ZEBRA ZXP Series 7

Service Manual

P1036102-002
Copyright Notice
© 2013 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.

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 Technologies Corporation reserves
the right to make changes, for the purpose of product improvement, at any time.

Trademarks
ZXP Series 7 is a trademark and Zebra is a registered trademark of Zebra Technologies
Corporation. Windows is a registered trademark of Microsoft Corporation in the United States
and other countries. All other trademarks or registered trademarks are marks of their
respective holders.

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.com/environment

P1036102-002 Rev. A
 Contents

1 • Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Printer Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3 Operator Control Panel (OCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.4 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.5 Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
1.6 Zebra Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2 • Installation and Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.2 Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.2.1 Printer without a Laminator . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.2.2 Printer with a Laminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.3 Setting up the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.3.1 Loading Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.3.2 Installing the Card Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2.3.3 Installing the Dual Cleaning Cartridge . . . . . . . . . . . . . . . . . . . .29
2.3.4 Installing the Cleaning Cassette . . . . . . . . . . . . . . . . . . . . . . . . .31
2.3.5 Loading a Print Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
2.3.6 Loading the Laminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
2.4 Connecting Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

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2.5 Connecting the Printer to your Computer . . . . . . . . . . . . . . . . . . . . . . . .50

2.5.1 Interface Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . .50
2.5.2 USB Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
2.5.3 Ethernet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
2.6 Installing the Windows Printer Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . .53
2.6.1 Installing the USB Printer Driver . . . . . . . . . . . . . . . . . . . . . . . . .53
2.6.2 Installing the Ethernet Printer Driver . . . . . . . . . . . . . . . . . . . . .59
2.7 Changing the Printer Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
2.7.1 General Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
2.7.2 Sharing Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
2.7.3 Ports Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
2.7.4 Advanced Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
2.7.5 Color Management Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
2.7.6 Security Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
2.7.7 Device Information Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
2.8 Changing the Printing Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
2.8.1 Card Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
2.8.2 Black Panel (K) Optimization Tab . . . . . . . . . . . . . . . . . . . . . . .88
2.8.3 Color (YMC) Optimization Tab . . . . . . . . . . . . . . . . . . . . . . . . . .91
2.8.4 Encoding Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
2.8.5 About Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

3 • Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
3.2 Card Movement During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
3.3 Printing Technologies and Ribbons . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
3.4 System-Level Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
3.5 Main PCBA (CPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

4 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
4.2 OCP Test Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
4.3 Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

5 • Replacement Procedures for the Printer . . . . . . . . . . . . . . . . . . . 113

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
5.2 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
5.3 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
5.4 Procedure List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
5.5 Kit List ( P1037750- ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
5.6 Procedures: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
5.6.1 Reject Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
5.6.2 Feeder Cartridge Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
5.6.3 Ribbon Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
5.6.4 Card Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

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5.6.5 Shroud for Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

5.6.6 Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
5.6.7 Rear Feeder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
5.6.8 Options Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
5.6.9 OCP PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
5.6.10 Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
5.6.11 Control Panel Door Open Sensor . . . . . . . . . . . . . . . . . . . . . .141
5.6.12 Print Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
5.6.13 Door Button and Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
5.6.14 Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
5.6.15 Panel, Plungers, and Springs . . . . . . . . . . . . . . . . . . . . . . . . . .148
5.6.16 Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
5.6.17 Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
5.6.18 Reject Bin Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
5.6.19 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
5.6.20 Main PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
5.6.21 Ethernet PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
5.6.22 Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
5.6.23 Feeder/Flipper/Options Assembly . . . . . . . . . . . . . . . . . . . . . .219
5.6.24 Feeder/Flipper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
5.6.25 Ground Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
5.6.26 Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
5.6.27 Feeder Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
5.6.28 Flipper Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
5.6.29 Options Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253

6 • Replacement Procedures for the Laminator . . . . . . . . . . . . . . . . 281

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281
6.2 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282
6.3 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
6.4 Procedure List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
6.5 Kit List ( P1037750- ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .286
6.6 Procedures: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288
6.6.1 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288
6.6.2 Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
6.6.3 Lower Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
6.6.4 Door Assembly (Door and Hinges) . . . . . . . . . . . . . . . . . . . . . .292
6.6.5 Latch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
6.6.6 Laminator / Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
6.6.7 Bottom Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299
6.6.8 Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
6.6.9 Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
6.6.10 Molded Ribbon Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
6.6.11 Square Corner Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304

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6.6.12 Laminator Heater Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .305

6.6.13 Halogen Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306
6.6.14 24V Heater Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309
6.6.15 Motor and Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .311
6.6.16 Laminator Controller PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . .314
6.6.17 Media Authentication PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . .316
6.6.18 Top Laminator Control Motor . . . . . . . . . . . . . . . . . . . . . . . . . .317
6.6.19 Bottom Laminator Control Motor . . . . . . . . . . . . . . . . . . . . . . .318
6.6.20 Staging Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319
6.6.21 Media Authentication Antenna PCBAs . . . . . . . . . . . . . . . . . . .320
6.6.22 Front Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322
6.6.23 Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
6.6.24 Cassette Latch Assembly (Top & Bottom) . . . . . . . . . . . . . . . .324
6.6.25 Thermopiles (Top & Bottom) . . . . . . . . . . . . . . . . . . . . . . . . . .332
6.6.26 Top Thermopile Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336
6.6.27 Bottom Thermopile Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337
6.6.28 Flexible Ribbed Rollers (Left & Right) . . . . . . . . . . . . . . . . . . .338
6.6.29 Card Staging Nip Rollers (Left & Right) . . . . . . . . . . . . . . . . . .339
6.6.30 Platen Overrun Roller (Top & Bottom) . . . . . . . . . . . . . . . . . . .340
6.6.31 Exit Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341
6.6.32 Cutters (Upper & Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
6.6.33 Laminate Ribbon Rollers (Top & Bottom) . . . . . . . . . . . . . . . . .346
6.6.34 Card Entry Sensor Cable Assembly . . . . . . . . . . . . . . . . . . . . .347
6.6.35 Card Laminator Sensor Cable Assembly . . . . . . . . . . . . . . . . .348
6.6.36 Card Exit Sensor Cable Assembly . . . . . . . . . . . . . . . . . . . . . .349
6.6.37 Door Sensor Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . .350

7 • Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

7.1 Cleaning the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
7.1.1 When to Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352
7.1.2 Initiate the Cleaning Process . . . . . . . . . . . . . . . . . . . . . . . . . .352
7.1.3 Clean the Card Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
7.1.4 Clean the Feeder Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .354
7.1.5 Polish the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .355
7.2 Cleaning the Laminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356
7.2.1 When to Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356
7.2.2 Initiate the cleaning process: . . . . . . . . . . . . . . . . . . . . . . . . . .356
7.2.3 Clean the Laminator Card Path . . . . . . . . . . . . . . . . . . . . . . . .357
7.2.4 Clean the Laminator Media Rollers . . . . . . . . . . . . . . . . . . . . .358
7.2.5 Clean the Laminator Oven (Heater Rollers) . . . . . . . . . . . . . . .360
7.3 Dual Cleaning Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
7.4 Manual Feed Cleaning Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363

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8 • ZXP Series Toolbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365
8.2 Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .366
8.3 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .367
8.3.1 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .367
8.3.2 Printer Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368
8.3.3 Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369
8.3.4 Laminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370
8.4 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371
8.4.1 Job Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371
8.4.2 Save/Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .373
8.4.3 Firmware and Lookup Tables . . . . . . . . . . . . . . . . . . . . . . . . . .374
8.4.4 Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .376
8.5 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
8.5.1 Clean Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
8.5.2 Clean Laminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .393
8.6 Print Test Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .394
8.7 Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .395
8.7.1 Magnetic Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .395
8.7.2 Smart Card (contact and contactless encoding) . . . . . . . . . . .397
8.8 Advanced Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399
8.8.1 Configure Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399
8.8.2 Security Roles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405
8.9 Print Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406

A • Printer Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407

B • Network Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
C • Magnetic Card Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
D • Smart Card Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
E • Spare Part Kits and Upgrade Kits . . . . . . . . . . . . . . . . . . . . . . . . . 429
F • ZXP Series 7 Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
G • Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
H • Upgrade Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
I • Worldwide Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual vii

viii Zebra ZXP Series 7 Card Printer Service Manual P1036102-002
 1
Introduction

1.1 Description
This Manual provides detailed information on the installation, operation, and maintenance of
Zebra ZXP Series 7 Card Printers manufactured by Zebra Technologies Corporation.

The ZXP Series 7 offers the choice of single- or dual-sided direct to card printers with a range
of options that can be installed in the factory or added later so the printer can be scaled as
business needs grow or demands change.

The single-sided Laminator lays down and seals a laminating film on the top surface of the
printed card for added security; the dual-sided Laminator lays down and seals laminating
film on both the top and bottom surfaces of the printed card. A variety of Laminating Films
are available for specific uses; for details, go to http://www.zebra.com/supplies.

References to “the printer” in this document apply to either the single-sided or the dual-
sided Printer.; similarly, references to “the laminator” apply to either the single-sided or the
dual- sided Laminator.

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 1: Introduction
Printer Components

1.2 Printer Components

Printer only

Print Cover Options Cover Feeder Cartridge

Release Button

Operator Control
Panel (OCP)

Output
Hopper

Manual
Feed Slot

Reject Bin

Ribbon Drawer

Printer with Laminator

Laminator Cover Print Cover Options Cover Feeder Cartridge

Release Button Release Button

Operator Control
Panel (OCP)

Output
Hopper

Manual
Feed Slot

Laminator Reject Bin

Bottom Cover
Ribbon Drawer

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 1: Introduction
Operator Control Panel (OCP)

1.3 Operator Control Panel (OCP)

The printer is equipped with an OCP Display and three “soft” OCP Buttons which give access
to the printer menus. The menus can be accessed when the printer status shows READY.

• Press the MENU button, to access the Main Menu.

• Press the INFO button, to access and view the Printer Settings Menu.

1.3.1 Messages
The OCP Display provides printer status information. The messages displayed fall into three
categories:

• Operational, see Page 4.

• Warning, see Page 5.
• Error, see Page 5.

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 1: Introduction
Operator Control Panel (OCP)

Operational Messages

MESSAGE DESCRIPTION
ALARM An error message needs to be cleared before normal operations
can resume.
CANCELING The Cancel button was pressed, and the current operation is
being terminated.
CONFIGURATION DATA Configuration data is being transferred from the computer to
the printer.
CONTACT OPERATION Contact Smart Card is being encoded; i.e., the card is in position
and data is being transferred.
CONTACTLESS OPERATION Contactless Smart Card is being encoded; i.e., the card is in
position and data is being transferred.
COOLING Cooling printhead to temperature.
PRINTHEAD TEMPERATURE
COOLING Ready to accept a print job, laminator cooling; e.g., when
WAITING TO LAMINATE switching from 2-sided laminating to 1-sided laminating.
DIAGNOSTIC Diagnostic testing in progress.

JOB DATA Data is being transferred from the computer to the printer.

LAMINATING Print job received, laminating in process.

MAG OPERATION A Magnetic Stripe Card is being encoded; i.e., card is in position
and data is being transferred.
MANUALLY INSERT CARD Waiting for manual card feed (this function is set via the Card
FROM FRONT Setup Tab on page 78).
OFFLINE Status toggled (offline/online) via the OCP Advanced
Settings Menu.
PAUSING The Pause button was pressed.

PRINTING Print job received, printing in process.

READY Ready and at temperature.

STANDBY Printer is in “sleep” mode; i.e., power save mode.

WAIT Performing a self test on startup.

INITIALIZING
WARMING Ready to accept a print job, laminator warming; e.g., when
WAITING TO LAMINATE switching from 1-sided laminating to 2-sided laminating, or when
the printer has just powered up and the laminator is warming.
WARMING Warming printhead to temperature.
PRINTHEAD TEMPERATURE
WARNING Indicates that additional OCP instructions need to be performed;
e.g., RIBBON LOW, etc.

