebra Otherwise Zebra pays CPT carriage paid to nearest airport customer pays custo mers duties taxes and freight from airport to destination If Zebra determines that the product returned for warranty service or replacement is not defective as herein defined the customer will
10. this manual The printer is performing an A card flip to th te sid FLIPPING CARD A card flip to the opposite side IS OCCUFINQ Firmware is downloading to DOWNLOADING FW the printer B Laminating Station Status Messages SCREEN MESSAGE MEANING ACTION P ON Initial The Laminator can accept LAMINATING Card lamination is occuring power Mode The Laminator is not yet at WARMING UP the temperature needed for Wait lamination e TROUBLESHOOTING C Print Station Alert Messages SCREEN MESSAGE MEANING ACTION The ribbon has not been removed while the cleaning Remove ribbon operation is in progress REMOVE RIBBON The printer ribbon has run Replace printer ribbon OUT OF RIBBON out Remove the jamed card IMECHANICAL ERROR The printer has an error Ensure the card is not moving the card internally out of specification Add more cards or adjust the Th f OUT OF CARD ecard foederis empty card feeder to accept the cards The printer has an error ROTATION ERROR moving the card in the Card Remove card Flip COVER OPEN The cover is open Close the cover HEAD OPEN The print head is not locked Lock the print head in its lower into position position Check that the data is suitable COMMAND ERROR The data being sent from the for printing Try reprinting a card host is not recognised from known good dat
11. to Electromagnetic FE ees enpa 73 23 EEC L EN 60950 1992 and modified TE Amendments A1 to Product safety by 93 68 EEC A11 1997 1999 5 CE R amp TTE Directive EN300330 2 V1 1 1 Radio frequency interferences For a formal Certificate please contact Compliance Engineering at the Camarillo facility Model P520 conforms to the following specification C FCC Part 15 Subpart A Section 15 107 a and Section 15 109 a Class B digital device This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses ans can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or tel evision reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference s by one or more of the following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and the receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected
12. 01 Cleaning Card Kit box of 100 cards 105909 057 Cleaning Swab Kit box of 25 swabs Documentation Part Number Description 105572 004 i Series Documentation CD 980415 001 EPCL Programmer s Guide English only 980327 001 P520 P520 Maintenance Manual English only Miscellaneous Part Number Description 105600 008 Driver CD 806503 001 Card Punch slots card for lapel clip 104527 001 Lapel Clips pack of 100 clips sa APPENDIX C APPENDIX C World Wide Sales and Support Zebra Technologies Corporation Card Imaging Division 1001 Flynn Road Camarillo CA 93021 8706 USA Phone 1 805 579 1800 Fax 1 805 579 1808 Toll Free in US 800 452 4056 e mail cards zebracard com Zebra Technologies Corporation Card Imaging Division 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 zebracard com Zebra Technologies Corporation Card Imaging Division Latin America 6175 NW 153 Rd Suite 121 Miami Lakes FL 33014 USA Phone 1 305 558 8470 Fax 1 305 558 8485 e mail latinsales zebracard com Zebra Technologies Corporation Card Imaging Division Asia Pacifique 1 Sims Lane 06 11 387355 Singapore Phone 65 84 20 322 Fax 65 84 20 514 e mail asiasales zebracard co
13. D CARD OUTPUT HOPPER This items is used for printing cards Install card Output hopper onto printer by hooking over bottom edge of card exit aperture OPERATION B 2 e 5 Rejected Card Box The P520 Printer is equipped with a Rejected card Box When an encoding can not be completed the card is ejected into the Rejected Card Box The P520 Printer counts the number of cards which go into the Reject Card Box After 10 cards the printer stops the Amber LED Flashes and a LCD Message is displayed indicating the need to empty the reject box WHEN TO MAINTAIN When the LCD screen reports message HOW TO MAINTAIN 1 Press the top of the Rejected Card Box Door as shown Allow the door to swing down and open 2 e Remove all cards from the Rejected Card Box Fag OPERATION 3 Swing the Rejected Card Box Door and press the top An audible click signals the locked position 4 Press the Clear Button on the front panel to re start the current printer job and to clear the rejected cards counter OPERATION 2 6 Feeding one card at a time A Manual Feed Slot is avalable on the side of the Card Feeder cover for feeding single cards Cleaning Cards are fed manually through this slot The Feeder must be empty for manual card feeding to work properly For one at a time printing feed cards through slot on side of Feeder Do not feed more than one card at a time E OPERATION 2 e 7 Printing a Test Ca
