Zebra Technologies 640I-UHF card Printer User Manual

Zebra Technologies Corporation card Printer Users Manual

user manual -4

74 Zebra P630i & P640i Card Printer User’s Manual 980541-003 Rev. B
980541-003 Rev. B Zebra P630i & P640i Card Printer User’s Manual 75
5
Printer Operation
Printing requires the Windows printer driver and your card design/issuing software or printer
command-level programming through the printer interface.
P630i & P640i Printers can be used with any Windows 2000 or Windows XP software
application program, using the drivers provided on CD with the printer. Refer to Section 3 for
instructions on installing the Printer Driver.
i Series Printers require the use of i Series ribbons for full color printing. These Resin Thermal
Transfer and Dye Sublimation ribbons are specifically designed for the i Series Printers
76 Zebra P630i & P640i Card Printer User’s Manual 980541-003 Rev. B
Printer Operation
Creating a Sample Card
Creating a Sample Card
Before you begin a new printing session, print a sample card to ensure that the cards will be
printed correctly. Follow the steps below to create your first card:
1. Open a new Microsoft Word document.
2. If the Card Printer was not selected as the default printer, go to File > Print; and choose
Zebra Card Printer from the printer names list; e.g., Zebra P640i.
3. Click the Close button.
4. Go to File > Page Setup.
5. Select the Paper Tab (above left); and under Paper Size, choose CR-80 Standard.
6. Select the Margins Tab (above right); and under Margins, set Top = 0.1", Bottom = 0.2",
Left = 0.2", and Right = 0.1".
7. Under Orientation, select Landscape or Portrait.
8. Click on OK.
9. View the blank Microsoft Word document (2.13" x 3.37").
10. Design a card with both black and colored text and with colored pictures.
Printer Operation
Printing a Sample Card
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Printing a Sample Card
Once you have completed creating your sample card, you are ready to print. Ensure your
printer has a Ribbon Cartridge installed. Refer to Section 2 for instructions on installing the
ribbon and loading the cards.
Print your sample card as follows:
1. Select File > Print to open the Print dialogue box.
2. Ensure the following settings in the Print dialogue box:
• Name: Zebra Card Printer; e.g., Zebra P640i
• Print to file: Unchecked
• Page Range: All
• Number of Copies: 1
• Collate: Unchecked
• Print what: Document
• Print: All pages in range
• Pages per sheet: 1 page
• Scale to paper size: No Scaling
3. Click the OK button.
4. Observe the printing process. The data download time will vary depending on the
complexity of the card design and the processing speed of the computer.
5. Once the printing is completed, the card is ejected from the printer.
6. Check the card for any discrepancies. If the sample card is correct, your Card Printer is
ready to produce more cards. For print quality issues, refer to Section 7.
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6
Cleaning
Cleaning the System
This section will guide you through the recommended cleaning processes to be performed on
your Printer:
Card Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Printhead Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Platen Care and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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.
Caution • PROTECT YOUR FACTORY WARRANTY!
The recommended cleaning procedures must be performed to maintain your
factory warranty. Other than the recommended cleaning procedures described in
this manual, allow only Zebra authorized technicians to service the Printer.
NEVER loosen, tighten, adjust, bend, etc., any part or cable inside the printer.
NEVER use a high pressure air compressor to remove particles in the printer.
80 Zebra P630i & P640i Card Printer User’s Manual 980541-003 Rev. B
Cleaning
Card Cleaning
Card Cleaning
Your Printer includes a simple cleaning system using a 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. By default, 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.
Cleaning
Cassette
Cleaning
Printhead Cleaning
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Printhead Cleaning
The card cleaning system using the Cleaning Cassette will normally do an adequate job of
cleaning the cards. However, a separate Printhead cleaning, using swabs, can remove more
stubborn deposits when print anomalies persist.
Step 1. Place the printer power switch in the ON ( | ) position.
Step 2. Open the printer Main Cover. The Printhead will raise for easy access.
Step 3. Remove the Ribbon.
Step 4. Clean the Printhead by moving an alcohol-moistened swab tip side-to-side across the
Printhead elements. Only use moderate force.
Step 5. Allow two to three minutes for the Printhead to dry.
Step 6. Re-install the Ribbon.
Step 7. Close the printer Main Cover.
To reorder swabs, reference the Printer Media List.
