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Zebra P640I User Manual

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Zebra
P640i Card Printer
Card Printer
User Guide
980541-001 Rev. A

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  • Page 1 ® Zebra P640i Card Printer Card Printer User Guide 980541-001 Rev. A...
  • Page 2 © 2004 ZIH Corp. The copyrights in this guide and the printers described therein are owned by Zebra Technologies Corporation. Un- authorized reproduction of this manual or the software in the label print engine may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506).
  • Page 3 P640i Card Printer User Guide Caution • The separate Quick Start Guide shows how to set up the printer using the standard USB interface. If your printer was configured for the optional Parallel or Ethernet connections, refer to Technical Note 9 in Section 4 of this Guide for instructions on driver installation.
  • Page 4: Warranty Information

    90 days (except where otherwise denoted) from date of purchase. This war- ranty becomes void if the item is modified, improperly installed or used, or damaged by accident or neglect. P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 5 Zebra. Specifically for software, Zebra is not liable for any inciden- tal or consequential damages caused by abuse or misapplication of the software or by its use in vio- lation of the U.S. copyright law or international treaty. 980541-001 Rev. A P640i Card Printer User Guide...
  • Page 6: Agency Approvals

    Do not dispose of this product in unsorted municipal waste. This product is recyclable. Please recycle according to your local standards. For more information, please see our web site at: http://www.zebra.com/recycle CONTACT INFORMATION Zebra Technologies • Card Printer Solutions North America 1001 Flynn Road Camarillo, CA 93012-8706 USA...
  • Page 7: Table Of Contents

    Printing basics ............3 What makes the P640i a different kind of printer ......3 What to expect when you turn on the power .
  • Page 8: Table Of Contents

    Error messages............27 viii P640i Card Printer User Guide 980541-001 Rev. A 10/15/2004...
  • Page 9 P640i Specifications ........
  • Page 10 Set up the Printers individually ......... 83 P640i Card Printer User Guide...
  • Page 11: Introduction

    Push Indicator Hopper buttons Mag encod- er (optional) 980541-001 Rev. A Introduction Cleaning Print station station P640i Card Printer User Guide Main cover Transfer toggle Rotate clockwise to separate trans- Laminating station Flip station Card transport knob For manual repo-...
  • Page 12: Overview

    Introduction Overview Overview The P640i Printer is a complete, fully automatic photo ID card fabricator. It comprises six functional elements: • Card hopper • Magnetic (“mag”) encoder - optional feature • Cleaning station • Print station • Flip station • Laminator Because the P640i Printer is fully automatic, it requires no attention from the operator other than media loading and an occasional vacuuming.
  • Page 13: Printing Basics

    YMC dyes are not. What makes the P640i a different kind of printer The print station in the P640i has no pinch rollers that need cleaning to maintain accuracy 980541-001 Rev. A Print head...
  • Page 14: What To Expect When You Turn On The Power

    Introduction Printing basics In the P640i the card is transported on a belt-driven truck that maintains precise registration Transport motor Toothed blet Card truck Platen the fan running , and a clicking sound inside the printer (the flip station resetting itself).
  • Page 15: Test Card

    The P640i printer receives data through one of three types of connector: Ethernet (optional feature), USB (standard feature) or Parallel (Centronics type, optional feature). Test card You may sometimes be asked to print a test card. This is the pattern stored in the printer’s memory (it has nothing to do with the computer).
  • Page 16: Ribbon Button

    If back side printing is not enabled, the printer will synchronize on the next yellow panel when the RIBBON button is pressed. P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 17: Indicator Light Summary

    (any location), card missing (any location), no gap be- tween laminator patches. = light on = light flashing P640i Card Printer User Guide Introduction INDICATOR LIGHT SUMMARY MAIN COVER OPEN, Laminator too hot, card...
  • Page 18: A Typical Card Production Sequence

    7. After its face cleaning the card is driven under the print head again, this time to print a yellow (Y) dye image - the first of three color passes. P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 19 12. As the card passes between the transfer rollers the laminate patches are rolled into place. They are then permanently bonded to the card by a pair of heated rollers applying pressure to the top and bottom surfaces. 980541-001 Rev. A INDICATOR LIGHT SUMMARY P640i Card Printer User Guide Introduction Upper cassette Cutter...
  • Page 21: Media Handling

    3. Place the weight on top of the card stack. 980541-001 Rev. A Media Handling If there is no mag stripe, and if there is P640i Card Printer User Guide...
  • Page 22: Hot Loading

    1. Open the main cover of the printer, then remove the spent cleaning cassette by pulling it toward you. 2. Remove the protective foil from the replacement cleaning cassette. P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 23: Why 10 Cards Is The Normal Clean Frequency