14. OTING 6 Printing shows very pale or inconsistent results Possible Cause A Ribbon have been stored improperly or is damaged B Cards may not meet specifications C Contrast and or Intensity may be set to values which are too high D Dust or embedded contamination on elements of the Print Head gt gt Solution A1 Change ribbon and print again B1 Use a different supply of cards C1 Adjust Contrast and or Intensity values in software D1 Perform a Cleaning of the Print Head see 4 2 Cleaning the Print Head Printing shows blurry printed image Possible Cause A Ribbon may not be correctly positioned B e Ribbon may not synchronized on the correct color panel position C Cards may not meet specifications D Dust inside the printer and or dirty Cleaning Roller gt gt Solution A1 Open cover and press down the Print Head Unlock Lever to open the Print Head carriage The Print Head will move up A2 Check that the ribbon is properly rolled onto the ribbon cores A3 Push down on the Print Head Lock Lever until an audible click signals the locked down position A4 Ribbon will automatically synchronize A5 Print again B1 Open cover and press down the Print Head Unlock Lever to open the Print Head carriage The Print Head will move up B2 e Push down on the Print Head Lock Lever until an audible click signals the locked down position B3 Ribbon will auto
15. Status XXXXXXXXXXXX XXXXXXX OPERATION B OPERATION PRINTING SAMPL Printing with the P520 Printer requires the Windows Printer Driver your card desi gn issuing software or printer command level programming through the printer inter face The P520i Card Printer can be used with any Windows 98 SE ME NT 4 0 2000 or XP software application program using the drivers provided with the printer This section contains information on the printing of a dual sided card in color using the 5 Panel color ribbon YMCKK and the Windows Printer Driver BEFORE installing updated printer driver versions always delete the existing printer driver version from your computer using Add Remove from the Windows Control Panel PRINTING A SAMPLE CARD E 3 1 To install the P5201 Printer Driver proceed as follows IMPORTANT NOTE Ensure that your PC printer port is set to ECP mode and also ensure that you have deleted any previous versions ot this printer driver If you have any doubts please contact your IT department 8 PRINTING A SAMPLE CARD O Start your computer and then Windows Insert your Zebra Driver CD into an available drive 7 Wait for the Driver Install Wizard to self launch and follow the instrutions Printer Drivers _ i Series Card Printers Printers supported by this CD include P310 P3201 PA20 3 2 Printing a sample card You can either follow the steps below to print your
16. User s Manual P520i Cn Card Printer DE Solutions Part Number 980477 001 Rev B 2004 ZIH Corp FOREWORD This manual contains installation and operation information for the P520i Series card printers manufactured by Zebra Technologies Corporation RETURN MATERIALS AUTHORIZATION Before returning any equipment to Zebra Technologies Corporation for in warranty or out of warranty repair contact Repair Administration for a Return Materials Authorization RMA number Repack the equipment in the original packing material and mark the RMA number clearly on the outside Ship the equipment freight prepaid to the address listed below For USA and Latin America Zebra Technologies Corporation Card Imaging Division 1001 Flynn Road Camarillo CA 93021 8706 USA Phone 1 805 579 1800 FAX 1 805 579 1808 For Europe Asia and Pacific EMEA Technical Support Gordon Road High Wycombe Bucks HP13 6EQ UK Phone 44 0 870 241 1527 FAX 44 0 870 241 0765 COPYRIGHT NOTICE This document contains information proprietary to Zebra Technologies Corporation This document and the information contained within are Copyrighted by Zebra Technologies Corporation and may not be duplicated in full or in part by any person without written approval from Zebra While every effort has been made to keep the information contained within current and accurate as of the date of publication no guarantee is given that the document is error
17. a PARAMETERS ERROR The features of the card are Check the windows driver not recognised or the data for options and printer type the stripe is incorrect Check the data format Check that the cards are loaded with the magnetic stripe in the Data cannot be written or correct orientation Check whe ENCODING ERROR read from the magnetic stripe ther high or low coercivity cards on the card have been specified Check that the data conforms to ISO speci fications See Appendix A of this manual for further information REJECT BOX FULL The reject box is full Empty Reject Box CHECK RIBBON eg ribbon or none detec Install proper ribbon ed Press the Select Button and fol PRINTER LOCKED Printer is locked low the Passcode Menu instruc tions Ribbon Errors Check that the print ribbon has not run out Lock and then unlock the print head assembly this resynchronises the ribbon automatically When using a color ribbon it should advance automatically so that the leading edge of the yellow panel is beneath the print head Ensure that the correct ribbon type has been specified in the Windows driver Card Feed amp Mechanical Errors Ensure that the card thickness adjustment has been set up correctly to allow one card to feed Magnetic Encoding Errors Check that the cards are inserted correctly in the printer Ensure that the cards are low or high coercivity as req
