Zebra P520 Owner's manual

User’s Manual

P520i

Part Number.980477-001 Rev. B

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-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.

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iv

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 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.

v

DECLARATIONS OF CONFORMITY

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.

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.

Model: P520i conforms to the following specification:

FCC Part 15, Subpart A, Section 15.107(a) and Section 15.109(a)

Class B digital device

73/23/EEC

modified

by 93/68/EEC

1999/5/CE

EMC Directive

EN 55024 (2001)

EN 60950 (1992) and

Amendments A1 to

A11 (1997)

Immunity to Electromagnetic

Disturbances

Radio frequency interferences

89/336/EEC

modified by

92/31/EEC

and

93/68/EEC

RF Emissions control

RF Emissions and immunity

for radio equipment

Low voltage

Directive

R&TTE Directive

EN300330-2 V1.1.1

EN 55022 (1998)

EN 301489-3 V1.4.1

Product safety

For a formal Certificate, please contact Compliance Engineering at the

Camarillo facility.

vi

v

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.

P520i 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 P520i Plastic Card Printer employs Dye Sublimation and Resin Thermal Transfer

technologies. Model numbers include identifiers that specify options are shown using

the following lettering conventions:

P520i - X X X X X - X DO

Smart Card:

O = No

E = Yes

Magnetic Encoder:

O = No Windows Driver

M = Yes & 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: I = 120 Vac (US) and

U = Parallel & USB 220 Vac (Europe)

C = Ethernet & USB U = 240Vac (UK)

}

Ship-away kit

vii

vi

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.

viii

vii

1

2

3

4

5

6

TABLE OF CONTENTS

GETTING STARTED • • • • • • • • • • 1

1•1 Unpacking your • • • • • • • • • • • • • • • • • • • • • • • • • • 1

1•2 Indicators and control • • • • • • • • • • • • • • • • • • • • • • 3

1•3 Printer installation • • • • • • • • • • • • • • • • • • • • • • • • 4

OPERATION • • • • • • • • • • • • • • 7

2•1 Printer Features • • • • • • • • • • • • • • • • • • • • • • • • • • 7

2•2 Loading Printing Ribbons • • • • • • • • • • • • • • • • • • • 8

2•3 Loading Lamination Patch • • • • • • • • • • • • • • • • • • • 10

2•4 Loading cards • • • • • • • • • • • • • • • • • • • • • • • • • • • 11

A- Card Feeder • • • • • • • • • • • • • • • • • • • • • • • • • • • 11

B- Card Cleaning Cartridge • • • • • • • • • • • • • • • • • • 12

C- Card Thickness Control Lever • • • • • • • • • • • • • • 13

D- Card Output Hopper • • • • • • • • • • • • • • • • • • • • • 13

2•5 Reject Card Box • • • • • • • • • • • • • • • • • • • • • • • • • • 14

2•6 Feeding one card at a time • • • • • • • • • • • • • • • • • • 16

2•7 Printing a test card • • • • • • • • • • • • • • • • • • • • • • • • 17

2•8 Printer menu information • • • • • • • • • • • • • • • • • • • 18

PRINTING A SAMPLE CARD • • • • • • 23

3•1 Install P520i Printer Driver • • • • • • • • • • • • • • • • • • • 24

3•2 printing a sample card • • • • • • • • • • • • • • • • • • • • • 25

CLEANING • • • • • • • • • • • • • • • 27

4•1 Cleaning system • • • • • • • • • • • • • • • • • • • • • • • • • • 28

4•2 Cleaning the print head • • • • • • • • • • • • • • • • • • • • • 29

4•3 Cleaning the Laminator rollers • • • • • • • • • • • • • • • • 30

4•4 Card Cleaning cartridge • • • • • • • • • • • • • • • • • • • • 31

TROUBLESHOOTING • • • • • • • • • 33

5•1 Interpreting LCD Display messages • • • • • • • • • • • • 33

A- Printing Station Status Messages • • • • • • • • • • • • 33

B- Laminator Station Status Messages • • • • • • • • • • 34

C- Print Station Alert Messages • • • • • • • • • • • • • • • 34

D- Laminator Station Alert Messages • • • • • • • • • • • 34

5•2 Print Quality Issues • • • • • • • • • • • • • • • • • • • • • • • • 37

TECHNICAL SPECIFICATIONS • • • • • 41

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APPENDIX A • • • • • • • • • • • • • • 45