Caution • Only use foam-tipped swabs. Never use a sharp object to scrape deposits
from the print head. Permanent damage to the print head will result.
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Cleaning
Platen Care and Cleaning
Platen Care and Cleaning
The Platen plays an important part in the printing process, providing a rigid supporting surface
for the card as it passes under the Printhead.
Because flatness is important, the Platen is surface ground to close tolerances. Any
irregularities in the surface due to abrasion, dings, or even seemingly unimportant particles of
debris can noticeably degrade printing performance.
Step 1. Remove the Platen.
Step 2. Clean its surface with soapy water.
Step 3. Dry it with a lint-free cloth.
Step 4. Return the Platen to the Truck, pin and spring facing to the left, taking care not to
dislodge the spring.
Important • Regular cleaning of the Platen helps maintain performance.
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7
Troubleshooting
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.
• Open the main cover, then look for obvious problems, such as a card where it should not
be, media outages or misfeeds (color ribbon, laminate, cleaning cassette).
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Troubleshooting
Error Messages
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.
Troubleshooting
Indicator Light Status
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Indicator Light Status
READY MEDIA ALARM PRINTER STATUS
GREEN YELLOW ORANGE RED
Ready to print.
Printer busy.
Laminator(s) in sleep mode. When not in use, the heaters
cool at 1o F per minute.
Laminator(s) heating up, but not yet at operating
temperature.
Normal.
No cards in hopper, color ribbon out, cleaning tape out,
laminator cassette(s) out.
Mag encoding write failure.
Normal.
Serious error conditions, including: Main Cover open,
Laminator too hot, Card Transport stalled, card not seated
properly, mag encoding verification error, head-lift failure,
ribbon jam, card jam (any location), card missing (any
location), no gap between laminator patches.
Printhead temperature error, or internal firmware problem.
= LIGHT OFF
= LIGHT ON
= LIGHT FLASHING
✔
✔
✔
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Troubleshooting
Print Quality Problems
Print Quality Problems
This section will help you resolve print quality problems. The print quality is dependent on
several factors. 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 procedures below:
Example • Small spots appear on the printed card with a non-printed area or a different color.
• Possible Cause:
Contamination on the card surface.
Solution:
Check that cards are stored in a dust free environment.
Use a different supply of cards.
Clean the printer; see “Cleaning the System” on page 79.
Important • Operator should contact Zebra Card Printer Solutions Customer Service before
changing any factory settings within the printer.
Troubleshooting
Print Quality Problems
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Example • There are non-printing horizontal lines (white) on the card surfaces.
• Possible Cause:
Ribbon is not correctly positioned.
Solution:
Ensure that the ribbon is properly rolled onto the ribbon cores and that there are no
wrinkles in the ribbon.
Replace ribbon; see “Installing the Ribbon” on page 15
• Possible Cause:
Printhead is dirty.
Solution:
Clean the printhead; see “Printhead Cleaning” on page 81.
• Possible Cause:
Printhead elements are damaged (e.g., scratched or burnt).
Solutions:
Replace the printhead; contact Zebra Customer Service.
88 Zebra P630i & P640i Card Printer User’s Manual 980541-003 Rev. B
Troubleshooting
Print Quality Problems
Example • Printing shows very pale or inconsistent results.
• Possible Cause:
Ribbon has been stored improperly or is damaged.
Solution:
Change the ribbon and print again; see “Installing the Ribbon” on page 15.
• Possible Cause:
Cards may not meet specifications.
Solution:
Use a different supply of cards.
• Possible Cause:
Brightness and/or contrast may be set to values which are too high.
Solution:
Adjust brightness and/or contrast values in software; see “Image Adjustment Tab”
on page 64.
• Possible Cause:
Dust or embedded contamination on elements of the printhead.
Solution:
Clean the printhead; see “Printhead Cleaning” on page 81.
Troubleshooting
Print Quality Problems
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Example • Printing shows blurry printed image.
• Possible Cause:
Ribbon may not be correctly positioned.
Solution:
Check that the ribbon is properly rolled onto the ribbon cores, with no wrinkles.
Replace ribbon, making sure it locks in place, and print again; see “Installing the
Ribbon” on page 15.
• Possible Cause:
Ribbon may not be synchronized on the correct color panel position.
Solution:
Open lid, then close lid to synchronize ribbon.