18. e See Appendix C ONLY USE cards that comply with ISO 7810 amp 7811 standards for magnetic stripe cards The magnetic stripe must be flush to the surface of the card to work properly Never use cards which have taped on magnetic stripes as APPENDIX A B MAGNETIC ENCODER CLEANING There exists two different processes to clean the Magnetic stripe Encoder The first process consists of a standard cleaning of the printer This cleans the most important parts of the printer including the print Head Transport Roller and Magnetic Stripe Encoder refer to chapter 4 Cleaning for more instructions The second process consist of a cleaning of the Magnetic Encoder using the Menu Button from the LCD Display To access the Magnetic Cleaning Menu proceed as below 1 Leave power on 2 Remove cards from the card feeder 3 Insert one presaturated card provided through slot on the side of the Card Cartridge 4 Press the Menu button until the LCD screen shows CLEANING MENU 5 Press the Select button to select 6 Press the Menu button again until the LCD screen shows CLEAN MAG HEAD 7 Run this operation by pressing the select button ISO STANDARD ENCODING Track Field Separator Track density Valid Characters of characters 1 210BPI Alphanumeric Ed ASCII 20 95 2 75BPI Numeric AQ ASCII 48 62 3 210BPI Numeric 107 ASCII 48 62 Bit per inch
19. e Print Head always use approved ribbons DO NOT TOUCH the print head or the electronic components on the print head carriage Discharges ofelectrostatic charge from the human body or other surfaces can damage the print head or other electronic components used in this devi ce 1 Remove ribbon from packaging 2 e With printer power ON and Printer Ready status open cover and press down on the Print Head Unlock Lever to open the print head carriage The print head carriage will pop open Ce OPERATION 3 e Load ribbon onto the supply spindle 1 under print head carriage and empty core with tape attached onto the take up spindle 2 Make sure the ribbon comes off the top of the supply spindle and feeds to the top of the take up spindle 4 Push down on the Print Head Lock Lever until an audible click signals the locked down position 5 e Close Cover Please note that the ribbon automatically synchronises whenever the print head lock down occurs The card flipper will not operate and an error will be indicated if you try to flip a card when the cover is open OPERATION Fo 2 e 3 Loading Lamination Patch The P520 Printer requires approved patches see Appendix C Clear patches hologram patches or Overlay varnishes are specifically designed for your P520 Printer For optimum performance and printer life Laminator always use approved patches 1 e Remove patc
20. eparate Print head cleaning using swabs can remove more stubborn deposits when print anomalies persist To avoid deposits only use foam tipped swabs 1 Switch power Off open cover raise Print Head and remove the Ribbon TT 0 2 e Clean Print Head by moving alcohol moistened swab tip side to side across Print Head elements Only use moderate force Make sure the elements are dry before switching on To reorder swabs see Appendix C Never use a sharp object to scrape deposits from the print head Permanent damage will result CLEANING 6 4 e 3 Cleaning the Laminator Rollers A cleaning using the Cleaning System with cards usually suffices moreover your printer is equipped with two cleaning rollers situated before the card enter the Laminator The upper roller has a coating that collects any loose particles on the surface of cards However a separate Laminator Station cleaning can remove more stubborn deposits To avoid deposits only use foam tipped swabs Never touch the rollers with fingers WHEN TO MAINTAIN Cleaning frequency varies with different environments Clean when lamination anomalies persist HOW TO MAINTAIN 1 Switch OFF your printer and open cover Make sure the Laminator rollers cool down 2 Press down on the unlock lever to open the Laminator braquet 3 Clean the two Laminator rollers and the two transport rollers gently with a swab The above transport ro