Introduction • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 45

A- Media Loading orientation • • • • • • • • • • • • • • • • 46

B- Magnetic Encoder Cleaning • • • • • • • • • • • • • • • • 47

APPENDIX B • • • • • • • • • • • • • • 49

Introduction • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 49

A- Media Loading orientation • • • • • • • • • • • • • • • • 50

B- Smart Card Contact Station Interface • • • • • • • • • 50

APPENDIX C • • • • • • • • • • • • • • 51

Available Full-Color Ribbons • • • • • • • • • • • • • • • • • 51

Available Monochrome Ribbons • • • • • • • • • • • • • • • 52

Print Ribbons vs Laminator Compatibility • • • • • • • • 52

Available Patch Ribbons • • • • • • • • • • • • • • • • • • • • 53

Cards for Printing and Lamination • • • • • • • • • • • • • 53

Cards Suitable for Printing Only • • • • • • • • • • • • • • • 53

Accessories • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 54

x

1

GETTING STARTED

1

GETTING STARTED

1 • 1 Unpacking your card printer

Your P520i 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.

2

GETTING STARTED

In addition to user documentation, make sure the following items are included with

your P520i printer:

If any items are missing, please contact your dealer.

To reorder, please refer to Appendix C of this

manual.

CLEANING KIT

POWER CABLE(5)

PRINTER DRIVER CD

(Printer Documentation CD)

CARD HOPPER

CLEANING CARTRIDGE

Parallel CABLE

(for “U” Interface Option only)

GETTING STARTED

3

1 • 2 Indicators and Control

Your P520i printer has an LCD Display, two LED’s and two Panel Buttons.

The 16 character LCD 2-Line Display is used

for:

• Showing the printer’s current status

• Providing operator and service messages

(chapter 5)

The two LEDs are used for:

• 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:

• Clearing an error status (when LCD Display shows

an error and Alert LED is on).

• Invoking automatic retry of the operation which

gave the error.

• Selecting a Menu Option when in Menu Mode.

Note: The buttons beep when pressed.

P520

LCD Display

Menu Button “Next”

Clear Button “Select”

Power LED

Alert LED

LCD

Display:

LEDs:

Panel

Buttons:

1 • 3 Printer Installation

The following will guide you through the installation of your P520i printer.

CAUTION: Limit AC power supplied to the P520i

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 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.

GETTING STARTED

4

5

OPERATION

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

USB Computer

Connection

Ethernet Computer

Connector Option

OPERATION

6

The following shows the function of the switch and indicators found on P520i

Printers that use Ethernet Computer Interfaces.

Press the Ethernet Push button with the printer ON to to get a Test Card.

Press and hold the Switch while turning ON the Printer to perform a RESET.

TCP/IP

ENABLED STATUS

101.2.228 ADDRESS

255.225.25.0 SUBNET MASK

10.1.2.1 DEFAULT GATEWAY

Enabled TIMEOUT GATEWAY

NETWARE

ENABLED STATUS

Unknown FRAME FORMAT

Unknown MODE

GENERAL

2159748 SERIAL NUMBER

00074D20F484 HARDWARE ADDRESS

8.00 (3133A FIRMWARE (DATE CODE)

ERROR

None GENERAL

None TCP/IP

None NETWARE

JET ADMIN

ENABLED STATUS

PORT CONFIGURATION

PORT NAME

Online PRINTER STATUS

Enabled BIDIRECTIONAL

CONNECTED TO

None ERROR

ZebraNet Print Server Confiruration

FIRMWARE IS COPYRIGHTED

LED Action Status Being Signaled

Red Flashing Power-On Self Testing

Red Solid > 30 sec Failure of Power-On Tests

Red/Green Flashing Alternately Firmware Download mode

Green Solid > 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 Test Card

LEDs

Ethernet Push

Button

Ethernet Indicators

Ethernet Push Button

7

OPERATION

2

OPERATION

2 • 1 Printer Features

The following shows the features found on your P520i Printer:

Standard Features: Optional Features:

1 • Print Head Unlock Lever A • Smart Card Contact Station

2 • Print Head B • Magnetic Encoder Station

3 • Card Thickness Control Lever

4 • Card Feeder

5 • LCD Display and two panel Buttons

6 • Card Cleaning Cartridge

7 • Laminator

8 • Laminator Unlock Lever

9 • Card Output Hopper

10 • Rejected Card Box

11 • Cleaning Roller

OPERATION

8

2 • 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 life (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 • 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.

OPERATION

9

3 • 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 • 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.

2

1

OPERATION

10

2 • 3 Loading Lamination Patch

The P520i Printer requires approved patches (see Appendix C).

Clear patches, hologram patches or Overlay varnishes are specifically designed for

your P520i Printer. For optimum performance and printer life (Laminator), always use

approved patches.

1 • Remove patch 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

empty core with the spindle screw ( with tape

attached) onto the take-up spindle “2” .

Make sure the patch comes off the top of the supply

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.

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