• Possible Cause:
Cards may not meet specifications.
Solution:
Use a different supply of cards.
• Possible Cause:
Dust or embedded contamination inside the printer.
Solution:
Clean the printer; see “Cleaning the System” on page 79.
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Troubleshooting
Print Quality Problems
Example • No printing on the card.
• Possible Cause:
Ribbon may not be installed in the printer.
Solution:
Check for ribbon in the printer.
• Possible Cause:
Cards may not meet specifications.
Solution:
Use a different supply of cards.
• Possible Cause:
Cable on printhead may be disconnected.
Printhead elements may be scratched or burnt.
Solution:
Contact Zebra Customer Service for printhead repair or replacement information.
Troubleshooting
Print Quality Problems
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Example • Irregular white lines in the print, like the ribbon is wrinkling -- Ribbon Wrinkle.
• Possible Cause:
Ribbon may not be correctly positioned.
Solution:
Check to make sure that the ribbon is loaded correctly.
• Possible Cause:
Cards may not meet specifications.
Solution:
Use a different supply of cards.
• Possible Cause:
Dirty printhead and/or print path.
Solution:
Clean the printhead; see “Printhead Cleaning” on page 81.
Clean the print path.
• Possible Cause:
Worn or uneven platen roller surface.
Solution:
Replace the platen roller; contact Zebra Customer Service.
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Troubleshooting
Print Quality Problems
Poor color registration
• 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; contact Zebra
Customer Service.
• 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. Contact Zebra Customer Service.
• Check printed card for damage on corners or edges. Example: the card may be
scraping along the underside of the hopper base molding. Contact Zebra
Customer Service.
• Printhead pressure too light; contact Zebra Customer Service.
• Printhead may be running hot. Will occur if head resistance incorrectly entered in
driver software. Contact Zebra Customer Service.
• Toothed transport belt pulley may be slipping on drive shaft. Tighten set screws (make
sure the screws bear on flats on the shafts). Contact Zebra Customer Service.
• Check platen spring -- spring height should be the same as the pin height. Contact
Zebra Customer Service.
Poor color rendering
• Possible source issues - poor quality photos or graphics, card layout application
settings. Isolate the problem by printing a known image.
• Vary brightness and contrast controls; see “Image Adjustment Tab” on page 64
• Fine tune if necessary using Contrast Adjust; see “Color Calibration” on page 69.
Faint, non-uniform image
• Printhead pressure too low; contact Zebra Customer Service.
• Printhead not pivoting freely; contact Zebra Customer Service.
Important • Changes in contrast settings will not take effect until power is cycled.
Troubleshooting
Print Quality Problems
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Gaps in image at edges and corners
• Possible de-lamination/wear of platen’s rubber surface. Try cleaning platen; see
“Platen Care and Cleaning” on page 82. If unsuccessful, replace platen; contact Zebra
Customer Service.
• 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; see
“Printhead Cleaning” on page 81.
• White stripe means blown pixel (non-functioning heating element). One or two blown
pixels in isolation may be acceptable to some. Otherwise replace printhead; contact
Zebra Customer Service.
• 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; contact Zebra Customer Service.
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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 Color Sensor.
• Both ribbon cores not fully engaged on Spindles.
• Ribbon not secured to Take-up Core.
ALARM light stays ON after error condition is cleared
• Some alarms require recycling power in order to clear.
• Main cover interlock switch may not have actuated when cover closed.
• Alarm condition not corrected.
Card has both front and back images printed on same side
• Check selections made in Card Setup; see “Card Setup Tab” on page 63.
• Card failed to flip. Run Flip Test to check flip action; see “Flip Station Routines”
on page 71.
MEDIA light ON steady, but no obvious visual problem
• Color ribbon not in Color Sensor.
• Color ribbon supply and/or take-up cores not engaging properly on spindles.
• Cleaning cassette not engaging properly on the take-up drive.
• End of patch.
• Laminate misfeed.
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 take-up and supply torques. Contact Zebra Customer Service.
Note • There is a delay after closing the cover before the ALARM light goes out.
Troubleshooting
Unusual Noises/Unreported Events
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K (Black) panel sticks to card
• 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 take-up and supply torques. Contact Zebra Customer Service.
• Color image printing with K (black) panel. Check selections made in Printing
Preferences; see “K (Black) Panel Tab” on page 67.