    When the color ribbon is exhausted, a warning message appears on the monitor, and the MEDIA light on the printer turns on. Important • for easy ribbon loading.. 980541-001 Rev. A Opening of the main cover elevates the printhead P640i Card Printer User Guide Media Handling Loading the color ribbon Takeup drive...
  • Page 24 Color Empty ribbon core P640i color ribbon, left, and empty core, right. The flange end with internal grooves goes to the back. Important • Are both the new ribbon and takeup cores fully home on the arbors, as far back as they will go? You should hear a click.
  • Page 25: Laminating Station

    This can be confusing if you don’t follow the procedure outlined in this guide. The cassettes are differentiated by color-coded dots:Red = UPPER Yellow = LOWER 980541-001 Rev. A P640i Card Printer User Guide Media Handling Laminating Station...
  • Page 26: Main Components Of The Laminating System

    Turn the UPPER latch counterclockwise, the LOWER clockwise. Caution • If either of the latch plates is opened, even unintentionally, the cassette affected must be removed and the laminate reeled in, see page 2-6. P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 27: Loading The Cassettes

    Make sure it is in the correct position for the partial width laminate you are using. 980541-001 Rev. A P640i Card Printer User Guide Media Handling Laminating Station...
  • Page 28: Installing The Cassettes

    “patch” of laminate onto the transfer roller. If laminate does not feed automatically, press the LAMI- NATE button. P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 29: Clearing The Laminate Channels

    (it will click into place, with its far leg against the back plate of the laminator). Press the LAMINATE button to load the transfer roller(s). 980541-001 Rev. A Laminate cutter guide P640i Card Printer User Guide Media Handling Laminating Station...
  • Page 30: Laminating Smart Cards

    (the printer driver allows adjustment of the cut location). Loading procedure for smart card laminate is exactly the same as for standard laminate. P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 31: Troubleshooting

    Image Adjustment Start > Printers (or Printers and Faxes) > Right click Zebra P640i > Printing Preferences > Image Adjustment Brightness and Contrast controls on the image Adjustment screen have same effect on the printed image as do similar controls on typical office color printers. Click Reset to restore default conditions.
  • Page 32: Troubleshooting Quality Problems

    Try cleaning platen. If unsuccessful, replace platen. Reference Technical Note 2 • Possible non-uniformity of card thickness, or card surface defects. P640i Card Printer User Guide Technical Note 4 Technical Note 2 Technical Note 4 Technical Note 4 980541-001 Rev. A...
  • Page 33: Continuous White Or Black Stripes On Card's Longer Dimension

    • Could be on either edge. Almost certainly due to ribbon fold-over, but could be a head non-pivoting problem, or an image size problem. 980541-001 Rev. A Troubleshooting quality problems Technical Note 4 Technical Note P640i Card Printer User Guide Troubleshooting Technical Note 4...
  • Page 34: Consistent Image Defects, Card After Card

    Settings > Printer Adjustment > Laminate Station Adjust. Reference Technical Note 6 Technical Note 2 Technical Note 4 5. Typically, the set Technical Note 4, Printer Adjustment Technical Note 2 Technical Note 6 P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 35: Laminate Not Parallel With Card Edges

    • Cleaning cassette not engaging properly on the takeup drive. Section 2 • See Laminator spot check, page 3-3 980541-001 Rev. A Unusual Printer/Lmainator Events Technical Note 6 P640i Card Printer User Guide Troubleshooting Technical Technical Note 8 Technical Note 5...
  • Page 36: Completely Unexpected Print Results

    Reference Technical Note Rattling noise every 10 cards • Cleaning cassette not firmly engaged. Reference 5, Flip Station Adjustment Technical Note 2 P640i Card Printer User Guide Technical Note 4, Printer Adjustment Technical Note 4 Technical Note 4, Printer Adjustment...
  • Page 37: Unusual Events

    Guide. Error messages Most P640i error conditions are identified by the printer itself, and are reported by the computer as error messages with corrective actions. Error messages are not further described in this section of the manual, which deals only with fault conditions that are not reported automatically.
  • Page 38 • Open the main cover, then look for obvious problems, such as a card where it shouldn’t be, media outages or misfeeds (color rib- bon, laminate, cleaning cassette). • Check this section, referring if necessary to the relevant Tech Note. P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 39 (any location), card missing (any location), no gap be- tween laminator patches. = light on = light flashing 980541-001 Rev. A P640i Card Printer User Guide...
  • Page 41: Technical Notes