21. essage is B CLEANING TROUBLESHOOTING This section offers solutions to potential problems you may experience with your P520 printer The table below lists the screen messages that will be displayed on the printer s LCD both during normal operation and to alert operator of any error conditions There is also some additional information dealing with quality issues concerning printing onto cards 5 e 1 Interpreting LCD Display messages A Printing Station Status Messages SCREEN MESSAGE MEANING ACTION INITIALIZING Power ON Initialization is occuring READY Ready for Print Data Wait for the ready message WAIT TEMPERATURE A pause for a Print Head cool down is occuring DOWNLOADING DATA ne data is being recei The yellow bit map is being printed The magenta panel is being printed The cyan panel is being printed A monochrome bit map is being printed A varnish bit map is being printed An ultra violet bit map is being printed A hologram bit map is being printed PRINTING YELLOW PRINTING MAGENTA PRINTING CYAN PRINTING MONO PRINTING VARNISH PRINTING UV PRINT HOLOGRAM TROUBLESHOOTING B A Printing Station Status Messages Continued SCREEN MESSAGE MEANING ACTION The printer is encoding the The printer is prompting for Carry out thg cleaning CLEAN PRINTER operator maintenance procedure an detailed in section 4 of
22. h from packaging 2 With printer power ON and printer Ready status open cover 3 Press down on the Laminator Unlock Lever to open the laminator bracket The laminator bracket will pop open 4 Load patch onto the supply spindle 1 under laminator bracket and align the notch of the 5 empty core with the spindle screw with tape attached onto the take up spindle 2 NS Make sure the patch comes off the top of the supply O spindle and feeds to the top of the take up spindle 5 Push down on the Laminator Lock Lever until an audible click signals the locked down position 6 Close Cover Please note that the ribbon automatically synchronises whenever the laminator head lock down occurs 0 OPERATION 2 e 4 Loading Cards To help you load print and collect cards the P520 has the following items A CARD FEEDER This items is used for loading cards 1 Open Card Feeder Cover by putting your fingers on both sides and rotating the cover in a clockwise direction to the open position 2 Install cards into Feeder as shown 3 Close Card Feeder Cover DO NOT bend cards or touch print surfaces as this can reduce print quality The surface of the cards must remain clean and dust free Always store cards in an enclosed container Ideally use cards as soon as possible If cards stick together carefully shuffle them See Chapter 6 Technical Specif
23. he printer An attached external Smart Card Programmer can be used to program Smart card chips SMART CARD CONTACT POINTS PINS ICI 63101000 E CI C4 car SMART CARD CONTACT POINTS C6 Vpp C7 1 0 C8 RFU GND when chip is at station C5 GND DO NOT position printing over the Smart Card Chip so APPENDIX B Accessories amp Supplies Please contact your Zebra authorised dealer to place an order for accessories and supplies Use only Zebra approved card ribbon and patches media Using non approved card or rib bon media can void your warranty Refer to the Accessories section for more information about Card and Ribbon Media available from Zebra Technologies Corp AVAILABLE FULL COLOR PRINTER RIBBONS Part Number Description Cards roll 800015 440 YMCKO 200 800015 540 YMCKO 330 800015 448 YMCKOK 170 800015 480 YMCKK 200 800015 445 YMCK 250 800015 545 YMCK 400 800015 470 YMC 300 800015 450 Kdye O 500 800015 460 KrO 500 800015 443 YMCUvK 200 800015 543 YMCUvK 300 APPENDIX C 6 AVAILBLE MONOCHROME RIBBONS Part Number Description Cards roll 800015 101 Black 1000 800015 102 Red 1000 800015 103 Green 1000 800015 104 Blue 1000 800015 106 Gold 1000 800015 107 Silver 1000 800015 109 White 1000 800015 185 Scratch off Gray 840 800015 301 Black 1500
24. ications for card requirements and capacities OPERATION B INSTALL CARD CLEANING CARTRIDGE This items is used to clean the cards entering the printer It must installed before using the printer 1 Remove Card Cleaning Cartridge from plastic bag and peel off protective wrapper from adhesive cleaning roller 2 e Open printer cover and remove the yellow reminder tape from the location for the Cleaning Cartridge 3 Make sure the arrow on top of the assembly is facing towards the rear of the printer Hook assembly into slot on printer and rotate down Ensure the assembly locks in place Faz OPERATION C CARD THICKNESS CONTROL LEVER This items is operated by the user to prevent more than one card feeding into the printer at the same time and causing a jam Open cover and adjust lever to the correct position for the card thickness you are using Repeat for different card thickness Factory setting is for 30 mil 0 762 mm card thickness See diagram below Card thickness A 60mil 1 524mm to 50mil 1 27mm B 40mil 1 016mm C 30mil 0 762mm D 20mil 0 508mm E Less than 20mil 0 508mm Start at lowest position and move lever up to match card thickness For other card thickness start lever at lowest position and move up until cards feed Note For Lamination cards should only be 30 mil cards and composite PVC is prefered for optimum performance