Loud rattling/screeching from card transport
• 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 cannot rotate upward to disengage from the cleaning roller.
Completely unexpected print results
• Color ribbon out, or nearly out. Replace ribbon; “Installing the Ribbon” on page 15.
• Main cover opened during a print job. Open and close main cover, then press
RIBBON to re-sync ribbon. Reprint last job.
• Color ribbon panels out of sync, see previous action.
• Color ribbon not advancing consistently. Color ribbon supply and/or take-up cores not
engaging properly on spindles.
• 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.
• Color ribbon torn, or jamming intermittently. Clear jam. Pull out more from supply
roll and reattach to take-up roll.
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Troubleshooting
Unusual Noises/Unreported Events
Unusual events
In any of the following cases, and all other unusual events, try power cycling first, then
investigate specific issues:
• Printhead descends before card arrives. Contact Zebra Customer Service.
• Printhead stays down after card has gone away. Contact Zebra Customer Service.
• Laminate cutter fails to operate. Contact Zebra Customer Service.
• Unusual media light indications. Contact Zebra Customer Service.
Laminator spot check
• Make sure the Transfer Toggle is in the RUN (horizontal) position.
• Upper or lower laminate feed problems: remove, then replace transfer guides,
discarding laminate patches on transfer rollers. Check for laminate where it should not
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 mis-feeding of laminate due to poor engagement of white plastic idler on
cassette with drive roller. Mark the upper core to check that it rotates (no need to mark
the lower core - watch the notches on the laminate core). Feed laminate by pressing
the LAMINATE button.
• Laminate patch may be wrapped around the heated roller, causing card feed problems
and/or poor lamination. Turn printer OFF, remove the laminate patch immediately.
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, > 180 if absent - numbers valid only if transfer guides installed).
Note • Remember, the P640i Printer includes upper and lower laminators; the P630i Printer
has the upper laminator only.
Troubleshooting
Printhead Failures
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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 (i.e., components on the
head itself).
• These are independent problems, not necessarily co-located, that may require
replacement of the printhead; contact Zebra Customer Service.
Random occurrences of white (unprinted) spots
• 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
•See “Printer Adjustment” on page 58.
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 (on either edge)
• Almost certainly due to ribbon fold-over.
• Could be a head non-pivoting problem; contact Zebra Customer Service.
• Could be an image size problem.
Consistent image defects, card after card
• Debris on platen. Clean platen; see “Platen Care and Cleaning” on page 82.
• Platen surface not flat. Clean platen; see “Platen Care and Cleaning” on page 82.
Replace if necessary.
Debris on platen
• Clean platen; see “Platen Care and Cleaning” on page 82.
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Troubleshooting
Printhead Failures
Random colored patterns on image
• Ribbon wrinkling. Reduce take-up torque. Check printhead pressure. Contact Zebra
Customer Service.
• 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; “Color
Calibration” on page 59. Typically, the set of values should be the same for each
color.
• Printhead running too hot. Can happen after head replacement if head resistance
incorrectly entered through printer driver. Contact Zebra Customer Service.
Random colored lines
• Probably resulting from excessive take-up torque. Contact Zebra Customer Service.
Scratches/dings on long edges of card
• Look for a narrow band of abrasion up to about 0.1" (2.5 mm) in from either or both
of the long edges. Contact Zebra Customer Service.
• Card hopper base set too low. Contact Zebra Customer Service.
Troubleshooting
Laminate Problems
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Laminate Problems
Laminate not centered on card
• Vertical offset adjust (mechanical adjustment).
• Horizontal offset: Properties > Device Settings > Printer Adjustment > Laminate
Station Adjust; see “Laminator Station Adjustments” on page 72.
Laminate not parallel with card edges
• Skew adjust (mechanical adjustment).
• If using partial width laminate, edge guide not properly installed (one of
two positions).
• Transfer guide not properly installed.
• Laminate patch wrapped around heated roller.
Laminate wrinkling
• Can occur at end of roll. Remove cassette. If nearly out, discard. Install fresh roll.
• If not end-of-roll problem, suspect obstructions in laminate feed path.
Laminate bunches up outside the cutter assembly
This can happen to either upper or lower laminates.
• Failing to latch the cassette. Unlatch the cassette, gently wiggle the cassette out of its
pocket, then latch the cassette.