    Interlock “cheating” is not something the operator should do, but as a technician you will need to run the P640i with the main cover open. Cut a narrow strip of plastic from a used CR-80 card, fold it, then push it into the interlock slot in the center wall. When the ALARM light goes out, the interlock switch is closed.
  • Page 42: Technical Note 1 - General Information

    Technical Note 1 - General Information Model P640i with card receiver may be “hot loaded” while the printer is powered up and operating (unlike the main cover, right, opening the card hopper cover does not disable the printer). P640i Specifications Card size: ISO CR-80 (2.125"...
  • Page 43: Id/Key

    Net weight 35 lb (15.9 kg) net. Shipping weight 43 lb (19.5 kg). Sensors and interlock switches in the P640i You cane learn a lot about how the P640i functions by spending a few minutes thinking about its various sensors and interlocks.
  • Page 44: Password Protection

    Check Use Password, then enter a password of your choice. > Printers (or Printers and Faxes) > Right click Zebra Start P640i > Properties > Device Settings > Control > Advanced Utilites > Show Sensor data Sensor Data Ribbon Panel Detect: The current reading of the color ribbon sensor.
  • Page 45 Start P640i > Properties > Ports Specifies the computer port to which the 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.
  • Page 46 Printing Defaults allows the system administrator to establish default settings such as print quality. Print Processor and Separator Page should be left alone. P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 47: Technical Note 2 - Card Transport

    Push the platen to the left against its spring, then pry the platen out using a CR-80 card. P640i Card Printer User Guide flatness...
  • Page 48: Truck Interlock (Arrowed)

    Determines the truck’s end stop position. Activated by a vertical flag on the left edge of the truck, photo above. Card presence sensor Located behind the mag encoder. Supply P640i Card Printer User Guide Take-up Cassette motion 980541-001 Rev. A...
  • Page 49: Cleaning Cassette

    Transport Parameters in the Driver Run Clean Cycle Decontaminates the card cleaning roller Run Clean Cycle by activating the cleaning cassette. One clean cycle per click. P640i Card Printer User Guide...
  • Page 50: Avoid These Problems

    > Printers (or Printers and Faxes) > Right click Start Zebra P640i > Properties > Device Settings > Control > Run Clean Cycle Card Presence Sensor > Printers (or Printers and Faxes) > Right click Start Zebra P640i > Properties > Device Settings > Control >...
  • Page 51: Technical Note 3 - Magnetic Stripe Encoder

    Technical Note 3 - Magnetic Stripe Encoder The “mag encoder” is a factory option for the P640i. Mag encoder installation Replacement read/write heads are shipped pre- assembled to the bracket shown here. Check the location of the wire. This must be in the lower yellow right corner.
  • Page 52 Position the head with its rim a hair below the edges of the bracket, then retighten the clamp screws and lock nuts. 7. Complete the procedure by re-running Mag Posi- tion Adjust as in Step 4 above. P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 53: Magnetic Encoding Preferences

    Position Adjust routine. It is intended only for testing and diagnosis. > Printers (or Printers and Faxes) > Right click Start Zebra P640i > Properties > Device Settings > Printer Adjustment > Advanced Adjust Magnetic Encoding Preferences > Printers > Right click Zebra P640i > Printing Start Preferences >...
  • Page 54: Techncial Note 4 - Print Station

    Replacement heads are shipped with theis screw preset, but some fine tuning may be required. Not Used Yaw adjust (technician only) P640i Card Printer User Guide The angle of the print head #4-40 skt hd cap screw Access for head angle...
  • Page 55: Print Head Attachment Hardware

    (with plain P640i Card Printer User Guide free rotation Printing Preferences , then set both Brightness and , Tech Note 8, then select...
  • Page 56: Print Station Parameters In The Driver

    Print Station Parameters in the Driver > Printers (or Printers and Faxes) > Right click Start Zebra P640i > Properties > Device Settings > Status > Advanced (Information) See also: > Printers (or Printers and Faxes) > Start Right click Zebra P640i >...
  • Page 57: K (Black) Panel Printing

    ìspideryî in appearance unless compensated for. Unfortunately, these requirements are in opposite corners. The P640i provides three controls for K panel printing: these are: 1. Black panel compensation (Adjustment screen, this page TN4 - x) If a line of black dots is printed along the card motion axis, the heating element (pixel) in question doesn’t...
  • Page 58 To correct this, increase the adjust parameter to the point where the ribbon ceases to advance freely, then add the number. P640i Card Printer User Guide Example of ribbon wrinkling : If the printhead doesn’t press more to...
  • Page 59: Color Calibration