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 1: Introduction
Operator Control Panel (OCP)

Warning Messages
Warnings alert the operator to action that should be taken; the printer will generally
continue operation.

WARNING DESCRIPTION
(Printer will still operate)
BOTH LAMINATES LOW Indicates that both Laminate cassettes (Top and Bottom) are
low; see Loading the Laminate on page 36.
BOTTOM LAMINATE LOW Indicates that the Bottom Laminate cassette is low; see Loading
the Laminate on page 36.
CLEAN FEEDER Indicates that the Feeder needs cleaning; see Clean the Feeder
Path on page 120.
CLEAN CARD PATH Indicates that the Card Path needs cleaning; see Clean the
Card Path on page 119
CLEAN LAM CARD PATH Indicates that the Laminator Card Path needs cleaning; see
Clean the Laminator Card Path on page 123.
CLEAN LAM ROLLERS Indicates that the Laminator Rollers need cleaning; see Clean
the Laminator Media Rollers on page 124.
CLEAN LAM OVEN Indicates that the Laminator Heated Rollers need cleaning; see
Clean the Laminator Oven (Heater Rollers) on page 126.
RIBBON LOW Indicates that the Ribbon spool is low; see Loading a Print
Ribbon on page 33.
TOP LAMINATE LOW Indicates that the Top Laminate cassette is low; see Loading the
Laminate on page 36.

Error Messages
Refer to Section 4, Troubleshooting, for a list of the error messages, possible causes, and
possible solutions.

Errors are displayed when a situation causes the printer to stop operating. Depending on the
cause of the error message, restarting the printer or clearing the displayed error may return the
printer to operational status; or the printer may require troubleshooting and repair.

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 1: Introduction
Operator Control Panel (OCP)

1.3.2 Printer Menu Information

Main Menu

MENU Button
(Operating Mode Display)

RETURN

PRINT TEST CARDS See Print Test Cards Menu on page 8.

NETWORK SETTINGS Network Settings Menu on page 9.

ADVANCED SETTINGS See Advanced Settings Menu on page 10.

Main Menu
UP DOWN SELECT

• Press the UP button to move up the menu list

• Press the DOWN button to move down the menu list
• Press the SELECT button to select the item from the list.

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 1: Introduction
Operator Control Panel (OCP)

Info Menu

INFO Button
(Operating Mode Display)

Displays MCB FW Ver, MAB FW Ver, MSN (Machine Serial Number),

PRINTER INFO
PH S/N (Printhead Serial Number).

NETWORK INFO Displays DHCP, IP, Mask, GW, and MAC.

RIBBON INFO Displays Type, # Images, and % Remaining.

PRINTHEAD USAGE Displays Card Count and Printhead Lines.

REJECT BIN Displays number of cards in Reject Bin (Card Count = n).

CONFIGURATION INFO Lists RAM, Single or Dual Sided, and Options Installed: Mag, Encoder, Laminator.

LAMINATOR INFO * Displays LCB, MAB, LSN, Top installed (yes/no), Bottom installed (yes/no).

TOP LAMINATE INFO * Displays P/N, Type, # Images, and % Remaining.

BOTTOM LAMINATE INFO * Displays P/N, Type, # Images, and % Remaining.

LAMINATOR TEMPERATURE * Displays Settings: Top and Bottom temperature; and Current: Top and Bottom temperature.

LAMINATOR ODOMETER * Unit on (# days), Top on (# days), Bottom on (# days), # Laminated, # Processed.

CAL LUT INFO Displays info for LUT 1 (Look-Up Table 1) and LUT 2 (Look-Up Table 2).

CLEANING DUE Displays # Cards since last cleaning of Card Path, Feeder Path, Printhead, Laminator Path*, and
Laminator Oven*.

* Only applies to Printers with a Laminator.

Info Menu
PREV NEXT EXIT

• Press the PREV button to move up the menu list

• Press the NEXT button to move down the menu list
• Press the EXIT button to return to the Operating Mode Display

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 1: Introduction
Operator Control Panel (OCP)

Print Test Cards Menu

Main Menu

RETURN

COUNT Sets the number of Test Cards to be printed (1, 5, 10, ..., 100).

SIDES Selects single-sided or double-sided card printing.

GRADIENT BOXES
Selects Test Card to be printed; see OCP Test Cards on page 111.

DENSITY SETUP

NOTE: When a monochrome ribbon is installed, only the MONOCHROME ONLY

card is available.
MONOCHROME ONLY

Print Test Cards Menu

UP DOWN SELECT

• Press the UP button to move up the menu list

• Press the DOWN button to move down the menu list
• Press the SELECT button to select the item from the list

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 1: Introduction
Operator Control Panel (OCP)

Network Settings Menu

Main Menu

RETURN WITHOUT SAVE

SAVE SETTINGS

DHCP MODE Enable or disable the DHCP Mode.

SET IP ADDRESS Change the IP Address.

SET SUBNET MASK Change the Subnet Mask.

SET DEFAULT GATEWAY Change the GW (Gateway).

Network Settings Menu

UP DOWN SELECT

• Press the UP button to move up the menu list

• Press the DOWN button to move down the menu list
• Press the SELECT button to select the item from the list.

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 1: Introduction
Operator Control Panel (OCP)

Advanced Settings Menu

Main Menu

RETURN

SELECT LANGUAGE Displays current language, sets language option (English, French,
Spanish, German, Brazilian Portuguese, or Italian).

FLUSH PRINT QUEUE Deletes all pending print jobs in the printer.

PRINTER ONLINE Toggles printer Online / Offline.

CLEAN PRINTER See Clean Printer Menu on page 11.

SET SLEEP TIMER Sets sleep timer function value (never, 30 minutes, 60 minutes,
120 minutes, or 480 minutes).

SET SCREEN CONTRAST Adjusts the OCP display contrast (20 min, 50 max, default 35).

CLEAR REJECT BIN Resets reject bin card count to 0.

POLISH PRINTHEAD When enabled in the ZXP Toolbox (see Page 392), Printhead
Polishing can be done via the OCP (see Page 355). Use is
password protected and limited to Zebra-authorized
service personnel.

Advanced Settings Menu

UP DOWN SELECT

• Press the UP button to move up the menu list

• Press the DOWN button to move down the menu list
• Press the SELECT button to select the item from the list.

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 1: Introduction
Operator Control Panel (OCP)

Clean Printer Menu

Advanced Settings Menu

RETURN
Refer to Section 7, Preventive Maintenance, for detailed cleaning instructions.

CLEAN CARD PATH Use the Print Path Cleaning Card, and step through the cleaning process.

CLEAN FEEDER Use the Feeder Cleaning Card, and step through the cleaning process.

CLEAN LAM CARD PATH * Use the Laminator Cleaning Card, and step through the cleaning process.

CLEAN LAM ROLLERS * Use a Cleaning Swab, and step through the cleaning process.

CLEAN LAM OVEN * Use the Laminator Hot Roller Cleaning Card (with adhesive), and step
through the cleaning process.

* Only applies to Printers with a Laminator.

Clean Printer Menu

UP DOWN SELECT

• Press the UP button to move up the menu list

• Press the DOWN button to move down the menu list
• Press the SELECT button to select the item from the list

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 11

 1: Introduction
Technical Specifications

1.4 Technical Specifications

Standard Features
• 300 dpi (11.8 dots/mm) print resolution,
• Image size 1006 * 640 pixels
• USB 2.0 and Ethernet 10/100 connectivity
• Microsoft Windows Certified drivers
• 200 card capacity feeder (30 mil)
• 15 card reject hopper (30 mil)
• 100 card output hopper (30 mil)
• Manual feed capability
• ix Series™ intelligent media technology
• 21-character x 6-line LCD operator display with configurable soft keys
• Kensington® physical lock slot

Optional features
• FIPS 201 compliant single-sided and dual-sided laminator
• Lockable enclosures and card feeder

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 1: Introduction
Technical Specifications

Specifications
Encoding options and specifications
• Magnetic stripe encoder – AAMVA and ISO 7811 (new and pre-encoded, tracks 1, 2,
and 3, high and low coercivity)
• ISO 7816 Smart Card Contact Station for third party external contact encoders
• Combined MIFARE® ISO 14443 A & B (13.56 MHz) contactless and ISO 7816 Contact
Encoder with EMV level 1 certification, and PC/SC compliance (supported over USB
and Ethernet)

Software
• ZMotif™ SDK support and sample code for application integration in various languages
and development environments.
• Microsoft Windows Certified printer drivers with Toolbox utility features: Windows 7,
Vista, and Server 2008 (all 32 and 64 bit compatible); and Windows XP and Server 2003
(both 32 bit compatible)
• CardStudio™ card design and issuance software with direct to print support
• Virtual PrintWare™

Printing and laminating specifications

• Color dye sublimation or monochrome thermal transfer printing
• Single-sided and dual-sided printing
• Printing throughput

Click to Drop (s) Throughput (cards/hr)

Ribbon Front Back w/o Laminator w/Laminator w/o Laminator w/ Laminator
YMCKO YMCKO N/A 18 N/A 300 N/A
YMCKOK YMCKO K 21 N/A 225 N/A
Monochrome K N/A 5 22 1375 265
Monochrome K K 10 26 555 260
YMCK YMCK N/A N/A 28 N/A 270
YMCKK YMCK K N/A 35 N/A 200
NOTE: Printing throughput (cards per hour) based on batch printing with USB connectivity. Times may
vary depending on the computer configuration.

• Printing and mag stripe encoding throughput

Click to Drop (s) Throughput (cards/hr)

Ribbon Front Back w/o Laminator w/Laminator w/o Laminator w/ Laminator
YMCKO YMCKO N/A 20 N/A 295 N/A
YMCKOK YMCKO K 24 N/A 225 N/A
Monochrome K N/A 8 20 650 265
Monochrome K K 13 26 435 260
YMCK YMCK N/A N/A 32 N/A 270
YMCKK YMCK K N/A 38 N/A 195
NOTE: Printing throughput (cards per hour) based on batch printing with USB connectivity. Times may
vary depending on the computer configuration.

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 13

 1: Introduction
Technical Specifications

• Near photographic print quality

• Edge-to-edge printing on standard CR-80 media
• Image placement specification:

0 - .1

.20 - .45 .20 - .45

0 - .1

Dimensions are in millimeters Allow skew of

± .05

• Skew: ±.05mm

• Simultaneous printing, encoding, and laminating capability

• One-pass single-sided and dual-sided wasteless lamination
• Laminate placement specification:

1.6 ± .80

PATCH LENGTH
82.5 ± .5

1.6 ± .80

1.6 ± .80

Dimensions are in millimeters

1.6 ± .80

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 1: Introduction
Technical Specifications

Supplies specifications
• Zebra’s intelligent technology RFID tags authenticate and automate ix Series™
ribbons and Zebra True Secure™ i Series laminates to assure the best quality possible
• Card cleaning rollers are included with each ribbon carton
• Specially designed cleaning supplies simplify preventative maintenance
• True Colours® ix Series™ ribbons
• True Secure™ i Series laminates

NOTE: For optimum print quality and printer performance, use of Zebra genuine supplies
is recommended.

Card specifications/compatibility
• Card Thickness: 10 – 50 mil (0.25 – 1.27mm)
• Card Thickness for lamination: 30 mil (0.76 mm) only
• Card Size: CR-80, ISO 7810 format, Type ID-1
• Card Material: PVC and composite, PET, PET-G, PET-F, and Teslin® composite
• Technology Cards: contact and contactless smart cards
• Specialty cards: adhesive backed, transparent (IR-blocked), signature panel, and select
key-tag types
• Transparent cards / key-tag cards

85.6

8.4 A
23.7
27.9 B

C
53.9
B

6.8 A
Dimensions are in millimeters

Area A: Translucent window allowable only if IR Blocker is used. Key-tag holes allowed
only if hole is perforated and not punched through.
Area B: Translucent window is always allowable.
Area C: If Mag stripe is present, IR Blocker is required.

