Zebra® P630i / P640i Card Printer User’s Manual 980541-003 Rev.
P630i, P640i Card Printer User’s Manual 980541-003 Rev.
Foreword This manual contains installation and operation information for the Zebra P630i and P640i card printers manufactured by Zebra Technologies Corporation. Copyright Notice © 2006, ZIH Corp. This document contains information proprietary to Zebra Technologies Corporation. This document and the information contained within is Copyrighted by Zebra Technologies Corporation and may not be duplicated in full or in part by any person without written approval from Zebra Technologies Corporation.
Foreword Return Materials Authorization Product Disposal Product Disposal Information • Do not dispose of this product in unsorted municipal waste. This product is recyclable, and should be recycled according to your local standards. For more information, please see our web site at: http://www.zebra.
Foreword Declarations of Conformity Declarations of Conformity 89/336/EEC EMC Directive EN 55022 (1998) EMC Directive EN 301489-3 V1.4.1 EMC Directive EN55024 (2001) 73/23/EEC modified by 93/68/EEC Low voltage Directive EN 60950-1 (2001) Product safety 1999/5/CE R&TTE Directive EN300330-2 V1.1.
Foreword Icons Icons Throughout this manual, different icons highlight important information, as follows: Note • Indicates information that emphasizes or supplements important points of the main text. Important • Advises you of information that is essential to complete a task, or points out the importance of specific information in the text. Electric Shock Caution • Warns you of a potential electric shock situation.
Foreword P630i and P640i Printer Models P630i and P640i Printer Models The Zebra Product Number tells a story.
Foreword P630i and P640i Printer Models vi P630i, P640i Card Printer User’s Manual 980541-003 Rev.
Contents Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Copyright Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Return Materials Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Using Partial-Width Laminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Laminator Cassette(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearing the Laminate Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the Interface. . . . . . . . .
Contents Valid host name has not been assigned to the printer . . . . . . . . . . . . . . . . . . . . . . . . 77 Color differences may be attributable to the Windows operating system installed . . . 77 6 • Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 P640i Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Appendix A • Magnetic Encoder. . . . . . . . . . . . . . . . .
Contents x P630i, P640i Card Printer User’s Manual 980541-003 Rev.
1 Introduction Thank you for choosing the Zebra P630i or P640i Card Printer. This manual guides you to efficient start up and operation of your new Card Printer. The Zebra P630i and P640i Card Printers provide high speed, full color dual-sided card printing. A micro-positioning card transport system provides enhanced color photos. A range of interface, encoder/reader, and security options allow ordering the specific configuration suitable for a particular application.
Introduction Printer Features Printer Features The following figure shows features of the P630i/P640i Printer. Cleaning Cassette Ribbon Ribbon Take-Up Spool Flip Station Security Key (Optional) Card Feeder Output Hopper Control Panel Magnetic Encoder (Optional) Power Switch 2 Print Head Laminator Station (P640i) Laminator Station (P630i) AC Power Connector P630i, P640i Card Printer User’s Manual 980541-003 Rev.
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). RM Buttons DY E INAT LAM REA IA MED ALA BON RIB T PRIN Indicators PRINT Button Press the PRINT button to print the image stored in the printer’s memory.
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.
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. Note • The READY indicator is bi-colored. Its two color channels, green and yellow, function independently.
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. Power Switch 6 AC Power Connector DB9 Serial Interface Connector for Contact Smart Card Contact Station (Optional) USB Connector Ethernet Connector (Optional) P630i, P640i Card Printer User’s Manual Parallel Connector (Optional) 980541-003 Rev.
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.
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 & Driver CD USB Interface Cable 8 P630i, P640i Card Printer User’s Manual 980541-003 Rev.
Installation Installation Procedure Step 4. Remove the foam block from the top of the shipping carton. Step 5. Lift the printer from the shipping carton. Caution • The printer weighs approximately 15.9 kg (35 lbs). Step 6. Remove the protective plastic bag from the printer. Important • Save all the packing material and the shipping carton in case the 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.
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. 10 P630i, P640i Card Printer User’s Manual 980541-003 Rev.
Installation Installation Procedure Attach the Output Hopper Step 1. The Output Hopper is positioned on the right side of the printer to receive the printed cards. Install the Output Hopper by 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.
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. 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.
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.
Installation Installation Procedure Step 4. Route the Ribbon as shown in the figure below. The Ribbon Supply Spindle is freewheeling; pull ribbon off it as needed. If the tape removed from the new ribbon in step 2 is undamaged, use it to attach the end of the ribbon to the Take-Up Spool; otherwise use other adhesive-backed tape.