25. ller 1 can be temporary removed for an easy clean 4 Make sure the rollers are dry before Pushing down the bracket and switching on your printer CLEANING 4e 4 Card Cleaning Cartridge Your P520i Printer also has a Card Cleaning Cartridge This item cleans the cards entering the printer To ensure print quality the cleaning roller requires periodic replacements WHEN TO MAINTAIN When LCD screen reports message or at ribbon replacements Run a printer cleaning first see 4 1 Cleaning System for more instructions HOW TO MAINTAIN 1 Open Cover and locate Cleaning Cartridge 2 e Gently remove Cleaning Cartridge by rotating up and away from printer CLEANING 6 3 Remove Cleaning Roller from Cartridge and dis card 4 e Install new Cleaning Roller into Cartridge To avoid contamination always hold the Cleaning Roller assembly by the ends 5 e Carefully peel off wrapper from new Cleaning Roller while in Cartridge 6 Replace Cartridge into printer Make sure the arrow on top of the assembly is facing towards the rear of the printer Hook assembly into slot on prin ter and rotate down Ensure the assembly locks in place DO NOT touch the roller surface that contacts the cards 7 Close Cover See Appendix C for replacement Cleaning Rollers displayed until maintenance has been performed the printer will cotinue to operate 5 Although the CLEANING PRINTER m
26. lt Clear Button Select Alert LED Power LED lt gt The 16 character LCD 2 Line Display is used for e Showing the printer s current status e Providing operator and service messages chapter 5 The two LEDs are used for e Green Power LED Amber Alert LED with Beeper The Menu Button left is a push button used for Bringing printer into Menu Mode when pressed with the printer showing READY on the LCD Display Using in Menu Mode to scroll through Menu Options The Clear Button right is a push button used for e Clearing an error status when LCD Display shows an error and Alert LED is on e Invoking automatic retry of the operation which gave the error e Selecting a Menu Option when in Menu Mode Note The buttons beep when pressed GETTING STARTED Es 1 e 3 Printer Installation The following will guide you through the installation of your P520 printer pes GETTING STARTED CAUTION Limit AC power supplied to the P520 Printer to 110 230 V AC 60 50 Hz for an associa ted 1 40A 0 80A Limit excess current draw to 16 amps or less using an associated circuit breaker or other such device Never operate the printer in a location where operator computer or printer can get wet Personal injury could result The printer must be connected to an earthed electrical power supply and properly protected against electrical surges and grounding faults 1 Place the printer in
27. m CORPORATE HEADQUARTERS 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 980477 001B W r43 153 Zebra Technologies Corporation
28. matically synchronize B4 ePrint again C1 Use a different supply of cards D1 Perform a cleaning of the Print Head See 4 2 Cleaning the Print Head D2 Replace Cleaning Roller See 4 3 Cleaning Cartridge B TROUBLESHOOTING e No printing on the card Possible Cause A Ribbon may not be installed in the printer B Cards may not meet specifications C Cable on Print Head may be disconnected D e Print Head elements may be scratched or burnt gt gt Solution A1 Check for ribbon in the printer B1 Use a different supply of cards C1 Power off the printer and check the Print Head cable connections D1 Call Service for Print Head replacement information For optimum print quality always keep cover of the printer closed except during ribbon loading and card thickness control procedures The card flipper will not operate and an error will be indicated if you try to flip a card with the cover open TROUBLESHOOTING 6 6 TROUBLESHOOTING TECHNICAL SPECIFICATIONS General Color Printing Bar Code Fonts Cards e High speed printing amp laminating Small footprint Windows Drivers for 98SE ME NT 4 0 2000 and XP One year printer warranty One year print head warranty Color dye sublimation or monochrome thermal transfer printing 300 dpi 11 8 dots mm print resolution Edge to edge printing standard Code 39 Code 128 B amp C with amp without check digi
29. minator MODEL NAME D gt Hold Firmware Version Installed FIRMWARE VER VXXX Hold Laminations Performed COUNTER O Hold Laminator Model Name LAMINATOR o PARAMETERS First Ribbon Mark Offset Ribbon Sync Mark Offset Patch Centering Offset PEEL OFFS XXXX Heat Roller Temperature TEMPERATU XXXX Lamination and Cooling Times Hold Action Complete LAMINATOR LAMINATE j SINGLE SIDE SELF TEST SINGLE SIDE PROCESSING Action Complete LAMINATE o DUAL SIDE DUAL SIDE PROCESSING SELF TEST CARD 0 MENU CLEANING 0 MENU See Next Page be OPERATION Menu Tree Test Cards and Cleaning After 10 seconds of selection inactivity READY returns automatically ne Crau dl Printer Group ee Laminator Group Test Card Menu Action Complete SELF TEST CARD SELF TEST CARD va TEST PATTERN MENU TEST PATTERN ARES SELF TEST CARD Fa PARAMETERS PRINT PARAMETERS _PR De PN AAA SELF TEST CARD i MAG MAG PARAMETERS PROCESSING P EE SELF TEST CARD PU LAMINATOR LAMINATOR PROCESSING o P Status First remove both Ribbons and Plastic Cards then insert Cleaning 4 Card into Card Feeder Action Complete CLEANING CLEANING PRINTER MENU PRINTER CLEANING gt J Action Complete CLEANING le MAGNETIC HEAD MAGNETIC HEAD CLEAN MAG HEAD Appears only when option is installed In process