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 1: Introduction
Technical Specifications

Communications interfaces
• USB V2.0
• USB supports plug-n-play printer identification
• 10/100 BaseT

Electrical specifications
• Auto-switching single-phase AC power
• 90V~264V AC and 47–63Hz (50-60Hz nominal)
• FCC Class A
• Energy Star compliant
• Power Consumption
• Idle 100 W
• Initializing / Warm-up (no Laminator) 120 W
• Initializing / Warm-up (with Laminator) 450 W
• Printing (no Laminator) 120 W
• Printing and Laminating 250 W
• Sleep 20 W

Physical characteristics
• Height: 306mm (12.0in)
• Width (printer only): 699mm (27.5in)
• Width (printer with laminator): 964mm (38.0in)
• Depth: 277mm (10.9in)
• Weight (printer only): 12.2 kg (26.9 lbs)
• Weight (printer with laminator): 17.9 kg (39.5 lbs)

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 1: Introduction
Technical Specifications

Environmental
• Operating Temperature: 59º F/15ºC to 95º F/35ºC
• Storage Temperature: 23º F/-5ºC to 158º F/70ºC
• Operating Humidity: 20% to 80% inclusive, non-condensing
• Storage Humidity: 10% to 90% inclusive, non-condensing
• Media should not be above 140º F/60º C for longer than 200 hours, and above
90% relative humidity at 104º F/40º C for longer than 100 hours

Chinese Notifications

仅适用于海拔 2000m 以下地区安全使用

仅适用于在非热带气候条件下安全使用

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 17

 1: Introduction
Technical Specifications

Agency Approvals
Zebra ZXP Series 7 Card Printer complies with following applicable directives and standards
for the ITE: Residential, Commercial & Light Industry environments

• For US/Canada/Mexico/Australia&NZ
• FCC Class A, CFR 47, Part 15 Subpart B
• Part15 Subpart C
• Canadian STD RSS-210
• NOM-NYCE (Mexico)
• EN60950: EN60950-1 Safety Standard (TUV & NRTL)
• C-Tick (Australia)

• For Europe:
• Applicable Directives and Supporting Standards:

2004/108/EC EMC Directive, EN55022: Class A,

EN55024, EN61000-3-2, EN61000-3-3,
2006/95/EC LVD Directive, EN60950-1, CB Scheme

Declarations of Conformity
ZEBRA TECHNOLOGIES CORPORATION
Declares that the following Information Technology Equipment

Zebra ZXP Series 7 Card Printer

complies with following applicable directives and standards for the
ITE: Residential, Commercial & Light Industry environments

Applicable Directives and Supporting Standards:

2004/108/EC EMC Directive, EN55022:2010 Class A,
EN55024: 2010, EN61000-3-2:2006+A2:2009, EN61000-3-3:2008
2006/95/EC LVD Directive, EN60950-1:2006+A1:2010, CB Scheme

RFID Enabled
Applicable Directives and Supporting Standards:
99/5/EC R&TTE Directive, ETSI EN 301 489-3 V1.4.1 (2002-08), EN 300 220-2 V2.1.2 (2007-06)

For a formal certificate, please contact the Compliance Office at Zebra’s Agoura Hills 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”

18 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 1: Introduction
Technical Specifications

FCC Notice
FCC Regulations
This device complies with part 15 of the FCC Rules. Operation is subject to the following two
conditions: (1) This device may not cause harmful interference, and (2) this device must accept any
interference received, including interference that may cause undesired operation.

Note: This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency energy and, if
not installed and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a residential area is
likely to cause harmful interference in which case the user will be required to correct the
interference at his own expense.

Modifications not expressly approved by the manufacturer could void the user's authority to
operated the equipment under FCC rules.

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 (IC) Notice

This Class A digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.

Japanese Notification

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 1: Introduction
Icons

1.5 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.

Provides an example or scenario to demonstrate or clarify a section of text.

Electrostatic Discharge • Warns you of the potential for electrostatic discharge.

Electric Shock • Warns you of a potential electric shock situation.

Hot Surface • Warns you of a situation where excessive heat could cause a burn.

Caution • Advises you that failure to take or avoid a specific action could result in physical
harm to you, or could result in physical damage to the hardware.

1.6 Zebra Supplies

Genuine Zebra supplies meet stringent quality standards and are recommended for optimal
printing quality and proper printer performance.

ZXP Series 7 printers are designed to work only with Zebra True Colours® Ribbons and Zebra
True Secure Laminates.
™

20 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 2
Installation and Setup

2.1 General Information

This section will guide you through the installation and setup of the Card Printer. This consists
of the following procedures, which should be performed in the order presented.

2.2 Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.3 Setting up the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.4 Connecting Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.5 Connecting the Printer to your Computer . . . . . . . . . . . . . . . . . . . . . . . 50
2.6 Installing the Windows Printer Driver. . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.7 Changing the Printer Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.8 Changing the Printing Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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 2: Installation and Setup
Unpacking the Printer

2.2 Unpacking the Printer

2.2.1 Printer without a Laminator
Step 1. Inspect the shipping container to ensure that no damage has occurred during
shipment. If any damage is apparent, file a claim with the shipper.

Step 2. Open the shipping container.

Step 3. Remove the packing material and accessories.

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 4. Make sure the following items are included with the Printer:

Quick Start Guide CD-ROM with InstallWizard Dual Cleaning Cartridge

USB

Manual Feed USB Cable Power Cable

Cleaning Cassette

Feeder Cartridge Output Hopper

If any items are missing, please contact your supplier.

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 2: Installation and Setup
Unpacking the Printer

Caution • The Printer weighs approximately 12.2 kg (26.9 lbs); use two people to lift it out
of the shipping carton.

Step 5. Lift the Printer out of the carton by holding it with both hands.

Step 6. Place the Printer in a ___location that meets the following requirements:

Important • When moving the printer from storage (23º F/-5º C to 158º F/70º C) to the
operating area (59º F/15º C to 95º F/35º C), allow time to acclimate prior to operation.

• A reasonably dust-free and dirt-free environment.

• Flat surface at least 30 in (762 mm) x 12 in (305 mm) that can support the
weight of the Printer; additional space preferred. Allow a 4-inch clearance,
minimum, on all sides.
• Vertical clearance at least 32 in (813 mm).
• Temperature within the range of 59° to 95°F (15° to 35°C).
• Relative humidity 20 to 80% inclusive, non-condensing.
• Auto-switching single-phase AC Power, 90V~264V AC, 47-63Hz (50-60Hz
nominal); see Electrical specifications on page 16 for power consumption.

Step 7. Remove the Printer from the protective plastic bag.

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 2: Installation and Setup
Unpacking the Printer

2.2.2 Printer with a Laminator

Step 1. Inspect the shipping container to ensure that no damage has occurred during
shipment. If any damage is apparent, file a claim with the shipper.

Step 2. Open the shipping container.

Step 3. Remove the packing material and accessories from around the top of 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 4. Make sure the following items are included with the Printer:

Quick Start Guide CD-ROM with InstallWizard Dual Cleaning Cartridge

SS & DS
(Blue)

DS only
(Yellow)

Laminate Cassette(s) Feeder Cartridge Output Hopper

USB

Manual Feed USB Cable Power Cable

Cleaning Cassette

If any items are missing, please contact your supplier.

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Unpacking the Printer

Caution • The Printer with Laminator weighs approximately 17.9 kg (39.5 lbs); use two
people to lift it out of the shipping carton.

Step 5. Lift the Printer out of the carton by holding it with both hands.

Step 6. Place the Printer in a ___location that meets the following requirements:

• A reasonably dust-free and dirt-free environment.

• Flat surface at least 40 in (1016 mm) x 12 in (305 mm) that can support the
weight of the Printer; additional space preferred. Allow a 4-inch clearance,
minimum, on all sides.
• Vertical clearance at least 32 in (813 mm).
• Temperature within the range of 59° to 95°F (15° to 35°C).
• Relative humidity 20 to 80% inclusive, non-condensing.
• Auto-switching single-phase AC Power, 90V~264V AC, 47-63Hz (50-60Hz
nominal); see Electrical specifications on page 16 for power consumption.

Step 7. Remove the protective plastic bag from the Printer.

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Setting up the Printer

2.3 Setting up the Printer

2.3.1 Loading Cards

Caution • DO NOT bend cards or touch print surfaces as this can reduce print quality.
The surface of the cards must remain clean and dust free. Always store cards in an
enclosed container. Ideally, use cards as soon as possible.

Step 1. Remove the wrapping from the card stack.

Step 2. Holding the card stack by the sides (do not touch the print surfaces), hold it
vertically against a flat surface such as a desktop. If the stack is too thick for your
hand to hold it comfortably, use about half a stack at a time.

Step 3. Push the stack back and forth to an angle of about 45° from vertical, so as to separate
all of the cards.

Note • Static charges and edge burrs from the card die-cutting process can render individual
cards stuck together with significant adhesion force. These cards must be physically
separated from each other before inserting into the feeder; if not separated, feeding or
printing problems may occur.

Step 4. Restore the card stack to its original squared-off condition.

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Setting up the Printer

Step 5. Open the Feeder Cartridge Door, and slide the Card Stack Pusher all the way to the
right, until it locks in place.

Step 6. Place the card stack in the Feeder Cartridge in the correct orientation shown below.

Step 7. For optimum performance, ensure that the cards are fully seated; then close the
Feeder Cartridge Door.

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2.3.2 Installing the Card Hoppers

Feeder Cartridge
The Feeder Cartridge is positioned on the right side of the Printer and holds the cards to
be printed. Note that once in place, you can add cards as needed to the Feeder Cartridge
without removing it.

Step 1. Install the Feeder Cartridge by sliding it down and to the left into the receptacle.
You will need to apply enough pressure for it to “snap” into place.

Step 2. Ensure that the Feeder Cartridge locks securely in place.

Output Hopper
The Output Hopper is positioned on the left side of the Printer and receives the printed cards.

Step 1. Install the Output Hopper by inserting the two tabs on the right side of the hopper
into the two slots on the left side of the Printer.

Step 2. Ensure that the Output Hopper locks securely in place.

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Setting up the Printer

2.3.3 Installing the Dual Cleaning Cartridge

The Dual Cleaning Cartridge cleans the cards entering the Printer from the Feeder Cartridge.
The cartridge consists of a cartridge frame and two adhesive rollers.

Step 1. Locate the cartridge frame and the two adhesive rollers.
Step 2. Insert the adhesive rollers into the cartridge frame.

Step 3. Peel the protective wrapper from the adhesive rollers to expose the sticky surface.
Do not touch the sticky surface.

Step 4. The Dual Cleaning Cartridge is ready to use.

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Setting up the Printer

Step 5. Open the Options Cover.

Step 6. Locate the area where the Dual Cleaning Cartridge will be installed.

Step 7. Hold the cartridge by the extended handle.

Step 8. Insert the lip of the cartridge into the slot, and then push forward until it
snaps into place.
Step 9. If you are also installing the Manual Feed Cleaning Cassette, continue to the next
page; otherwise, close the Options Cover.

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2.3.4 Installing the Cleaning Cassette

The Manual Feed Cleaning Cassette cleans the cards entering the Printer from the Manual
Feed Slot. The cassette consists of a frame and an adhesive roller.

Step 1. Locate the cassette frame and adhesive roller.

Step 2. Insert the adhesive roller into the cassette frame.

Step 3. Peel the protective wrapper from the adhesive roller to expose the sticky surface.
Do not touch the sticky surface.

Step 4. The Manual Feed Cleaning Cassette is ready to use.

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Setting up the Printer

Step 5. If not already done, open the Options Cover.

Step 6. Locate the area where the Manual Feed Cleaning Cassette will be installed.

Step 7. Hold the cassette by the extended handle.