Installation Installation Procedure 4. Attach Ribbon to Take-Up Spool With Tape 1. Pass Ribbon Over the Round Guide Bar 2. Ribbon Goes Through the Ribbon Sensor 3. Ribbon Goes Under the Print Head Step 5. Close the printer main cover, then press the RIBBON button on the Control Panel.to initialize the color ribbon. If the MEDIA light fails to go out, check the ribbon sensor. Important • Color ribbon wrinkling and “fold-over” can seriously affect print quality 980541-003 Rev.
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.
Installation Installation Procedure 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 P630i Printer only to the upper surface. The Laminate (laminating film) is loaded into cassettes to protect it from dirt or other contaminants. See the figure below.
Installation Installation Procedure Upper Laminate Cassette Latch Plate (P630i and P640i) Heater Cores area Lower Laminate Cassette Latch Plate (P640i only) Hot Surface • If the printer has been in use, the Heater Cores area of the Laminator may be hot. Important • If either Latch Plate is opened, even unintentionally, the corresponding Cassette must be removed and the Laminate reeled in. 18 P630i, P640i Card Printer User’s Manual 980541-003 Rev.
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.
Installation Installation Procedure Step 4. If there is an empty laminate core in the Cassette, remove it. Loading the Laminate Cassette(s) uently Important • If you are using partial-width laminate in the Lower Cassette of a P640i Printer, read the following 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.
Installation Installation Procedure . Upper Cassette (Used on Both P630i and P640i) White Roller Up Notched End of Spool to Left Laminate Unrolls Under Spool Laminate Unrolls Over Spool Notched End of Spool to Right White Roller Down Lower Cassette (Used on P640i Only) Step 3. Pull out an inch or two of laminate past the lip of the cassette. Step 4. 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.
Installation Installation Procedure 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 is 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 Note • Since partial-width laminates are only used for the back (i.e.
Installation Installation Procedure These are shown in the following figure. 1.66“ 2“ BACK OF FC CARD 1.3” 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.
Installation Installation Procedure Inner Holeand-Slot Outer Holeand-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 P630i, P640i Card Printer User’s Manual 980541-003 Rev.
Installation Installation Procedure Step 2. Close the main cover. If there was a laminate error before you replaced the cassette, laminate will automatically feed from the just-loaded cassette, followed by a cutting action to free a “patch” of laminate onto the transfer roller. If laminate does not feed automatically, press the LAMINATE button on the printer control panel. Clearing the Laminate Channels If your scissor cuts were neat enough to pass for machine-made cuts, continue with printing cards.
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 replacement of the Transfer Guide can cause laminate skewing and misfeeding. Be sure the Transfer Toggle is set to RUN.
Installation Installation Procedure Step 2. Remove all wrapping from the card deck. 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. Step 4. Push the stack back and forth to an angle of about 45° from vertical, so as to separate all of the cards.
Installation Installation Procedure Step 6. Place the Card Weight on top of the card stack. Step 7. Close the Card Feeder Cover. 28 P630i, P640i Card Printer User’s Manual 980541-003 Rev.
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. USB Connector 980541-003 Rev.
Installation Installation Procedure 30 P630i, P640i Card Printer User’s Manual 980541-003 Rev.
3 Printer Driver Installation Overview Each computer that will use the P630i or P640i Printer must have the Printer Driver installed. A common Printer Driver serves both P630i 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: 980541-003 Rev.
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. Connect 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.
Printer Driver Installation Installing the Printer Driver (USB) Step 5. From the Main Menu, click Install Printer Driver. The Printer Setup window will open. 980541-003 Rev.
Printer Driver Installation Installing the Printer Driver (USB) Step 6. If an older P630i or P640i 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 rebooting, exit from the Driver Installation program and remove the CD. Then re-boot your computer and start over with Step 1.
Printer Driver Installation Installing the Printer Driver (USB) Step 7. This will bring up the End User License Agreement. To proceed with the installatiion, click Accept. Step 8. This will bring up the Add Zebra Printer Port window. Select the USB Port, and then click Next >>. 980541-003 Rev.
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 is 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. Step 10. This brings up the Configure USB Port window. If your printer is not listed in the Printer info area, click Browse.
Printer Driver Installation Installing the Printer Driver (USB) Step 12. This opens the Add Printer Wizard welcome window. Click Next >. 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 >. 980541-003 Rev.
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 >. Step 15. The next window helps install the software driver. Select Install the software automatically (Recommended) and then click Next >. Step 16. The Wizard will search for the Printer. The screen that appears while searching appears on the next page.
Printer Driver Installation Installing the Printer Driver (USB) Step 17. When the Wizard finds the Printer, it may display a window referring to compatibility, as shown below. If so, click Continue Anyway. 980541-003 Rev.