30. o Introduction cerscccccccscecccccccscsescces Media Loading orientation o o o o Smart Card Contact Station Interface APPENDIX GC ee ee eee o o o o ooo Available Full Color Ribbons Available Monochrome Ribbons o Print Ribbons vs Laminator Compatibility Available Patch Ribbons e oooooooo o Cards for Printing and Lamination Cards Suitable for Printing Only eeeeeeeere Accessories sooo eo 0000000000000 000000 45 45 46 47 49 49 50 50 51 51 52 52 53 53 53 54 GETTING STARTED 1 e 1 Unpacking your card printer Your P520 printer ships in a carton and protective anti static bag Keep all packaging material in case you need to move or re ship the printer While unpacking inspect the carton to ensure that no damage occured during shipping Please ensure that you have a clean and nearly dust free environment for proper operation and storage of the printer GETTING STARTED em In addition to user documentation make sure the following items are included with your P520 printer If any items are missing please contact your dealer To reorder please refer to Appendix C of this manual e GETTING STARTED 1 e 2 Indicators and Control Your P520 printer has an LCD Display two LED s and two Panel Buttons P520i LCD Display Clear A Menu Button Next gt
31. oll e K dye O 500 cards roll e YMC 300 cards roll e YMCK 250 400 cards roll e YMCK K 200 cards roll e YMCKO 200 330 cards roll e YMCKOK 170 cards roll e Clear Patch 1 or 0 6 mil e Clear Patch for mag stripe 1 mil e Clear Patch for smart card 1 mil Hologram 1 mil Varnish full overlay Thermal transfer 4 microns thick Clear and holographic options Clear Genuine Secure Hologram Custom Hologram e Centronics Parallel or Ethernet USB port Width 31 69 805mm Depth 9 25 235mm Height 10 43 265mm e Weight 47 28 Ibs 21 45 kg e 110 230 Volts AC 60 50 Hz e FCC Class B CE UL and CUL approved Operating Temperature 60 to 86 F 15 to 30 C e Operating Humidity 20 to 65 non condensing Storage Temperature 23 to 158 F 5 to 70 C e Storage Humidity 20 to 70 non condensing e Ventilation Free air Dye sublimation printing requires dye sublimation ribbons with either black or cyan magenta and yellow plus black resin panels Measured without card output hopper Options e Ethernet Port Smart Card Contact Station 0 76mm cards only e Magnetic Encoder 0 76mm cards only e Cleaning Supplies TECHNICAL SPECIFICATION B CENTRONIC CABLE INTERFACE The above drawing shows the required connections to use the printer centronic interface
32. oooooso 2 4 Loading cards o 0001000000000 0010011001000 0 0 Card Feeder eooooooooosssssooooo Card Cleaning Cartridge o o o ooooo o Card Thickness Control Lever o Card Output Hopper co 0000000000000 00 2 5 Reject Card Box Cy 2 6 Feeding one card ata time eeessssssesssesese 2 7 Printing a test card CoC 0000100000000 000 2 8 Printer menu information ooooooooso PRINTING A SAMPLE CARD 391 Install P520i Printer Driver oo o o 3e2 printing a sample card oooooooooooooo CLEANING e o o o o o oo oo ooo 4 1 Cleaning system OC 4e2 Cleaning the print head eeeesereeserececccs 4 3 Cleaning the Laminator rollers 4 4 Card Cleaning cartridge oo000 0000000000000 TROUBLESHOOTING o o o o o o o 5e1 Interpreting LCD Display messages Printing Station Status Messages cesse Laminator Station Status Messages re Print Station Alert Messages Laminator Station Alert Messages 502 Print Quality Issues ve oo con een nenn 000 TECHNICAL SPECIFICATIONS o 10 11 11 12 13 13 14 16 17 18 24 25 27 28 29 30 31 33 33 33 34 34 34 37 4 1 APPENDIX A ve eee ee oo oo ooo Introduction oeoooooocoooooooo o Media Loading orientation o o Magnetic Encoder Cleaning APPENDIXB ve ve o o oo oo ooo o
33. pay all handling and transportation costs Printheads Since printhead wear is part of normal operation the original printhead is covered by a twelve 12 month warranty Warranty period begins on purchase date To qualify for this warranty the printhead must be returned to the factory or to an authorized service center Customers are not required to purchase Zebra supplies media and or ribbons for warranty qualification However if it is determined that the use of other manufacturer supplies has caused any defect in the printhead for which a warranty claim is made the user is responsible for Zebra s labor and material charges required to repair the defect The warranty becomes void if the printhead is physically worn or damaged also if it is determined that failure to follow the preven tive maintenance schedule listed in the User s Guide has caused defect in the thermal printhead for which a warranty claim is made Spare Parts All parts maintenance kits options kits and print head accessories are warranted to be free of defects in material and workmanship for 90 days except where otherwise denoted from date of purchase This warranty becomes void if the item is modified improperly installed or used or damaged by accident or neglect DECLARATIONS OF CONFORMITY EN 55022 1998 RF Emissions control 89 336 EEC modified by EN 301489 3 V1 4 1 RF Emissions and immunity 92 3 1 EEC EMC Directive for radia equipment and Immunity