Step 8. Slide the cassette into place.
Step 9. Insert the lip of the cassette into the slot in the back panel.
Step 10. Press the cassette down until it seats and latches.
Step 11. Close the Options Cover.

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Setting up the Printer

2.3.5 Loading a Print Ribbon

The ZXP Series 7 Printer is designed to work only with Zebra True Colours® Ribbons in order
to achieve rich, vibrant image production over the full-color spectrum.

Step 1. Press the Print Cover Release Button.

2 1

Step 2. Open the Print Cover.

Step 3. Slide out the Ribbon Drawer until it stops. It is not necessary to remove it.

Step 4. Remove the printhead protective foam, if present.

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Setting up the Printer

Step 5. Take the print ribbon out of the box.

Step 6. Carefully unroll the print ribbon. Note that there is a clear leader with a sticky
surface holding the print ribbon in place. This leader needs to be pulled free and
rolled onto the take-up spool.
Step 7. Make sure the print ribbon comes off the bottom of the supply spool and feeds to the
bottom of the take-up spool.
Step 8. Set the print ribbon supply spool (PURPLE) into the supply carrier (PURPLE).

Step 9. Set the empty take-up spool (BLUE) into the take-up carrier (BLUE).

Step 10. Rotate the spools as required to take up excess slack in the ribbon.

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Step 11. Close the Ribbon Drawer.

Step 12. Close the Print Cover, and press down until it latches securely.

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Setting up the Printer

2.3.6 Loading the Laminate

Opening the Laminator

Note • The Lower Laminate Cassette is only present on the dual-sided laminator.

Step 1. Press the Laminator Cover Release Button, and lift the cover to its upright position. It
will remain in that position.

Step 2. Lower the Laminator Bottom Cover until it stops.

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Removing the Laminate Cassette(s)

Step 1. Rotate the locking lever maximum in the direction indicated in the figure below.

Step 2. Rotate the cassette to the mechanical stop in the direction indicated below.

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Setting up the Printer

Step 3. Remove the cassette(s) by pulling each cassette straight out from its spindle.

Step 4. Open the cassette(s), like a clam shell, by separating its two halves. Grasp the two
halves firmly with your fingers, then pull it apart. Do NOT use tools. (Upper
Laminate Cassette shown.)

Step 5. If there is an empty laminate core in the cassette, remove it.

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Setting up the Printer

Loading the Laminate Cassette(s)

Step 1. Remove a new roll of laminate from its packaging. There are two different laminate
rolls, one for the Upper Cassette (Blue) and one for the Lower Cassette (Yellow).

Important • The geared flange on the laminate spool is removable, but do not remove it. If it
does come off, snap it back onto the end of the spool.

Step 2. Place the roll of laminate in the Upper Laminate Cassette (present on both the
single-sided laminator and dual-sided laminator). Note the orientation of the laminate
spool with respect to the laminate cassette as shown in the figure below.

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.
Step 5. Remove a second new roll of laminate from its packaging (for dual-sided
laminator only).
Step 6. Place the roll of laminate in the Lower Laminate Cassette (present on the dual-
sided laminator only). Note the orientation of the laminate spool with respect to the
laminate cassette as shown in the figure below.

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Step 7. Pull out an inch or two of laminate past the lip of the cassette.
Step 8. 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.
Step 9. Cut the laminate flush with the cassette (as close to perpendicular as possible) with
scissors. Hold the scissors in one hand. Hold the cassette with the other hand. Press
the laminate firmly against the white roller thereby keeping the laminate from
moving while cutting.

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Step 10. Rotate the core to adjust the laminate overhang. Stop when the end of the laminate is
just beyond the lip of the cassette, as shown below.

Important • Check for laminate overhang any time the locking lever is pressed or the
cassette is removed.

0 - 0.5 mm
0 - 1/32"

0 - 0.5 mm
0 - 1/32"

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Setting up the Printer

Installing the Laminate Cassette(s)

Step 1. If the laminate cassettes are not already removed, remove the cassettes.

Step 2. Slide the cassette onto the spindle.

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Step 3. Ensure the cassette is fully seated on the spindle. Gently press the cassette until it is
flush against the laminator frame.

Step 4. Rotate each cassette (in the direction indicated in the figure below) until it stops.

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Step 5. Apply increasing rotational pressure, and listen for the audible click when the
locking lever snaps into place.

Step 6. The laminate is installed

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Setting up the Printer

Laminating Contact Smart Cards

Use registered laminate for the top surface of a contact smart card. This type of laminate
has a repeating pattern of an index hole and a rectangular cutout to expose the card’s
electrical contacts.

electrical contacts

rectangular cutout

index hole

Step 1. Remove the Upper Laminate Cassette; see Page 37.

Step 2. Open the cassette, and remove the laminate if present.
Step 3. Load the smart card laminate into the cassette; see Page 39.
Step 4. Cut the laminate, splitting the index hole as shown.

Cut the laminate, splitting the

index hole

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Step 5. Rotate the core to adjust the laminate overhang. Stop when the end of the laminate
(not the edge of the index hole) is flush with the cassette, as shown on Page 41.

Step 6. Install the cassette; see Page 42 for details.

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Setting up the Printer

Using Partial-Width Laminate

Note • Since partial-width laminates are only used for the back (i.e., lower) surface of the
card, this section only applies to the dual-sided laminator.

Laminates come in three widths:

“Full-Width” laminate is 2 in (51 mm) wide. The full-width laminate is used on the front (i.e.,
upper) or back (i.e., lower) surface of the card.

“Partial-Width” laminate is available in two widths:

• 1.66 in (42mm) wide laminate is used for cards with a writable signature panel
• 1.33 in (33 mm) wide laminate is used for cards with a magnetic stripe

For either partial-width laminate, a collar on the spool keeps the laminate positioned correctly.

2“

Full-Width

1.66“ BACK OF
FCCARD

Signature Panel

1.3”

Magnetic Stripe

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Using Partial-Width Laminate (continued)

Step 1. Remove the Lower Laminate Cassette; see Page 37.

Step 2. Open the cassette, and remove the laminate if present.

Step 3. Load the partial-width laminate into the cassette. Note that the collar on the laminate
spool is on the end opposite the geared flange.

Collar

Step 4. Trim the partial-width laminate; see Page 40.

Step 5. Rotate the core to adjust the laminate overhang; see Page 41.

Step 6. Install the cassette; see Page 42.

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 2: Installation and Setup
Connecting Power

2.4 Connecting Power

Electric Shock • Limit AC power supplied to the Printer to 90V~264V, 47-63Hz (50-60Hz
nominal). 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 source and properly protected against electrical
surges and grounding faults; the electrical reliability of the Printer is based on the
reliability of the main power source and the earth connection.

The Printer’s power supply is an internal unit that can only be serviced or replaced by
trained and authorized personnel.

1 2

(OFF)

Step 1. Place the Printer’s power switch in the OFF ( ) position.

Step 2. Depending on your local AC voltage, plug the appropriate power cord into the
Printer’s power connector and a grounded AC power source connection.

DO NOT SWITCH THE PRINTER ON.

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Connecting the Printer to your Computer

2.5 Connecting the Printer to your Computer

2.5.1 Interface Connector Locations

USB
10/100base-T

See Page 52 for

details.

See Page 51 for

details.

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Connecting the Printer to your Computer

2.5.2 USB Connection

Step 1. Connect the USB cable to the printer and the computer.

Step 2. Ensure that the printer’s power switch in the OFF ( ) position.

USB

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Connecting the Printer to your Computer

2.5.3 Ethernet Connection

Step 1. Connect the Ethernet Port on the rear of the printer to an Ethernet Network Port.

Step 2. Turn the printer’s power switch to the ON ( | ) position.

10/100base-T

10/100base-T

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 2: Installation and Setup
Installing the Windows Printer Driver

2.6 Installing the Windows Printer Driver

2.6.1 Installing the USB Printer Driver

Note • To install the Ethernet driver, see Page 65.

Step 1. If not already done, connect power to the printer. Turn power OFF.

Step 2. Connect the USB port on the rear of the printer to the computer’s USB port.
Step 3. Ensure that the Printer’s power switch is in the OFF (O) position.
Step 4. Insert the User Documentation and Drivers CD into the CD drive of the host
computer. The Main Menu will open.
Step 5. From the Main Menu, click Install Zebra Printer Driver.
Step 6. If a Printer and Driver is already installed on your computer, one of the following
Welcome window will be displayed; otherwise go to Step 8.

Step 7. Choose the maintenance operation to be performed:

a. If you are installing a newer version of the driver, select Upgrade to install the
new driver.

b. If you are installing the same version driver, select Modify to install additional
Ethernet or USB printer drivers.

c. Select Remove to remove the current printer driver. When asked about
removing the smart card readers drivers, click Yes to remove them; click No
to leave them installed. At the end of the un-install process, you will be asked
to re-boot your computer.

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Installing the Windows Printer Driver

Step 8. The InstallShield Wizard window will open. To proceed with the installation, click
the Next button.

Step 9. Select Install USB printer drivers, and click the Next button.

Step 10. Ensure that the printer’s power switch is in the OFF ( ) position, and then click
the OK button. After installation of the driver, you will be prompted to turn on
the printer.

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Installing the Windows Printer Driver

Step 11. This will bring up the License Agreement window. To proceed with the installation,
select the I accept the terms of the license agreement option; and then click the
Next button.

Step 12. This will bring up the Customer Information window. Enter your name and the
name of the company for which you work, and then click the Next button.

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Step 13. This will bring up the Choose Destination Location window.
• To accept the default destination ___location where setup will install the files, click
the Next button.
- or -
• Click the Change button, select a folder where setup will install the files, and
then click the Next button.

Step 14. This will bring up the Ready to Install the Program window. To continue, click the
Install button.

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Step 15. Observe the driver installation via Setup Status window.

Step 16. The Congratulations window will appear. Turn on the USB printer. Read the
instructions carefully, and then click the Next button.

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Step 17. When the InstallShield Wizard Complete window appears, click the Finish button.

Step 18. This completes USB driver installation

Note • You may need to change the card setup (card type, orientation, etc.), encoding, and/or
black panel settings via the Printer Driver; Changing the Printing Preferences on
page 77.

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Installing the Windows Printer Driver

2.6.2 Installing the Ethernet Printer Driver

Note • To install the USB driver, see Page 53.

Important • The Ethernet Network must be configured correctly, with the Printer and the host
computer on the same subnet. If you are not sure how to verify this or change the
configuration, consult someone knowledgeable on Ethernet Networks.

Step 1. If not already done, connect power to the printer. Turn power ON ( | ).

Step 2. Connect the Ethernet port on the rear of the printer to the Ethernet network
connection or directly to the computer’s Ethernet port.
Step 3. Ensure that the Printer’s power switch in the ON ( | ) position.
Step 4. Insert the User Documentation and Drivers CD into the CD drive of the host
computer. The Main Menu will open.
Step 5. From the Main Menu, click Install Printer Driver.
Step 6. If a Printer and Driver is already installed on your computer, one of the following
Welcome window will be displayed; otherwise go to, Step 8.

Step 7. Choose the maintenance operation to be performed:

a. If you are installing a newer version of the driver, select Upgrade to install the
new driver.

b. If you are installing the same version driver, select Modify to install additional
Ethernet or USB printer drivers.

c. Select Remove to remove the current printer driver. When asked about
removing the smart card readers drivers, click Yes to remove them; click No
to leave them installed. At the end of the un-install process, you will be asked
to re-boot your computer.

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Step 8. The InstallShield Wizard window will open. To proceed with the installation, click
the Next button.

Step 9. Select Install Ethernet printer drivers, and click the Next button.

Step 10. Ensure that the Printer’s power switch in the ON ( | ) position, and then click the
OK button.

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Installing the Windows Printer Driver

Step 11. This will bring up the License Agreement window. To proceed with the installation,
select the I accept the terms of the license agreement option, and then click the
Next button.