    Zebra P640i > Properties > Device Settings > Color Calibration 980541-001 Rev. A Color rendering in the P640i can be described in terms of a curve, which determines how much power is put into the printhead for a given shade. The Y, M and C “color curves”...
  • Page 60: Technical Note 5 - Flip Station

    One end of the flip spring locates in a cavity in the rear flipper arm, the other in a hole in the rear surface of the carrier molding. Spring Carrier P640i Card Printer User Guide Azimuth Collar adjust Slide bearing...
  • Page 61: Flip Station Adjustment Procedure

    2. On the host computer follow this sequence: (integr > Printers (or Printers and Faxes) > Right Start al with click Zebra P640i > Properties > Device Settings the rear > Control > Advanced Utilites flipper 3. Click Move Truck to Flip Station.
  • Page 62: Flip Station Routines In The Driver

    Flip Station Routines in the Driver > Printers (or Printers and Faxes) > Right click Start Zebra P640i > Properties > Device Settings > Control > Advanced Utilites Flip Test 1: Picks up a card, runs it to the flip station, flips it, raises it to the laminator infeed, then ejects it through the laminator.
  • Page 63: Carrier Motion

    If the card position is incorrect, the truck can depart, leaving the card in the force! Printers and Faxes) > Right click Zebra P640i > Properties > Device Settings > Control > Advanced Utilites >...
  • Page 64 - the U-shaped azimuth adjust molding may be driven off the end of its track. This causes the carrier to wobble as the “U” re-engages on the way down. event P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 65: Techncial Note 6 - Laminator

    Important • Always adjust the latch after adjusting either of the screws in the pocket. Skew adjust Laminate Latch ears Transfer guide , see Section 5. Transfer roller P640i Card Printer User Guide Do not adjust Verticle offset adjust cutter Upper cassette Heater compart- Lower cassette...
  • Page 66: Laminate Position Adjustments

    Don’t worry about vertical offset at this stage unless the laminate overhangs grossly, in which case proceed to the Vertical offset adjustment procedure, below. P640i Card Printer User Guide Laminate patch motion Transfer roller...
  • Page 67 Note • the screw pushes out the cassette, and that the note therefore the laminate patch, by for the lower approximately 0.03" (just under 1 mm) P640i Card Printer User Guide same three actions One full counterclockwise turn of...
  • Page 68: Laminator Parameters In The Driver

    Laminator Parameters in the Driver > Printers (or Printers and Faxes) > Right click Start Zebra P640i > Properties > Device Settings > Control > Advanced Utilities > Show Sensor Data is also available by this route: Sensor Data Device Settings >...
  • Page 69: Correcting Laminator Problems

    Laminate Station Adjust > Printers (or Printers and Faxes) > Right click Start Zebra P640i > Properties > Device Settings > Printer Adjustment > Laminate Station Adjust Length Adjust (mils): This is the length of the laminate “patch”.
  • Page 70 TOOLS Even after allowing cooling time, the assembly will be HOT, so hold it only ny its outer cover. P640i Card Printer User Guide If necessary, turn the transfer roller toggle to separate the transfer rollers and relieve pres- sure on the card.
  • Page 71: Technical Note 7 - Id/Log

    > Printers (or Printers and Faxes) > Right click Start Zebra P640i > Printing Preferences > Enable Logging: When checked, logging is active. Create New Log File Each Day: Check the File box, then type in a directory path to a folder of your choosing.
  • Page 72: Technical Note 8 - Using The Windows Printer Driver

    Technical Note 8 - Using the Windows Printer Driver The P640i printer driver includes setup and diagnostic tools in two distinct groups. These are Preferences and Properties. Generally speaking, Properties screens are intended for use only by the trained technician. This is because they can cause unexpected results if modified without the necessary experience.
  • Page 73: What Is Black Extraction

    K, omitting YMC from that region.) The K (black) panel is not a dye. It is more of a paint containing carbon black, which is highly visible to infrared-type readers. P640i Card Printer User Guide K (Black) Panel of a card, a same side...
  • Page 74 K (black) panel either on top of the YMC image, or replacing it entirely – your choice. Printing Preferences Reference Technical Note Printing Preferences Reference Technical Note P640i Card Printer User Guide Magnetic Encoding 3, Magnetic Encoder ID/Log 7, ID/Log 980541-001 Rev. A...
  • Page 75: Printer Properties

    Status , below. Sensor Data (Another way to display this screen is through this sequence, see page TN8-5: and Faxes) > Right click Zebra P640i > Properties > Device Settings > Sensor Data) , the location Status P640i Card Printer User Guide Status >...
  • Page 76 (if no job is in process, the buffer values will already be zero). > Printers (or Printers and Faxes) > Right click Start Zebra P640i > Properties > Device Settings > Control > Advanced Utilities Flip Test 1: see Tech Notes TN5 Flip Station...
  • Page 77: Update Backup Config