• Out-of-square scissor cut on the leading edge of the laminate. You can make this
easier by cutting the laminate above the latch. Remove all laminate scraps.
• Leading edge of laminate not reeled in even with the lips of the cassette. Cut the
leading edge of the fresh laminate as square as you can with scissors, then reel it in,
re-install, and latch the cassette.
Note • Any time you unlatch a cassette, you must check that the laminate is even with the lips
of the cassette before re-latching.
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Troubleshooting
Laminate Problems
Card jammed in laminator
• Dings or rough edges on the card (depending on vendor, card quality can vary, even
from batch to batch).
• Either of the cutters fails to cut, so the card is stopped dead by a “tail” of laminate,
now firmly held by the laminate feed roller, which can not be rotated by tugging on
the laminate.
• Heated Rollers, Infeed Rollers, or Outfeed Rollers not rotating.
Corrective Action:
Step 1. Turn off the printer; allow it to cool for about 10 minutes.
Step 2. Unscrew the heater assembly fastener, then partially withdraw the assembly with
the card.
Step 3. Pull the card out of the heater, inspect the rollers for laminate scraps and foreign
matter, then re-install the assembly. Do not use metal tools to clean the rollers.
Turn the Transfer Toggle clockwise (to the OPEN
position) to separate the transfer rollers and relieve
pressure on the card. When done, turn the Transfer
Toggle counterclockwise (to the RUN position).
RUN
OPEN
Hot Surface • Even after allowing cooling time, the assembly will be HOT, so hold it
only by its outer cover.
Troubleshooting
System Related Issues
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System Related Issues
Printer self-test takes more than a few minutes to complete.
READY indicator LED is not lit on the panel.
A communications problem exists.
Invalid IP address
• 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 consistency, it is recommended that the identical operating system
and settings be used on all computers generating print jobs.
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8
Technical Specifications
Specifications -- P630i / P640
Card size: Dimensions: 54 mm x 86 mm (2.125" x 3.375") nominal
Thickness: .75 mm (.03 in) ± 10%, frequently referred to as
“30 mil cards”
Card hopper: 150 cards
Throughput: 120 cards per hour dual-sided printing (YMC on front, K on back)
and laminating
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 (user
selectable) 952 pixels x 578 pixels, Standard
952 pixels x 600 pixels, Oversize 1
968 pixels x 610 pixels, Oversize 2
Magnetic stripe
encoder (option): Hi-Co type. 3-track, ISO and AAMVA compatible.
Cleaning system: Both card faces cleaned by high-tack roller. Roller is refreshed
automatically by transfer tape at selectable intervals (default 10 cards,
user-selectable 1 - 20 cards).
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Technical Specifications
Specifications -- P630i / P640
Laminating system: P640i: Separate laminators for front and back surfaces of card.
P630i: Single laminator for front surface of card.
Waste-free design with built-in cutters. Continuous 1 mil (0.025 mm)
thick polyester film in re-loadable cassettes.
Controls: Print, Ribbon advance, Laminate advance
Indicators: Ready to print, Media outage, Alarm
Data interface: USB, 10/100 Mbps Ethernet (option)
Windows drivers: Plug-and-Play 2000, XP
Security features: ID/Key (option), an ID/Code, and a printer-to-PC password lockout
Compliances: FCC Class A, UL/IEC/EN 60950-1
Voltage & frequency: 110 - 220 VAC, 50/60Hz
Power requirements: Printing + Laminating:
200 Watts Typical (after warm-up)
340 Watts Maximum
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
Net weight: 35 lb. (15.9 kg) net. Shipping weight 43 lb. (19.5 kg).
Dimensions:
Technical Specifications
Card Dimensions
980541-003 Rev. B Zebra P630i & P640i Card Printer User’s Manual 105
Card Dimensions
ISO standard dimensions for plain card
ISO standard dimensions for magnetic stripe card
980504-07-01
2.125 ± 0.002 in
(53.98 ± 0.050 mm)
Radius
0.125 in
(3.18 mm)
3.375 ± 0.010 in
(85.72 ± 0.25 mm)
0.009 ~ 0.034 in
(0.23 ~ 0.84 mm)
0.623 in (15.82 mm) min
0~0.115 in (2.92 mm) 0~0.115 in (2.92 mm)
MAGNETIC STRIPE
0.218 in (5.54 mm) max
106 Zebra P630i & P640i Card Printer User’s Manual 980541-003 Rev. B
Technical Specifications
Declarations of Conformity
Declarations of Conformity
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 liitettävä suojamaadoitus koskettimilla varustettuun pistorasiaan”
SE: “Apparaten skall anslutas till jordat uttag”
NO: “Apparatet må tilkoples jordet stikkontakt”
FCC Regulations
Models P630i & P640i have been tested and found to comply with the limits for a Class A
digital device, pursuant to Part 15 of the FCC Rules. Opreration is subject to the following two
conditions:
The device may not cause harmful interference, and The device must accept any
interference received, including interference that may cause undesired operation.