Step 12. This will bring up the Customer Information window. Enter your name and the
name of the company for which you work, and then click the Next button.

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Step 13. This will bring up the Search Ethernet Printers window.:

Setup will search for the Ethernet printers in the network and display the available
printers. Select the desired printer, and then click the Next button.

- or -
If Ethernet printer is in a different subnet and is not discovered by the host, you can
manually enter the Printer IP Address directly (circled below); and click the Next
button. Note that you can get the IP Address via the OCP by pressing the Info
button and selecting Network Settings.

Step 14. Enter the Location of the printer and any Comments regarding the printer, and then
click the Next button.

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Step 15. This will bring up the Choose Destination Location window.
• To accept the default destination ___location where setup will install the files, click
the Next button.
- or -
• Click the Change button, select a folder where setup will install the files, and
click the Next button.

Step 16. This will bring up the Ready to Install the Program window. To continue, click the
Install button.

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Step 17. Observe the Setup Status window.

Step 18. When the InstallShield Wizard Complete window appears, click the Finish button.

Step 19. This completes Ethernet driver installation.

Note • You may need to change the card setup (card type, orientation, etc.), encoding,
and/or black panel settings via the Printer Driver; see Changing the Printing
Preferences on page 77.

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 2: Installation and Setup
Changing the Printer Properties

2.7 Changing the Printer Properties

Card Printer Properties can be used to view the printer’s firmware, driver, and hardware
configurations; to view installed media; to access advanced settings via the ZXP Toolbox;
and to set features such as security, ports, and color management.

To access Printer Properties, select Start > Devices and Printers. Right click on the Zebra ZXP
Series 7 Card Printer listing, then select Printer properties.

2.7.1 General Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2.7.2 Sharing Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.7.3 Ports Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.7.4 Advanced Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.7.5 Color Management Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.7.6 Security Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.7.7 Device Information Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

The OK button applies and saves the settings, and then closes the Printer Properties.
The Cancel button exits Printer Properties. Changes made are abandoned.
The Apply button applies and saves the settings. Printer Properties remains open.
The Help button enables you to view a corresponding page of help information.

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2.7.1 General Tab

The General tab lists the name, ___location, model number, and features of the printer.

To access the General tab, select Start > Devices and Printers. Right click on the Zebra ZXP
Series 7 Card Printer listing, and select Printer properties > General.

• Location - Lets you specify where the printer is physically located.

• Comment - Lets you specify general information about the printer, such as the type
of print device and who is responsible for it. Once set, these fields can be displayed
by applications.
• Model - Shows the printer model number.
- Features - Specifies whether various options are available on the printer.

The Printing Preferences button takes you to Printing Preferences used to set selected
configuration parameters; see Changing the Printing Preferences on page 77.

The Print Test Page button sends the standard Windows test page to the printer.

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2.7.2 Sharing Tab

The Sharing tab lets you share the printer over the network and install additional drivers to
accommodate different operating systems.

Note that for Windows Vista and above, the Render print jobs on client computers checkbox
should be disabled.

To access the Sharing tab, select Start > Devices and Printers. Right click on the Zebra ZXP
Series 7 Card Printer listing, and select Printer properties > Sharing. Click on the Change
Sharing Options button to enable this tab.

For details, see Windows-provided help for standard property pages.

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2.7.3 Ports Tab

Important • Do not un-check the Enable bi-directional support option. If you modify this,
you will lose the communication to the printer.

Use the Ports tab to specify the computer port to which the printer is connected. This will have
been established at the initial installation of the printer and will not normally require attention.

To access the Ports tab, select Start > Devices and Printers. Right click on the Zebra ZXP
Series 7 Card Printer listing, and select Printer properties > Ports.

• Enable printer pooling; see Setting Up Printer Pooling on page 415 for details.

For details, see Windows-provided help for standard property pages.

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2.7.4 Advanced Tab

The Advanced tab determines the spooling (queuing) of print jobs and determines how
spooled jobs are handled relative to the most recent job.

To access the Advanced tab, select Start > Devices and Printers. Right click on the Zebra ZXP
Series 7 Card Printer listing, and select Printer properties > Advanced.

For details, see Windows-provided help for standard property pages.

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Changing the Printer Properties

2.7.5 Color Management Tab

The Zebra-provided color profile was designed to maximize color accuracy across the entire
color gamut of the printer.

User-created custom profiles can alter very specific colors or groups of colors to any other
color the user desires. For example: If the customer had a particular shade of red in the digital
image that was not coming out as desired, then a custom profile could alter just that shade of
red but leave all the other colors in the image the same.

A custom profile can also be used to perform more basic image transformations such as
converting full color image to shades of a single color (like sepia), changing brightness or
contrast, adjusting saturation or hue, etc.

To access the Color Management tab, select Start > Devices and Printers. Right click on the
Zebra ZXP Series 7 Card Printer listing, and select Printer properties > Color Management.
Click on the Color Management button to enable this tab.

When you click on the Color Management button, you will see the following three tabs:

Devices Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
All Profiles Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Advanced Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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Devices Tab
Use the Devices tab to select your printer and to view, add, and select profiles and behaviors to
use with your printer.

The Use my settings for this device checkbox must be selected to enable the following
button functions:

• The Add button allows you to add additional profiles to the color profile list.
• The Remove button allows you to remove profiles from the color profile list.

The Set As Default button allows you to set the selected profile as the default profile.

For details on color management, click on the Understanding color management settings
link (arrow above).

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All Profiles Tab

Use the All Profiles tab to view and manage the profiles that are in your system. Note that
color profiles are usually added automatically during the installation of new devices.

If you need to install a new profile, follow these steps:

Step 1. Click on the Add button.

Step 2. Observe the Install Profile browse window.

Step 3. Locate the desired color profile.

Step 4. Click on the Add button (in the Install Profile browse window).

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Advanced Tab
Use the Advanced tab to check your Windows Color System Defaults settings, verify ICC
Rendering to WCS Gamut Mapping, and calibrate your display (Display Calibration).

This tab allows you to configure advanced color management settings to ensure accurate
display and printing of color information.

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2.7.6 Security Tab

This is the standard Windows security screen, showing user access to various printer
control options.

To access the Security tab, select Start > Devices and Printers. Right click on the Zebra
ZXP Series 7 Card Printer listing, and select Printer properties > Security.

For details, see Windows-provided help for standard property pages.

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2.7.7 Device Information Tab

The Device Information tab provides printer information, job condition, printer history, and
security status. Access to Media Info and ZXP ToolBox is included.

To access the Device Information tab, select Start > Devices and Printers. Right click on the
Zebra ZXP Series 7 Card Printer listing, and select Printer properties > Device Information.

• The Media Info button takes you to the Media Info screen; see next page.
• The ZXP Toolbox button takes you to the ZXP Toolbox which provides advanced
configuration capabilities and tools to manage the operation of your printer; see
Section 8, ZXP Series Toolbox, for details.
Note that the ZXP Toolbox relies on the Windows driver to communicate with the printer.

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Media Info
Media Info screen shows ribbon status and top and bottom laminate status.

- Ribbon: Shows the ribbon type installed and the number of ribbon sets remaining.
- Top Laminate: Shows the top laminate type and the number of laminate
panels remaining.
- Bottom Laminate: Shows the bottom laminate type and the number of laminate
panels remaining.

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2.8 Changing the Printing Preferences

To access Printing Preferences, select Start > Devices and Printers. Right click on the
Zebra ZXP Series 7 Card Printer listing, and select Printing preferences.

2.8.1 Card Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

2.8.2 Black Panel (K) Optimization Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.8.3 Color (YMC) Optimization Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.8.4 Encoding Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.8.5 About Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

The Toolbox button launches the ZXP Toolbox; see Section 8 for details.
The Restore Defaults button restores the default values for the page.

The OK button applies and saves the settings, and then closes the Printing Preferences.
The Cancel button exits Printer Properties. Changes made are abandoned.
The Apply button applies and saves the settings. Printing Preferences remains open.
The Help button enables you to view a corresponding page of help information.

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2.8.1 Card Setup Tab

To access the Card Setup Tab, select Start > Devices and Printers. Right click on the Zebra
ZXP Series 7 Card Printer listing, and select Printing preferences > Card Setup.

• Card options allows the user to select the Card Source and Card Destination.
- Card source
• Manual feed slot
• Feeder cartridge -- default
• Already in printer (for applications that use this feature)
- Card destination
• Output hopper -- default
• Reject bin
• Leave in printer (for applications that use this feature)
- Image size
• Default Size (1006 * 640 pixels): Note that this setting should always been
used unless you are printing images that were specifically designed for other
Zebra printer models.
• CR-80 (952 * 578 pixels): For Zebra P640i Card Printer compatibility.
• Bordered (968 * 610 pixels): For Zebra P640i Card Printer compatibility.

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• Printing options:
This section allows the user to select the card orientation (Portrait or Landscape), to print
If you modify any of these settings, click the Apply button before printing a test card.

The Test Print button prints a test card.

• Ribbon info and options:

- Ribbon type shows the type of ribbon (e.g., YMCKOK) installed in the printer. Note
that this is automatically detected from the ribbon.
- Ribbon combination allows you to select the combination of panels to be printed
on each side (e.g., YMCKO Front/YMCKO Back).
Depending on the ribbon type installed, the Front and Back buttons let you set
options for:

• Black Panel Options on page 80

• Overlay Varnish Options on page 83
• Uv Panel Options on page 84

• Laminator info and options:

These options apply only to printers with laminator. This section automatically shows the
presence of the laminator and laminate. You can select the Lamination mode via the
dropdown menu.

- Any: Any combination of laminate can be installed (default).

- Top: Top laminate only must be installed.
- Bottom: Bottom laminate only must be installed.
- Top and bottom: Both top and bottom laminate must be installed.
- Pass through: Top and bottom laminate must be removed. This option allows a card to
pass through the laminator without having laminate applied.

Laminate only can be used to laminate pre-printed cards. This is a special-purpose

function that is enabled when the Lamination mode is set to Top, Bottom, or Top and
bottom and the Card destination is set to Output hopper. When selected, the card is passed
from the input hopper, through the printer without being printed, to the laminator for
lamination, then to the output hopper.

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Black Panel Options

The Black Panel Options pop-up window allows you to manage and configure the use of the
Black Panel (K panel) extraction when the selected Ribbon Combination shows the K panel on
the same side as the Y, M, and C panels (e.g. YMCK Front / K Back).

To access the Black Panel Options pop-up window, select Start > Devices and Printers. Right
click on the Zebra ZXP Series 7 Card Printer listing, and select Printing preferences >
Card Setup. From the Card Setup tab, select a Ribbon Combination that has YMC and K all
on the same side. The Front K Extraction… and/or Back K Extraction... buttons will become
active. Press the appropriate button to open up the pop-up window.

The figure below shows settings for the front side of the card; settings for the back side of the
card are identical.

This feature ensures that black text or black bitmaps will be printed with the Black Panel
(K panel). Without this option, black may be printed in composite (YMC) creating a dark
gray image instead of true black.

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To extract black areas from color images, several selections can be made.

• Select black panel extraction type:

- Disable black extraction does not use the K panel for any part of the image. This
selection will have the effect of rendering all black images as YMC composite.

- Print YMC composite and K black uses both the K panel and the Y, M, and C
panels to print the portions of the image that are identified as black. This selection will
result in a dark, black image; but the edges will be smooth (due to the continuous tone
nature of the YMC dyes), not the sharp edges typically desired for a barcode.

- Print all black data (default) uses only the K panel to print the portions of the image
that are identified as being black.

• Apply black extraction on: Note that this function is dependent on the image having
areas defined as text, graphics (lines, rectangles, and other non-text graphic objects), and
bitmaps (color images, photos, pictures, etc). If the image is flattened, then this function
does not apply.

- Black text applies black extraction to areas of the image identified as text.

- Black graphics applies black extraction to areas of the image identified as graphics.