    - a very useful diagnostic tool. 980541-001 Rev. A Back to Advanced Utilites > Printers (or Printers and Faxes) > Right click Start Zebra P640i > Properties > Device Settings > Control > Advanced Utilities Mag Position Adjust: see Tech Notes TN3 Magnetic Encoder...
  • Page 78 “Communications Failure” messages occur frequently. Device Settings > Printers (or Printers and Faxes) > Right click Start Zebra P640i > Properties > Device Settings > Adjustment Print Station Adjust: see Tech Notes TN4 Print Station Laminate Station Adjust: see Tech Notes TN6...
  • Page 79 Device Settings Color Calibration > Printers (or Printers and Faxes) > Right click Start Zebra P640i > Properties > Device Settings > Color Calibration See Tech Notes TN4 Print Station. Printer Properties > Printers (or Printers and Faxes) > Right click Start Zebra P640i >...
  • Page 80: Idprint Lite

    CD, see below (these image files also come with the P640i driver when downloaded from the Web). Test for alignment of lamin-Test for ribbon wrinkling...
  • Page 81 Assuming IDPrint Lite is stored in its default location, launch it by going to the Windows Start menu, then All Programs, then to Zebra Technologies followed by ID Print Lite Typically, Image 1 is for the front of the card, and Image 2 the back.
  • Page 82: Card Setup

    IDPrint Lite program is closed. Card Setup £ ¢ Image 2 ¢ ¢ £ ¢ ¢ ¢ ¢ Image 2 ¢ £ Image 2 Image 3 ¢ screen found P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 83: Technical Note 9 - Installing The Windows Printer Driver

    Windows Printer Driver First things first For any of the operations described in this section you need the P640i Driver Software. This is on the Driver CD. It may also be downloaded from the Zebra Support Web page. Driver CD If you have the CD, place it in the computer’s CD-...
  • Page 84: Installing The Printer Driver

    The New Hardware Found message appears only if the P640i printer has never been installed on the computer to which it is now connected. If you plan to connect the P640i Printer to the computer’s parallel port, the computer, then shut down make the connection.
  • Page 85: Install Using Zebra's Printer Setup Screen

    Configure screen appears, USB or Parallel. Note • Compatibility Mode shold be enabled only if the P640i printer is connected to the computer’s parallel port through a third party “dongle” (a hardware security device). 6. Click Finish to complete the installation.
  • Page 86 “dongle” (a hardware security device) The P640i is always a Local Printer even if it is connected by Ethernet to a network of several computers. In such an installation the P640i...
  • Page 87 OK. This brings up a screen that offers another choice of printers, this time only from Zebra. Select Zebra Technologies and Zebra P640i. If you don’t have the CD, go to Step 10. 980541-001 Rev. A After selecting the P640i go to Step 11.
  • Page 88: Install Using "Add A Printer

    Printer Wizard screen. 14. The next screen warns that installation of the driver software may destabilize your system. The P640i driver software has been exhaustively tested in many installations, and has caused no problems of which Zebra is aware. Click Continue Anyway to complete the printer driver installation.
  • Page 89: Firewall Issues

    Switch on the printer, then test for functionality by printing a test card (press the PRINT button). Connect the Ethernet port (RJ45 receptacle) on the P640i printer to the network through a hub, switch or router. Use only a pass-through cable (also known as straight-through).
  • Page 90 10. From this point on the Add Printer Wizard will complete the installation semi-automatically. Check each screen to be sure the checked items are correct before moving on to the next. 11. Select Local printer. P640i Card Printer User Guide 980541-001 Rev. A...
  • Page 91 The P640i is always a local printer even if it is connected by Ethernet to a network of several computers. In such an installation the P640i printer driver would be on each of the separately installed connected computers, so the P640i would not be a “network printer”...
  • Page 92 Printer Wizard screen. 18. The next screen warns that installation of the driver software may destabilize your system. The P640i driver software has been exhaustively tested in many installations, and has caused no problems of which Zebra is aware. Click Continue Anyway to complete the printer driver installation.
  • Page 93: Technical Note 10 - Printer Pooling

    ATLUSB002 and ATLUSB003 ports, then click OK. The setup now is three printers (Zebra P640i 1, Zebra P640i 2, and Zebra P640i 3), and one “pool”, which is all of them. Using the printer pool Send print jobs to the pool, not to an individual printer.