Caution: Any changes or modifications to this device not explicitly approved by the
manufacturer could void your authority to operate this equipment.
This equipment complies with FCC radiation exposure limits set forth for an uncontrolled
environment. This equipment should be installed and operated with minimum 20 cm between
the radiator and your body. This transmitter must not be colocated or operating in conjunction
with any other antenna or transmitter unless authorized to do so by the FCC.
FCC Radiation Exposure Statement (applicable to 15.247 device only)
This equipment complies with FCC radiation exposure limits set forth for an
uncontrolled environment. This equipment should be installed and operated with
minimum 20 cm between the radiator and your body. This transmitter must not be
collocated or operating in conjunction with any other antenna or transmitter unless
authorized to do so by the FCC.
Industry Canada Notice
Operation is subject to the following two conditions: (1) this device may not interference, and (2) this device must accept any interference
including interference that may cause undesired operation of the device.
cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.
89/336/EEC
modified by
92/31/EEC and
93/68/EEC
EMC Directive EN 55022 (1998) RF Emissions control
EMC Directive EN 301489-3 V1.4.1 RF Emissions and Immunity for radio
equipment
EMC Directive EN55024 (2001) Immunity to Electro-Magnetic
Disturbances
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 V1.1.1 Radio Frequency Interferences
980541-003 Rev. B Zebra P630i & P640i Card Printer User’s Manual 107
Appendix A
Magnetic Encoder
Media Loading Orientation
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.
Caution • ONLY USE cards that comply with ISO 7810 & 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.
Magnetic
Stripe
108 Zebra P630i & P640i Card Printer User’s Manual 980541-003 Rev. B
Magnetic Encoder
Magnetic Card Stripe Encoding
Magnetic Card Stripe Encoding
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.
ISO Standard Encoding
AAMVA Standard Encoding
Track # Field
Separator Track
Density Valid
Characters # of
characters
1 ^ 210 BPI* Alphanumeric
(ASCII 20~95†)79‡
2=75 BPI*Numeric
(ASCII 48~62) 40‡
3 = 210 BPI* Numeric
(ASCII 48~62) 107‡
* Bits per inch
†Except the “?” character
‡Including three characters: Start, Stop, and LRC. Note that these three
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.
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 three characters: Start, Stop, and LRC. Note that these three
characters are automatically managed by the magnetic encoder according to
the ISO Standard Norms.
980541-003 Rev. B Zebra P630i & P640i Card Printer User’s Manual 109
Appendix B
Smart Card Contactless
Encoder
Introduction
Smart cards can have a built-in microprocessor and/or memory chip. The printer may be
equipped with an optional contactless station for programming Smart Cards. Smart card
contactless encoders utilize a short-range radio signal. Use of the encoder is entirely under
control of the third-party application program -- no operator action is required. All other
printer operations remain the same as the standard model.
This section contains information on the additional operations of a P630i or P640i Printer
equipped with the optional Smart Card Contactless Station.
Media Loading Orientation
For contactless smart-cards, orientation is not a consideration (unless the card will be printed
on; see below).
110 Zebra P630i & P640i Card Printer User’s Manual 980541-003 Rev. B
Smart Card Contactless Encoder
Printing Contactless Smart Cards
Printing Contactless Smart Cards
When designing material to be printed on Contactless Smart Cards, be sure the printing will
not be on the smart chip area (i.e., the printing on either side of the card must not be on top of
or underneath the smart chip area).
By looking at an un-printed card very carefully, it is possible to see the chip location (as in the
figure on the left below). If you print in that area, results will be unsatisfactory (in the figure on
the right, the “star” should have been a single solid color).