34. rd Press and hold the Switch while turning ON the Printer to perform a RESET LEDs Ethernet Push Button ADDRESS SUBNET MASK DEFAULT GATEWAY TIMEOUT GATEWAY STATUS FRAME FORMAT MODE SERIAL NUMBER FIRMWARE DATE CODE GENERAL TCP IP NETWARE STATUS PORT NAME PRINTER STATUS BIDIRECTIONAL CONNECTED TO ERROR STATUS ZebraNet Print Server Confiruration FIRMWARE IS COPYRIGHTED ENABLED Enabled None 00074D20F484 HARDWARE ADDRESS Online TCP IP ENABLED 101 2 228 255 225 25 0 NETWARE ENABLED Unknown Unknown GENERAL 2159748 8 00 3133A ERROR None None None JET ADMIN PORT CONFIGURATION Ethernet Test Card e OPERATION OPERATION 2 1 Printer Features The following shows the features found on your P520 Printer Standard Features Optional Features 1 Print Head Unlock Lever A Smart Card Contact Station 2 e Print Head B Magnetic Encoder Station 3 Card Thickness Control Lever 4 Card Feeder 5 e LCD Display and two panel Buttons 6 Card Cleaning Cartridge 7 e Laminator 8 e Laminator Unlock Lever 9 Card Output Hopper 10 Rejected Card Box 11 Cleaning Roller OPERATION e 2 e 2 Loading Printing Ribbons The P520i Printer requires approved ribbons see Appendix C The Resin Thermal Transfer and Dye Sublimation ribbons and Lamination are specifically designed for your P520i Printer For optimum performance and printer lif
35. rd With ribbon and cards loaded your P520 printer is ready to print To check the operation of the printer and the laminator you should print a test card NOTE Test cards are not laminated 1 When the printer displays READY press the Next button left on your Control Panel to MENU PRINTER then the Select button right to PRIN TER INFO 2 Press twice the Next button to SELF TEST MENU and then Select to TEST PATTERN 3 A test card will print after a few seconds LCD display will show printing status Test Card is printed on both sides of the card This is an example of the test card Front Side Printer Operation Back Side Laminator Operation PLASTIC CARD PRINTER 5 bor PRINTER P520iEM 100 anal hy EM P2000 1806 4 Key N A Coba eran OFF Laranation OFF uvre N eed 120 300 dpi dr roma in Er gt MA ES OPERATION 2 e 8 Printer Menu Information The printer is equipped with an LCD Display and two key buttons which gives access to printer menus When the printer status shows READY press the Menu button to enter the Menu Mode Menu Button NEXT left Clear Button SELECT right When you are in Menu Mode the top line display shows menu information and the second line of display clarifies the function of the two NEXT and SELECT key buttons relative to the current menu item The printer will return to READY Mode if either of the two key But
36. rinter NEVER use a high pressure air compressor to remove particles in the printer CLEANING 6 4 e 1 Cleaning System Your P520 Printer includes a simple cleaning system using the Pre Satured Cleaning Cards provided The regular use of these cards will clean and maintain important parts of your printer that cannot be reached including the Print Head the Lamination station and Transport Rollers WHEN TO CLEAN When the LCD screen reports messages HOW TO CLEAN 1 Leave power on Open Cover and release Print Head Bracket Remove ribbon Close Print Head Bracket Close Cover Remove cards from Card Feeder 2 Insert one Pre Saturated Cleaning Card provided through slot on the side of the Card feeder Cover 3 Press the right panel button for a few seconds The card will feed into printer and carry out the cleaning process repeat the process with a new Cleaning card if necessary Note For a printer cleaning prior to the WHEN TO CLEAN signal press the Left Panel button until the LCD screen shows CLEANING MENU Press the right Panel button to select and one more time again to run the cleaning process Repeat first steps 1 amp 2 above A 28 CLEANING Although the CLEAN PRINTER message is displayed until the cleaning process has been performed the printer will continue to operate 4e 2 Cleaning the Print Head A cleaning using the cleaning system with cards usually suffices However a s