Printer Driver Installation Installing the Printer Driver (USB) Wait while the Wizard installs the software. Step 18. When software installation is complete, the following window will display. Click Finish. Step 19. This completes software driver installation. To use the P630i or P640i Printer, you would select it just like you would any other printer connected to a Windows system. 40 P630i, P640i Card Printer User’s Manual 980541-003 Rev.
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 mask. If you are not sure how to verify this or change the configuration, consult someone knowledgeable on Ethernet Networks. Step 1.
Printer Driver Installation Installing the Printer Driver (Ethernet) Step 4. From the Main Menu, click Install Printer Driver. The Printer Setup window will open. Click Install an Ethernet Printer and Driver. 42 P630i, P640i Card Printer User’s Manual 980541-003 Rev.
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. Step 6. This brings up the Configure Ethernet Port screen. Click the Browse button. 980541-003 Rev.
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 P630i) 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.
Printer Driver Installation Installing the Printer Driver (Ethernet) Step 9. This brings up the Add Printer Wizard. Click Next >. 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 >. Click Next >. 980541-003 Rev.
Printer Driver Installation Installing the Printer Driver (Ethernet) Step 11. The Add Printer Wizard / Select a Printer Port screen will now appear. 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. Check that the printer is turned on (and the READY LED is lit), then click Next >. Then click Next >. This will bring up the “Add Printer Software Wizard”, as shown on the next page.
Printer Driver Installation Installing the Printer Driver (Ethernet) Select the Manufacturer (Zebra Technologies) and the printer model number; then click Next >. Step 13. This brings up the “Name Your Printer” screen. Verify that the printer name is correct. Specify if you want to use this printer as your default printer (this can always be changed in the Windows Printers or Printers and FAXes control panel). Then click Next >. 980541-003 Rev.
Printer Driver Installation Installing the Printer Driver (Ethernet) Step 14. Specify whether or not you want to allow printer sharing, then click Next >. 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 >. 48 P630i, P640i Card Printer User’s Manual 980541-003 Rev.
Printer Driver Installation Installing the Printer Driver (Ethernet) Step 16. Click Finish. The following screen will appear. 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. 980541-003 Rev.
Printer Driver Installation Installing the Printer Driver (Ethernet) 50 P630i, P640i Card Printer User’s Manual 980541-003 Rev.
4 Settings and Adjustments Introduction This section describes settings and adjustments that can be made to the P630i and P640i Printers.
Settings and Adjustments Sensors and Interlock Switches Card Presence Sensor Cover Interlock Ribbon Motion Sensor Printhead Motion Sensor (Not Accessible) Truck Near Hopper Interlock Infeed Sensor Truck Home Sensor Outfeed Sensor Cleaning Sensor Ribbon Sensor (Not Accessible) Flip Sensor (Lower Laminator Present on P640i Only) Access Printer Sensor Data To access the Sensor Data screen, select Start > Printers (or Printers and Faxes).
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.
Settings and Adjustments Printer Properties Printer Properties To access the various Printer Properties, select Start > Printers (or Printers and Faxes). Right click Zebra P630i or Zebra P640i, then select Properties General Printing Preferences Brings up the preferences screen. Reference Printing Preferences below. Print Test Page Prints the standard Windows test page. Sharing This is sharing according to the Microsoft Windows definition.
Settings and Adjustments Printer Properties Ports Specifies the computer port to which the P630i or P640i is connected. This will have been established at the initial installation of the printer, and will not normally require attention. An exception to this is if you wish to use “printer pooling”, the ability to distribute print jobs to multiple printers. To enable printer pooling, check the “Enable Printer Pooling” box, then check multiple ports.
Settings and Adjustments Printer Properties Color Management 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.
Settings and Adjustments Printer Properties Device Settings 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: 1. Print Station Adjustment 2. Laminate Station Adjustment 3. Flip Station adjustment 4. Advanced Adjustments: a. Magnetic Encoder Position b. Smart Card Position 5. Card Hopper Pick Position 6. Cleaning Frequency 980541-003 Rev.
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 2.Magenta a.Gain b.Offset c.Preheat 3.Cyan a.Gain b.Offset c.Preheat 4.Black Panel Density 5.Black Panel Preheat 6.Contrast Adjustment 7. 8.
Settings and Adjustments Printing Preferences Control The following procedures can be performed from the Control screen: 1. Advance the Ribbon 2. Advance the laminate 3. Run a cleaning cycle 4. Print a test card 5. Clear an Error 6. Reprint the last card and select number of copies 7. Zero the buffer 8. Select advanced utilitles such as: a. Flip Test 1 b. Flip Test 2 c. Flip/Pause d. Move carriage e. Calibration f. Update the backup configuration g. Upgrade the firmware h. Send the features file i.