Smart Chip Location
980541-003 Rev. B Zebra P630i & P640i Card Printer User’s Manual 111
Appendix C
Smart Card Contact Station
Introduction
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).
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.
This section contains information on the additional operations of a P630i or P640i Printer
equipped with the optional Smart Card Contact Station.
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
112 Zebra P630i & P640i Card Printer User’s Manual 980541-003 Rev. B
Smart Card Contact Station
Laminating Contact Smart Cards
Laminating Contact 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.
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.
INDEX
MARKER
CUT
LINE
Note • When using smart card or registered laminates, the laminate length value in the driver
may need to be adjusted; see Laminator Station Adjustments on page 72.
980541-003 Rev. B Zebra P630i & P640i Card Printer User’s Manual 113
Appendix D
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.
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 Non-Volatile
Random Access Memory (NVRAM). If the serial
numbers fail to match, or if no ID/Key is detected,
the printer is disabled. The ID/Key is carried in a
2” x ¾” 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
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.
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.
114 Zebra P630i & P640i Card Printer User’s Manual 980541-003 Rev. B
Printer Security
Printer Parameters in the Driver
Printer Parameters in the Driver
ID/Code
The ID/Code, or password, synchronizes the driver
with the printer. This prevents use of the printer with a
PC not having the same ID/Code.
The initial ID/Code is assigned at the factory during
manufacture. The factory assigned code is located on
a sticker on the underside of the ID/Key.
To change this code, select Start > Printers (or
Printers and Faxes). Right click Zebra P630i, or
Zebra P640i, then select Properties > Device Settings
> Control > Advanced Utilities.
In the Change ID/Code window, enter the old password from 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 longer return the printer to the
factory settings.
Restoring the Backup Configuration Settings
Revert to Backup Config as follows:
Step 1. Turn power OFF.
Step 2. Remove the color ribbon.
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.
Printer Security
Printer Parameters in the Driver
980541-003 Rev. B Zebra P630i & P640i Card Printer User’s Manual 115
Password Protection
Password protection is not the same as ID/Code. Password protection blocks access to various
low level printer adjustment screens.
To enable password protection, select Start > Printers (or Printers and Faxes). Right click
Zebra P630i, or Zebra P640i, then select Properties > Device Settings > Control >
Advanced Utilities.
In the Password Protection section, check Use Password; and enter a password of
your choice.
116 Zebra P630i & P640i Card Printer User’s Manual 980541-003 Rev. B
980541-003 Rev. B Zebra P630i & P640i Card Printer User’s Manual 117
Appendix E
Worldwide Sales & Support
For Technical Support or Repair Services, contact the appropriate facility listed below.
North America and Latin America - Technical Support
Zebra Technologies Card Printer Solutions
1001 Flynn Road
Camarillo, CA 93012-8706 USA
Phone: +1 800 511 9909 (when calling from within the U.S.)
+1 805 577-7002, option 1 (when calling from Latin America)
email: techsupport@zebra.com
North America and Latin America - Repair Services
Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-of-
warranty repair, contact Repair Services 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:
Zebra Technologies Card Printer Solutions
1001 Flynn Road
Camarillo, CA 93012-8706 USA
Phone: +1 800 452 4034
+1 805 578 1201
email: repair-ca@zebra.com
118 Zebra P630i & P640i Card Printer User’s Manual 980541-003 Rev. B
Worldwide Sales & Support
Europe, Middle East, and Africa - Technical Support
Zebra Technologies Card Printer Solutions
Dukes Meadow
Millboard Road, Bourne End
Buckinghamshire SL8 5XF, UK
Phone: +44 (0) 1628 556 000
FAX: +44 (0) 1628 556 001
e-mail: cardts@zebra.com
Europe, Middle East, and Africa - Repair Services
Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-of-
warranty repair, contact Repair Services 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:
Zebra Technologies Card Printer Solutions
Pittman Way
Fulwood, Preston
Lancashire PR2 9ZD, UK
Phone: + 44 (0) 177 2 69 3069
FAX: + 44 (0) 177 2 69 3046
email: ukrma@zebra.com
Asia Pacific - Technical Support and Repair Services
Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-of-
warranty repair, contact Repair Services 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:
Zebra Technologies Card Printer Solutions
120 Robinson Road
#06-01 Parakou Building
Singapore 068913
Phone: + 65 6885 0833
e-mail: esoh@zebra.com
Website
www.zebracard.com

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