- Black bitmaps applies black extraction to areas of the image identified as bitmaps.
Black bitmaps will extract only black out of monochrome bitmaps not from color
bitmaps. For extracting from color bitmaps, Area manager settings are used; see
Defined areas, Except defined areas, and Full card on next page.

• Black level:
Every dot of a printed image has an RGB color value that ranges from 0, 0, 0 (pure black)
to 255, 255, 255 (pure white).

The black level setting allows the user to specify the threshold value for any given pixel to
be treated as black. The maximum setting is 25, 25, 25.

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Area manager:
This option is enabled when either the Defined areas (extract inside the zone) or the
Except defined areas (extract outside the zone) radio button is selected.

- Defined areas applies black extraction to areas of the image inside of the zones
specified in the Area manager.
- Except defined areas applies black extraction to areas of the image outside of the
zones specified in the Area manager.
- Full card applies black extraction to the entire image.
- Orientation: The Orientation selection sets the image orientation to either Portrait or
Landscape.
- Units: The Units selection sets the units to either inches or mm (millimeters). The
X-dimension, X-offset, Y-dimension, and Y-offset reflect these units.

To create a zone: Select the rectangle icon , click on an area of the image to establish
the first corner of the zone, drag the cursor until the zone is the desired size and shape,
then release the mouse button. Note that multiple zones can be defined.

To select, move, or resize a zone: Select the arrow icon , click on a zone to select it,
then drag it to move it, or drag on the edges to resize it.

To delete a zone: Select the rectangle icon with an “X” through it , then click on the
zone that you want to delete.

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Overlay Varnish Options

Overlay varnish is a durable layer of film applied to printed cards that reduces fading by
protecting the image from UV exposure.

The Overlay Varnish pop-up allows you to manage and configure the use of the Overlay when
the selected Ribbon Combination shows the O panel (e.g. YMCKO).

To access the Overlay Varnish pop-up window, select Start > Devices and Printers. Right click
on the Zebra ZXP Series 7 Card Printer listing, and select Printing preferences > Card Setup.
Select Ribbon info ... > Front Overlay ... or Back Overlay ...

Select the overlay varnish type - Option selection for applying overlay varnish ribbon to a
card. Default setting is Full overlay varnish.

There are various varnish options. A preview pane is shown for each selection.

- Disable overlay - Disables the overlay option; i.e., does not apply any overlay.
- Full overlay varnish (default) - Applies an edge-to-edge overlay.
- Selected area blank - Applies overlay only outside the area selected by user.
- Selected area overlay varnish - Applies overlay only in the area selected by user.
- Bitmap based overlay varnish - Applies a user-defined 1-bit monochrome bitmap as
an overlay.
- Smartcard ISO - Does not apply overlay on the area of the smartcard chip, for cards
according to the ISO/AFNOR norm.
- Smartcard AFNOR - Does not apply overlay on the area of the smartcard chip, for
cards according to the ISO/AFNOR norm.
- Magnetic Stripe - Does not apply overlay on the area of the magnetic stripe.

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Uv Panel Options
A UV Panel is used to print images (text or graphics) that will glow in the visible spectrum
when exposed to a UV Light. The UV Panel pop-up window is only available when using UV
ribbons (e.g., YMCUVK).

To access the UV Panel pop-up window, select Start > Devices and Printers. Right click on
the Zebra ZXP Series 7 Card Printer listing, and select Printing preferences > Card Setup.
Select Ribbon info ... > Front UV ... or Back UV ...

UV rendering method:
• Diffusion: This mode will render the UV content using error diffusion.
• Halftone: This mode will render the UV content using half-toning.
• Grayscale prints the bitmap image as a grayscale image, which is composed of shades
of gray, varying from black to white.

UV printing options:
• Rotate 180o rotates the provided bitmap image 180o.

Invert UV content inverts the bitmap image if not inverted in the application.

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Source of UV content
• Use unique image for each job: Each print job will send a unique UV image along with
the YMCK content.

• Bitmap based static image: Imports the bitmap image to print on the UV panel; e.g.,
import a security seal. The UV image that is selected will be the same for all jobs.
1. Select the Bitmap based static image radio button.
2. Click on the Browse button to bring up a dialog box for choosing the file.
3. Locate and select the file (a specific .bmp file on local drive). Note that the UV
image can be any standard .bmp image supported by windows applications like
Paint or Fax Viewer. (24-bit, 1-bit etc.).
4. Select the UV rendering method; see previous page.
5. Select the UV printing options; see previous page.
6. Click the OK button to close the UV Panel pop-up.
7. The Driver applies this .bmp image as full UV print on all print jobs sent to printer.

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• Extract UV from job image

Similar to K extraction, this mode allows you to print a selected portion of the YMC
image using the UV panel. Options include Defined areas, Except defined areas, and
Full card. These options are selected via their associated radio buttons.

Defined areas allows you to specify what areas will be also printed with YMC and UV.
Undefined areas will print YMC with UV in all areas except those that are indicated. Full
card will print the entire image with YMC and UV.

- Area manager: This section is enabled when either Defined areas or Undefined areas
is selected.
• The Orientation selection sets the image orientation to either Portrait or
Landscape.
• The Units selection sets the units to either inches or mm (millimeters). The X
dimension, X offset, Y dimension, and Y offset reflect these units.

To create a zone: Select the rectangle icon , click on an area of the image to establish
the first corner of the zone, drag the cursor until the zone is the desired size and shape,
then release the mouse button. Note that multiple zones can be defined.

To select, move, or resize a zone: Select the arrow icon , click on a zone to select it,
then drag it to move it or drag on the edges to resize it.

To delete a zone: Select the rectangle icon with an “X” through it , then click on the
zone that you want to delete.

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Add static text

When the Add static text checkbox is selected (checked), the Static Text Options button
is enabled. This option automatically prints a unique text value in a fixed ___location on a card
using the UV panel.

1. Click on the Static Text Options button to activate this option.

2. Observe the UV Panel popup.

3. Specify the Text ___location. Select the ___location from four pre-defined areas of a card
(Upper left, Upper right, Lower left, Lower right).
4. Specify the Text category (MAC address, Printer serial number, or Custom Text).
If Custom Text is specified, enter the text in the Custom Text field, up to
32 characters.
5. Click the OK button to close the UV Panel pop-up.

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2.8.2 Black Panel (K) Optimization Tab

The Black Panel (K) Optimization tab displays two identical adjustment sections (Front and
Back) to optimize black panel printing for the type of image being printed.

To access the Black Panel (K) Optimization Tab, select Start > Devices and Printers. Right
click on the Zebra ZXP Series 7 Card Printer listing, and select Printing preferences >
Black Panel (K). The front side and back side options are enabled based on the availability of
K panel in the ribbon combination.

• Optimize for: Black panel printing can be optimized to improve the quality of individual
elements that comprise the image. There are separate optimization settings for Text,
Barcodes, and Mixed content.
- Text sharpens the edges of fonts. This setting will make barcodes appear darker.
- Barcode sharpens fine lines to improve barcodes for scanning. This setting will make
text and graphics appear lighter.
- Mixed (default) combines the optimum settings for text, barcode, and graphics
printing in most applications.

Click on the Advanced button for additional black (K) panel optimization options to further
fine tune black (K) panel printing; see next page.

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Advanced Black Panel (K) Optimization

The Advanced Black Panel (K) Optimization tab displays two identical adjustment sections
(Front and Back) to optimize black panel printing for the type of image being printed.

• Monochrome conversions: This section is used to control multi-tone printing when using
a monochrome ribbon. The available options are Dither error diffusion (default), Dither
6x6 halftoning, and Threshold (also known as Dither pure black on white); see next page
for details.
• Controls:

- Threshold sets the transition point between black (0) and white (255); i.e., pixel
values less than the threshold value would be black, and pixel values greater than the
threshold value would be white.

- Brightness controls overall the brightness of the image. Move the slider to the right to
lighten the image or to the left to darken the image.

- Contrast controls the difference between the light and dark areas of the image. Move
the slider to the right to increase the contrast and vice versa.

• Preheat controls the intensity of the image. Increase the value to enhance edges. Reduce
the value if bleeding is present. Note that the Preheat setting does not affect the preview
image but is applied to the image during the printing process.

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Monochrome Conversion
The monochrome panels in the ribbon can only print binary (pure on or off) images.
Monochrome conversion is used to convert continuous tone 8-bit-per-pixel RGB or gray
image content into binary1-bit-per-pixel content.

• Color Image
The sample image to the right is the original color image used
to make the following monochrome conversions.

• Dither error diffusion (default)

Error diffusion is a dithering technique to convert full color or
gray images into a binary image that when printed simulates
having a continuous tone response. The error diffusion
technique is usually preferred on pictorial images since it
produces a sharper and more detailed image.

• Dither 6x6 halftoning

Halftoning is a dithering technique to convert full color or gray
images into a binary image that when printed simulates having
a continuous tone response. The halftoning technique is
coarser looking than error diffusion but does not have the
inherent image structure seen with error diffusion.

• Threshold
Threshold (also know as Dither pure black on white) converts
full color or gray images into a binary image by a threshold
comparison. If a gray pixel value is above the threshold, it
converted to a white pixel; and if its below the threshold, its
converted to a black pixel.This method will not simulate
shades like error diffusion or halftoning does and is thus not
recommend to be used with pictorial content. However, it will
accurately preserve straight edges on graphics, barcodes, and
text and is the preferred conversion for those types of images.

SUMMARY
Error diffusion/halftoning: Use on pictures. Image content dictates if error diffusion or
halftoning would look best. For the majority of time, error diffusion is better.

Threshold: Use on text, barcodes, line art, and simple graphics.

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2.8.3 Color (YMC) Optimization Tab

To access the Color (YMC) Optimization Tab, select Start > Devices and Printers. Right
click on the Zebra ZXP Series 7 Card Printer listing, and select Printing preferences >
Color (YMC) Optimization. Not available for monochrome/KdO/KrO ribbons.

These color adjustments modify only how the pictures print. These adjustments do not
affect the image files. (That type of adjustment would be made in an image processing
application program.)

• Full color printing adjustments (-25 to +25 range) include Brightness, Contrast, Gamma,
Saturation, Red, Green, and Blue. Adjustments are reflected in the preview image.
- Sharpening filter options are None, Low, Normal (default), and High. Adjustments
are not reflected in the preview image. By default, the image file is automatically
sharpened; i.e., edges are enhanced within the image. If sharpening has already been
done, this function can be turned off (None). The Low and High options are available
if additional sharpening adjustment is required.
- Preheat adjustment ranges from -50 to 50, default = 0. Increasing the preheat value
will darken up edges of fonts, fine lines, and color edges that are against a white or
very near white background. In some cases, increasing the preheat value too much
can cause the white or near white images to print with as light color cast. Increasing
the preheat might also improve color-to-color mis-registration that may occur for
certain images.

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2.8.4 Encoding Tab

The Encoding tab lets you to manage the various magnetic and smart card encoding options.

To access the Encoding Tab, select Start > Devices and Printers. Right click on the Zebra ZXP
Series 7 Card Printer listing, and select Printing preferences > Encoding.

• Magnetic encoding:
- Disable magnetic encoding: Prevents the printer from encoding a card, whether the
job has magnetic encoding data in it or not.
- Encode only: Disables printing, whether the job has an image to be printed or not.
- Magnetic encoder verification ON: Verifies the data that is written to the card before
declaring the encoding action to be successful.
- Coercivity: Selections are High and Low.
- Magnetic encoding type: Selections are ISO, AAMVA, CUSTOM, and BINARY.
ISO is the default. Custom settings are adjusted using the ZXP Series Toolbox.
BINARY is not currently supported.

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2.8.5 About Tab

The About Tab shows the copyright and the driver version for the Zebra ZXP Series 7
Card Printer.

To access the About Tab, select Start > Devices and Printers. Right click on the Zebra ZXP
Series 7 Card Printer listing, and select Printing preferences > About.