Settings and Adjustments Printing Preferences Card Setup From the Card Setup screen, the operator can adjust the following settings: 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.
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 screen, select Start >Settings >Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Printing Preferences > Image Adjustment.
Settings and Adjustments Printing Preferences YMC (Color) Printing 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.
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.
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 is, instances where all three YMC values are at the maximum (full intensity).
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.
Settings and Adjustments Laminator Station Adjustments Eject Card Picks up a card, runs it to the flip station, raises it to the laminator infeed, then ejects it through the laminator. Like Flip Test 1, but done once only, and without flipping.
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. Horizontal 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.
Settings and Adjustments Laminator Station Adjustments 68 P630i, P640i Card Printer User’s Manual 980541-003 Rev.
5 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. 980541-003 Rev.
Troubleshooting Indicator Light Status Indicator Light Status = LIGHT FLASHING = LIGHT ON READY GREEN YELLOW MEDIA ALARM ORANGE RED PRINTER STATUS Ready to print Printer busy Laminator heating up, but not yet at operating temperature Laminator heaters in sleep mode (when not in use, the heaters cool at 1oF per minute) Printhead temperature error, or internal firmware problem. No cards in hopper, color ribbon out, cleaning tape out, laminator cassette(s) out.
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) • Color ribbon not in ribbon sensor. • Both ribbon cores not fully engaged on spindles. • Ribbon not secured to takeup core. • No ribbon type or wrong ribbon type specified in Printer Properties. Reference Printing Preferences in Chapter 4, Settings and Adjustments.
Troubleshooting Unusual Noises/Unreported Events • 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 • Printhead running too hot. Can happen after head replacement if head resistance incorrectly entered through printer driver. Contact Zebra Customer Service. • Color gain and offset too high. Contact Zebra Customer Service. • Check ribbon takeup and supply torques. Contact Zebra Customer Service.
Troubleshooting Quality Problems Laminator spot check Note • Remember, the P640i Printer includes upper and lower laminators; the P630i Printer 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.
Troubleshooting Quality Problems • Toothed transport belt wrong length. Poor color rendering Important • Changes in contrast settings will not take effect until power is cycled. • 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. • Vary brightness and contrast controls in Preferences > Image Adjustment.
Troubleshooting Laminate Problems Laminate Problems Laminate not centered on card • Vertical offset adjust (mechanical adjustment). • Horizontal offset: Properties > Device Settings > Printer Adjustment > Laminate Station Adjust. Laminate not parallel with card edges • Skew adjust (mechanical adjustment). • 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.
Troubleshooting System Related Issues Image missing at top or bottom of card • 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 • Could be on either edge.
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.
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6 Technical Specifications P640i 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.
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: 50o to 95oF (10o to 35oC), 20 to 80% RH non-condensing. Storage: -4o to 158oF (-20o to 70oC), 5 to 90% RH non-condensing Dimensions: see drawing Net weight: 35 lb. (15.9 kg) net. Shipping weight 43 lb. (19.5 kg).
Appendix A Magnetic Encoder Magnetic Card Stripe Encoder This section contains information on the additional operations of the P630i or P640i Printer with Magnetic Card Stripe Encoder.The magnetic encoder uses high coercivity.
Magnetic Encoder Magnetic Card Stripe Encoder AAMVA Standard Encoding Track # Field Separator Track Density Valid Characters # of characters 1 % 210 BPI* Alphanumeric 82‡ 2 : 75 BPI* Numeric 40‡ 3 % 210 BPI* Alphanumeric 82‡ *Bits per inch ‡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.
Appendix B Smart Card Contact Station Introduction This section contains information on the additional operations of a P630i 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 records, or other types of data. The printer may be equipped with an optional contact station for programming Smart Cards (ISO 7816).
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.
Appendix C Printer Security ID/Key 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. IDKey The ID/Key has a non-alterable memory containing a unique 64-bit serial number that is compared prior to each print job with a serial number stored in the printer’s nonvolatile RAM. If the serial numbers fail to match, or if no ID/Key is detected, the printer is disabled.
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 with the printer.
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. 980541-003 Rev.
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Appendix D Worldwide Sales & 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.
Worldwide Sales & Support Corporate Headquarters Zebra Technologies Card Printer Solutions, Asia/Pacifique 1 Sims Lane # 06-11 387355 Singapore Phone: + 65 84 20 322 Fax: + 65 84 20 514 e-mail: asiasales@zebra.com 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 Website www.zebracard.com 90 P630i, P640i Card Printer User’s Manual 980541-003 Rev.