37. rs include identifiers that specify options are shown using the following lettering conventions Ship away kit m P520i X X X X X X DO Smart Card i O No E Yes Magnetic Encoder O No Windows Driver M Yes amp User Documentation Magnetic Encoder Options O No 1 Stripe down HICO 2 Stripe Down LOCO 3 Stripe Up HICO 4 Stripe Up LOCO Memory O Standard Power Cord Interface 120 Vac US and U Parallel amp USB 220 Vac Europe C Ethernet amp USB U 240Vac UK ICONS Throughout this manual different icons highlight important information as follows Important general information Mechanical hazard such as one associated with moving parts capable of resulting in equipment damage or personal injury Electrical hazard such as an exposed voltage point capable of causing electrical shock and personal injury An area where electrostatic discharge ESD can cause component damage Use a grounding wrist band Elevated temperature hazard capable of producing a burn Keep Card Printer clean by minimizing cover open time TABLE OF CONTENTS GETTING STARTED ee 1 1 Unpacking your Vie ye TENE TER Oe eae 1e2 Indicators and control see 193 Printer installation 0 0 0 0 0 OPERATION 2e1 Printer Features o ooooooo n o 2 2 Loading Printing Ribbons s esssssseeseeeees 2 3 Loading Lamination Patch oooo
38. t 2 of 5 amp 2 of 5 industrial UPCA EAN8 amp EAN13 PDF 417 2D bar code Internal Normal 100 point Bold 100 point True Type fonts available via Windows Driver e Types PVC Composite e Card width length ISO CR 80 ISO 7810 2 125 54mm by 3 375 86mm e Option Magnetic Stripe ISO 7811 e Option Smart Card ISO 7816 2 e Card thickness 10mil 0 25mm to 50mil 1 25mm for printing only and 0 8mm for printing and lamina tion e Card Feeder capacity up to 300 cards 10mil up to 100 cards 30mil e Card Output Hopper capacity 300 cards 10mil up to 100 cards 30mil TECHNICAL SPECIFICATION E CARD DIMENSIONS ISO STANDARD DIMENSIONS FOR PLAIN CARD 2 125 0 002in 53 98 0 050mm 3 375 0 010in Radius 85 72 0 asm 0 125in 3 18mm 0 009 0 034in 0 23 0 84mm ISO STANDARD DIMENSIONS FOR MAGNETIC STRIPE CARD 0 218in 5 54mm max MAGNETIC STRIPE 0 0 115in a gt 15in 2 92mm CHIP POSITION FOR SMART CARD 0 357 in 9 07 mm 0 720 in 18 3 mm 28 46 mm 0 403 in 10 25 mm AR 0 403 in 10 25 mm 0 782 in 19 87 mm 0 782 in 19 87 mm AFNOR Cards ISO 7816 Cards 5 TECHNICAL SPECIFICATION Ribbons Patches Overlay Varnish Interfaces Mechanical Electrical Environmental Monochrome 1000 1500 cards roll Monochrome colors back red blue green silver gold white e K resin O 500 cards r
39. tons is not pressed within ten seconds of entering Menu mode P520 LCD Menu Trees 8 OPERATION Menu Tree Printer station READY After 10 seconds of READY selection inactivity READY returns automatically PRINTER INFORMATION Model Number of Printer MODEL NAME XK H gt Hold Firmware Version PRINTER MODULE MENU Installed FIRMWARE VER V3 21 pS Hold Number of Cards Printed COUNTER OR H gt Hold Number of Cards in Reject Box REJECT BOX Sie HO Hold Image Centering Offset Pixels PRINTER ida ET X Y PARAMETERS FES Benz D gt Hold x ine Contrast Setting COLOR a D gt Hold Stripe Ty Mic O LOCO NONE MAG OPTION See gt Hold Printer Ribbon Driver Selection RIBBON RIBBON TYPE O Hold INFORMATION 800015 xxxX o Remaining Ribbon SA D Hold Sends Card to Output Hopper EJECT CARD ui PROCESSING MAIN MENU PRINTER EJECT CARD Appears only when option is installed See Laminator or Group SELF TEST CARD o MENU CLEANING 0 MENU XXXXXXXXXXXX XXXXXXX See Following Pages gt OPERATION Menu Tree Laminating station MAIN MENU READY READY After 10 seconds of selection inactivity READY returns automatically PRINTER MODULE MENU LAMINATOR LAMINATOR 0 MENU INFORMATION See Menu Mode lt Printer Group Model Number of La
40. uired and are set up correctly in the printer driver Cleaning Alert The printer has counted the number of cards printed and has automatically flagged that a cleaning routine needs to be carried out See Chapter 4 PRINTING A SAMPLE CARD B D Laminating Station Alert Messages SCREEN MESSAGE COVER OPEN HEAD OPEN OUT OF RIBBON OUT OF CARD COMMAND ERROR NO ACCESS ROTATION ERROR RIBBON FAILURE TEMPERATURE ERR FLASH ERROR MEANING ACTION The cover is open Close cover The Laminator Head is rai Latch down the Lamination sed Head The Laminator has run out A Th dinih Check for a jamed card ere IS NO Cara Uine Ensure the card is not out of Laminator PR specification An error occured while Produce an initialization by MECHANICAL ERROR switching Printer Off and On The Laminator has received Check then resend an invalid Command or Command Parameter ted A Laminator Flip over error Check for Card Jam occured Open Laminator Bracket 7 remove card and close during the cool down per Bracket Check Lot Code of iod the Lamination Ribbon roll Lamination Temperature fai lure The film is glued to the card Laminator Flash Memory produced an error B PRINTING A SAMPLE CARD TROUBLESHOOTING 5 e 2 Print Quality Issues This section will help you resolve print quality problems The print quality is dependent on several factors
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