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 3
Theory of Operation

3.1 Introduction
This section includes four major topics:

Card Movement During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Printing Technologies and Ribbons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

System-Level Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Main PCBA (CPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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Card Movement During Printing

3.2 Card Movement During Printing

Step 1. The card is fed from the Card Hopper into the Printer.

Step 2. As the card is moved into the Printer, it is cleaned via the Cleaning Cartridge; this
cleans dust and dirt particles from both sides of the card.

Step 3. If the Printer includes an optional Smart Card Encoder (either contact-style or
contactless), the card is moved to the Encoder; and the smart card is encoded. As
the card is encoded, it is checked to verify that it was encoded properly. If encoding
fails, the card is moved to the Reject Bin. This is done to avoid wasting time and
ribbon panels on a defective card. If the encoding is successful, the card is moved
into the pre-print position, just before the Printhead.

Step 4. If the Printer includes an optional Magnetic Stripe Encoder, the card is moved to the
Encoder; and the magnetic stripe is encoded. The card is then backed up and run
through the Magnetic Stripe Encoder again; on this pass the card is read to verify
that the magnetic stripe was properly encoded. If encoding fails, the card is moved
to the Reject Bin. As with failed smart card encoding, this is done to avoid wasting
time and ribbon panels on a defective card. If the encoding is successful, the card is
moved into the pre-print position, just before the Printhead.

Step 5. The card is printed.

Dye-Sublimation Printing

When the Print Cover is opened and closed, the ribbon is synchronized, thereby
bringing the leading edge of the Yellow ribbon panel (e.g., a YMCK ribbon) under
the Printhead.

The leading edge of the card is moved under the Printhead (over the Platen Roller),
and the Printhead is lowered. Lowering the Printhead reduces the space between
the Printhead, the ribbon, and the card, which produces sharper images.

As the card and ribbon move along, each element of the Printhead receives a pulse
of variable width; a wider pulse results in a hotter element which melts a larger
amount of yellow dye onto that particular spot on the card.

After this Yellow (Y) pass is completed, the Printhead is raised, the card is moved
back, and printing continues with the Magenta (M) ribbon panel, then the Cyan (C)
panel, then the Black (K) panel if present, then an Overlay (O) panel if present.

Thermal-Transfer Printing

If using a monochrome ribbon, the card makes a single pass under the Printhead.
The Printhead elements are energized to either on or off. The on level actually
transfers the spot of resin under the Printhead element to the card. This results in the
sharpest possible images; for bar codes you want the sharpest edges and highest
contrast between dark and un-printed areas.

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Step 6. For dual-sided printing, the card is now moved back to the Card Flipper where the
card is turned over (rotated 180 degrees). The card is moved into the Print Engine;
and the card is printed (same as Step 5).

Step 7. If the Printer has a Laminator:

a. The card is moved through the Printer into the Laminator.

b. As the card passes through the Laminator, laminating film is applied to the
card, the top side or both sides depending on the Laminator.
c. The card (with the laminating film) then passes between a pair of heated rollers,
which seal the laminating film to the card.
d. The card is moved from the Laminator to the Card Exit, where it falls into the
Output Hopper attached to the left side of the Laminator.

Step 8. If the Printer does not have a Laminator; the card moves through the Printer, where
it falls into the Output Hopper attached to the left side of the Printer.

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 97

 3: Theory of Operation
Printing Technologies and Ribbons

3.3 Printing Technologies and Ribbons

There are two types of printing technology used in the printer: Dye Sublimation and Thermal
Transfer. The technology to use is determined by the type of dye or ink on the ribbon.

Monochrome Ribbons have a single color ink on the length of the ribbon. The printer is
programmed to use Thermal Transfer printing for monochrome ribbons.

Multi-Panel Ribbons have a repeating sequence of panels of different dye. RFID Multi-Panel
Ribbons have an RFID tag on the supply spool; the RFID code identifies the ribbon type and
panel count. (Note that the lack of an RFID tag will be interpreted by the printer as being a
Monochrome Ribbon.) Printing with a Multi-Panel Ribbon requires multiple passes of the card
under the Printhead, once per panel.

For dual-sided printing, a typical situation would be to print a full-color graphic (such as a
person’s picture) along with black text and/or bar-coding on the front, and black text and/or
bar-coding on the rear. In this case, a YMCKK Multi-Panel Ribbon would be used.

A YMCKK ribbon has successive panels as follows:

Color Technology Function / Usage

Yellow (“Y”) Dye Sublimation Full-Color Printing and Dye
Sublimation Black Printing
Magenta (“M”) Dye Sublimation Full-Color Printing and Dye
Sublimation Black Printing
Cyan (“C”) Dye Sublimation Full-Color Printing and Dye
Sublimation Black Printing
Black Resin (“K”) Thermal Transfer K Resin Black Printing (for the
front of the card)
Black Resin (“K”) Thermal Transfer K Resin Black Printing (for the
back of the card)

Thermal Transfer Dye Sublimation

Printing Process Printing Process

(YMCKK Black Black Cyan Magenta Yellow

Pattern (“K”) (“K”) (“C”) (“M”) (“Y”)
Repeats) Resin Resin Dye Dye Dye

Ribbon Movement From Supply Spool

Other ribbons are available for the printer; see the Supplies List on the Driver and
Documentation CD that came with the printer, or go to the Zebra Card Printer Solutions
website at www.zebra.com.

98 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 3: Theory of Operation
Printing Technologies and Ribbons

The ribbon synchronizes to it’s “starting” position whenever the Print Cover is opened and
then closed. For a YMCKK ribbon, the starting position is with the leading edge of a Yellow
Panel at the printhead ___location.

The figure below shows how the YMCKK ribbon and card move relative to each other
during printing.

1. Ribbon Moves Black Panel Printhead at

into Position at Printhead Fixed Position

2. Card is Fed to Printing Position

Under the Printhead

3. Card and Ribbon Move Together

as Black Panel is Printed

4. Card and Ribbon Stop at

End of Black Panel

5. Ribbon is Stationary; Card is Moved

Back to Printing Position

6. Card and Ribbon Move Together

as Yellow Panel is Printed

In addition, the driver software allows the user to specify which ribbon panels are printed on
either side of the card.

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 99

 3: Theory of Operation
Printing Technologies and Ribbons

Dye Sublimation Printing

In Dye Sublimation Printing, each printhead heating element is applied voltage at one of a
number of pulse widths.

A wider pulse results in the element getting hotter, which converts more of the dye (at that
pixel ___location) to a gas and diffuses it into the surface of the card (a wider pulse gives more
intense color at that pixel).

This is repeated for each of the dye panels (i.e., Yellow, Magenta, and Cyan), to result in full-
color images.

Ribbon Carrier Printhead

Layer

Ribbon
Ink Layer Gaseous Dye is
Card
Absorbed by Card

Thermal Transfer Printing

In Thermal Transfer Printing, voltage is either applied or not applied to each printhead printing
element. If voltage is applied, the ink at that ___location is transferred to the surface of the card.

Each pixel is either printed (i.e., the ink is transferred to the card) or not; there are no
intermediate levels.

Thermal Transfer printing with a black (K) resin panel is used for printing bar codes, since
contrast between the light and dark areas is the highest and the edges are the sharpest.

Ribbon Carrier Printhead

Layer

Ribbon
Ink Layer Ink is Transferred to
Card
Surface of Card

100 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 System-Level Electronics

P1036102-002
UHF Mod
OPTIONS MODULE or
AC Switch & DB9 for
CA_ACPWR (P1013793) Felica Mod
EMI Filter 200W Power Supply External
(PWR_SW, (PWR_SUP, Contact USB Barcode
CA_SUP_GND Media Auth Coupler SmartCard Mag Module PCBA
P1035695) P1008702) Station Host Reader
(P1014040) (PCBA_CPLR_MA, Authentication (PCBA_MAG_MOD_IF
Ports (BARCD)
P1008230-02) (Contact SmartCard P1038451-01) Mag Head

or
for User Auth) ( MAG_ISO)
CA_MTRS_ENG_GND

(P1031857)
(P1029730) P1029189
Ground Plate CA_CPLR_MA

CA_MAG_MOD_IF

(P1027378-01)
(P1027378-02)
CA_MTR_RIBT_GND (300844-001) LED
(GND_MCB,

PCBA_UHF_CAR
(P1029884)

PCBA_FELICA_CAR
P1010902) CA_BRUSH_EXIT SEN_OPMG
(P1022300) MTR_OPMG
PE Media Auth PCBA Options Module Detector (P1039207)
CA_SW_GND (PCBA_MAB, Mag PCBA (PCBA_MAG_
(P1013891) 404870-003P) SmartCard Module (PCBA_OPMAG,
CA_ENGINE_GND MOD_DET,

(Osprey P/N: P1004275)

(SC_MOD, P1038415-01) P1038478-01)

CA_LAM_AC (P1029986)
CA_LAM_GND 806882-001) or SmartCard Coupler
(P1041281) CA_OPTIONS_GND Ext Contact Stn i/f (PCBA_CPLR_SC)
PCBA (if required) CA_MTR_OPMG-MOD_GND (P1033288)

(P1042978)
(PCBA_EXTCNT_IF,

CA_EXT_DB9

WiFi Antenna (ANT, P1005199)

CA_LAM_DC (P1030139) CA_EXT P1006651-01) CA_MTR_OPCM_GND
MAG

CA_MAB
(Osprey P/N: P1004276) (P1043050) (P1033220)

CA_UCONN

(P1025470)
CA_BARCD

CA_DCPWR (P1030122: DC output CN2 is conn)

(Osprey P/N: 300827-001: DC output CN2 is term block)
CA_USRAUTH
CA_SC_MOD

CA_OPMAG (P1026484)
Laminator Ethernet (P1029151) or
CA_LAM_CTL (P1030001) MTR_OPCM
(LAM) Periph Board CA_SC_MOD
(Osprey P/N: P1004277) (P1029200)
USB (PCBA_ENET,
OPMAG_PD_N

_EXT
These connections Port P1006890-02 (P1042729) CA_MTR_OPCM-MOD_GND (P1033283)
SEN_RIBA Tri-Color are combined into or
(404790-003P) Emitter CA_PH P1006890-03) SmartCard
(P1037316) FSI Conn Module PCBA Gap
FAN_PH (blower) (PCBA_SC_MOD, Sensor Gap SEN_OPCD
(P1044307) P1028126-01) SEN_OPCM Sensor (300238G-002)

CA_OPSC_RF
3.4 System-Level Electronics

CA_ENGINE_GND (P1032223) Connectors (P1029126)

Print Head Main Controller Board PCBA
(PCBA_MCB, Options Module
(PH, CA_MTR_OPCD_GND
SmartCard PCBA
P1040725) P1047494-01) CA_OPSC
(PCBA_OPSC,
PH_GND (P1027859)
P1028104-01) MTR_OPCD
Ground Plate (P1044093)
CA_OCP_PLUG
SMARTCARD

CA_OCP_RECEPT
(GND_ENG, OCP Assy
(P1032161) (P1032163)
P1030086) (OCP,
P1027292) CA_EP_DEBUG These connections
IP/EP Diagnostic Board are combined into
CA_IP_DEBUG CA_FLIP_PWR (P1026479)
(PCBA_DIAG_IF, CA_FLOPSC
JTAG CA_FLIP_CTL (P1026480)
P1043417-01) (P1026476)
These connections
CA_SEN_RIBB CA_MTRS_ENG_GND are combined into
(P1037399) CA_FLOPMAG
OPSC_PD_N

(P1026478)
MTR_OPCM_CTL

MTR_CAM (P1009302)
CA_BRUSH_CLSOUTS (P1029745-001)

CA_THERM
(P1051848)
CA_BRUSH_FEED_RGHT (P1029727)
CA_BRUSH_FEED_LEFT (P1029728) MTR_OPMG_CTL

Thermistor
CA_MTR_FEED_GND (P1029744-001) SEN_RIBB Tri-Color
CA_OPTIONS_GND MTR_MAIN (P1009157-001)

Zebra ZXP Series 7 Card Printer Service Manual

CA_MTR_RIBS_GND (P1029883-001) (405030-003B) Detector
(P1032220) Flipper Board PCBA
CA_MTR_RIBS_GND (PCBA_FLIP,
SEN_TENC Gap P1021234-01)
CA_MTR_MCB (P1014939)
(300364-003) Sensor MTR_RIBS (P1020449) CA_MTR_FLCD_GND
SEN_EXIT Gap
Ground Plate (300364-010) Sensor MTR_FLCD

CA_SEN_MCB (P1014941)
(GND_FLOP, (P1042321)
SEN_SENC Gap
P1029901) (300364-002) Sensor CA_MTR_FLRO_GND
CA_MTR_RIBT_GND
SEN_CAM Gap
MTR_FLRO
(300364-008) Sensor MTR_RIBT (P1020406)
(P1026465-002)
MTR_SP
SEN_CSYN Gap
CA_FLIP_SHFT_GND (P1029747-001) (300364-009) Sensor
Gap SEN_FLCD
CA_MTR_FLCD_GND (P1032300) Sensor (P1030185)
SEN_DOOP Gap FAN_PWR
CA_MTR_OPCD_GND (P1032300) FEEDER
CA_MTR_FLRO_GND (P1032281) (300238G-004) Sensor
CA_BRUSH_ATM (P1029833) CA_MTR_FEED_GND Gap SEN_FLRO
CA_BRUSH_FLIP (P1032340) Sensor (300364-007)
FAN_SP1
CA_MTR_OPMG-MOD_GND (P1033288)
CA_MTR_OPCM-MOD_GND (P1033283) MTR_FEED Gap SEN_FDOP
(P1041216)
(Individual motor cables)

Sensor (300364-006)
FAN_SP2
3: Theory of Operation
System-Level Electronics

FLIPPER

101
 3: Theory of Operation
Main PCBA (CPU)

3.5 Main PCBA (CPU)

PCBA Layout

* J50, J51, and J52 are on the bottom side of the Main PCBA

102 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 3: Theory of Operation
Main PCBA (CPU)

PCBA Connections

Connector PCBA ID Functional Description

J1 ETHERNET INTERFACE Ethernet Daughterboard
J2 USB_PERIPH_PC USB peripheral interface from host PC
J3 SEN_RIBA Ribbon tri-color sensor (detector)
J4 SEN_RIBB Ribbon tri-color sensor (emitter)
J5 PH_PWR Power to printhead
J6 JTAG RESERVED
J7 DCPWR DC power input to board
J8 MTR_RIBT Ribbon take-up motor
J9 SEN_TENC Ribbon take-up encoder wheel sensor
J10 LAM_CTL Control signals to Laminator
J11 SEN_EXIT Exit sensor
J12 -- RESERVED
J13 -- RESERVED
J14 -- RESERVED
J15 -- RESERVED
J16 MTR_MCB Stepper motors driven by MCB
J17 -- RESERVED
J18 USB_HOST_SP RESERVED
J19 USRAUTH User Authentication
J20 BARCD Barcode Reader
J21 OCP Operator Control Panel
J22 MAB Media Authentication Board
J23 SEN_CAM RESERVED
J24 SEN_MCB Various sensors
J25 N/A N/A
J26 UHF/FELICA RESERVED
J27 FDFLIP_CTL Control signals to Flipper Board
J28 FDFLIP_PWR Power to Flipper Board
J29 PH_DATA Printhead Data
J30 USB_HOST_PANEL USB Dual Host cable
J31 -- RESERVED
J32 IP_DEBUG RESERVED
J33 EP_DEBUG RESERVED
J34 SEN_RIBA_NEW Ribbon tri-color sensor (emitter)
J35 SEN_RIBB_NEW Ribbon tri-color sensor (detector)
J36 THERM RESERVED
J50* OPSC SmartCard option board
J51* OPMAG Mag option board
J52* DIAG I/F Diagnostic test

* J50, J51, and 52 are on the bottom side of the Main PCBA

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 103

104
Main PCBA
200W Power Supply
(PWR_SUP)

2 Tri-Color
IP/EP Diagnostic Board SEN_RIBA
Emitter
(PCBA_DIAG_IF,
5

Thermistor
Main PCBA (CPU)

P1043417-01) Tri-Color
SEN_RIBB

CA_DCPWR
Ethernet Detector

CA_UCONN
J2

CA_THERM
Daughter
Board
Flipper CA_FDFLIP_PWR (PCBA_ENET)
J28
Module
J1

J7
PCBA CA_FDFLIP_CTL

J52
J35

J34

J36

J30
3: Theory of Operation

(PCBA_FLIP) J27

J24 Gap
DC-DC SEN_SENC
Sensor
Mag PCBA CA_OPMAG Power
J51

USB_PERIPH_PC
(PCBA_OPMAG) Conversion Gap
SEN_CAM

USB_HOST_PANEL
Sensor Interface Sensor
(tri-color sensor circuit,
PCBA Block Diagram

USB Logic Gap

74HC14's for digital sensor inputs, SEN_CSYN
CA_SEN_MCB

A2D for analog inputs) Sensor

Debug Interfaces
USB Interfaces Gap
SmartCard PCBA CA_OPSC SEN_DOOP
J50 Sensor
(PCBA_OPSC)
Remote Board Interfaces

MCB Sensor Interfaces

CPU Subsystem
(FPGA, DDR, Flash,
Media Auth clock buffering, I2C mux, etc.) Gap
Coupler PCBA J9 SEN_TENC
External Module Interfaces Sensor
(PCBA_CPLR_MAB) Print Head Interface
Gap
CA_CPLR_MAB J11 SEN_EXIT
Sensor

Media Auth PCBA CA_MAB (PH_PWR)

J22 J5
(PCBA_MAB) CA_PH Print Head
(PH)
J29
(PH_DATA)
MCB Motor Driver Interfaces
CA_LAM_CTL 2
Laminator (LAM) J10 FAN_PH

2
OCP Support PCBA CA_OCP A3979 A4983 A3966 BEMF Circuit J8 MTR_RIBT
J21
(PCBA_OCP)

Zebra ZXP Series 7 Card Printer Service Manual

Barcode CA_BARCD
Reader J20 J16
(BARCD)
J26
serviceable unit, circuit analysis to the component level is pointless.

J19

4 4 2
These motors each plug into
a C/A (CA_MTR_MCB) that

CA_USRAUTH
connects to J16 here.

CA_UHF-FELICA
SmartCard
Authentication
(Contact SmartCard
for User Auth) UHF/Felica
(PCBA_USRAUTH)
MTR_RIBS

MTR_CAM

MTR_MAIN
Most of the circuitry in the printer is on the Main PCBA. Since the Main PCBA is not a

P1036102-002
 4
Troubleshooting

4.1 Introduction
The table on the next page offers causes and solutions to symptoms related to improper
operation. Check the table on the following pages when experiencing any loss of operation
or print quality.

For additional information on troubleshooting and advanced operations, you can access an
extensive Knowledge Base at km.zebra.com.

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 105

 4: Troubleshooting
Introduction

OCP Error Messages

Important • If the Possible Solution does not solve your problem, contact Zebra
Technical Support.

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

5 FIRMWARE UPGRADE Firmware upgrade incompatibility. Verify the version, and retry installing the
ERROR firmware.
6 DIAGNOSTIC ERROR Error encountered in Diagnostic Mode. Power cycle the printer, and retry.

7 FIRMWARE UPGRADE Firmware upgrade failed. Verify the version, and retry installing the
ERROR firmware.
8 CRITICAL ERROR Major malfunction encountered. Contact Zebra Technical Support.
SHUTTING DOWN
3001 PRINTER OFFLINE Status toggled (offline/online) via the Change status to online via the OCP
OCP Advanced Settings Menu. Advanced Settings Menu.
4003 CARD JAM Card is jammed in the Printer. Clear the card path.

4014 CARD FEED ERROR Card is jammed in Feeder Cartridge, a. Clear card jam in Feeder Cartridge,
and re-seat Feeder Cartridge.
b. Ensure that cards are not stuck
- or - together and that they are the correct
thickness (10 to 50 mil).

The printer is out of cards. a. Load cards in the Feeder Cartridge.

b. Re-seat the Feeder Cartridge.
4015 CARD NOT INSERTED Card was not fed into the Manual Retry and feed a card into the Manual
Feed Slot within 30-second period. Feed Slot, or cancel the operation.
5001 OUT OF RIBBON Print ribbon has run out. Load a new roll of print ribbon.

5002 INVALID RIBBON Print ribbon does not match the printer. Verify the part number of the print ribbon
is correct on OCP.
5003 RIBBON JAM Print ribbon is jammed. a. Check the print ribbon.
b. Reinstall the print ribbon.
c. Repair the break in the print ribbon
and reinstall.
5006 RIBBON BEMF ERROR Problem with the Back EMF (BEMF) of Contact Zebra Technical Support.
the ribbon motors.
5007 RIBBON COLOR DETECT Print ribbon is not installed correctly. Reinstall the print ribbon. If reinstalling
ERROR the ribbon does not solve the problem,
contact Zebra Technical Support.
5008 INVALID RIBBON Print ribbon does not match the printer. a. Verify the part number of the print
ribbon is correct on OCP.
b. Power cycle the printer, and retry.
6009 FLASH ERASE ERROR There is a problem when accessing Power cycle the printer, and retry.
flash memory.
6010 FLASH ERASE VERIFY There is a problem when accessing Power cycle the printer, and retry.
ERROR flash memory.

6011 FLASH PROGRAM ERROR There is a problem when accessing Power cycle the printer, and retry.
flash memory.
6012 FLASH PROGRAM VERIFY There is a problem when accessing Power cycle the printer, and retry.
ERROR flash memory.
6013 INVALID FW S-RECORD There is a problem when accessing Power cycle the printer, and retry.
flash memory.

106 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 4: Troubleshooting
Introduction

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

6015 - GENERAL MEMORY There is a problem when accessing Power cycle the printer, and retry.
6025 ERROR general memory.
7001 CARD FEED ERROR Card is jammed in Feeder Cartridge, a. Clear card jam in Feeder Cartridge,
and re-seat Feeder Cartridge.
b. Ensure that cards are not stuck
- or - together and that they are the correct
thickness (10 to 50 mil).

The printer is out of cards. a. Load cards in the Feeder Cartridge.

b. Re-seat the Feeder Cartridge.
7003 PRINTHEAD CABLE Printhead cable loose or disconnected. Check printhead cable connection,
ERROR reconnect if loose or disconnected.
7004 CARD EJECT ERROR Card from previous job is stuck in the exit Remove the card from the exit area.
area.
7008 PRINT COVER OPEN This warning will be displayed if the cover This warning will be cleared when the
protecting the Printer Module is opened. printer cover is closed.
7010 PRINTHEAD MOTION Printhead did not move to proper position Power cycle the printer, and retry.
ERROR during initialization.
7013 MOTOR VOLTAGE ERROR Incorrect voltage detected at one or Power cycle the printer, and retry.
several motors in the unit.
7014 SCRIPT PROCESSING Internal logic error. Power cycle the printer, and retry.
ERROR
7015 MAG MOTION ERROR This is a magnetic encoding retrace error. Power cycle the printer, and retry.
7018 SMARTCARD ERROR • Encoding error. a. Ensure that you are using the correct
• Faulty card. card type.
b. Check that the cards are loaded in the
correct orientation.
c. Ensure that the data conforms to ISO
Specifications.
d. Retry writing and reading.
7019 SCRIPT CONTENT ERROR Internal logic error. Power cycle the printer, and retry.
7020 SCRIPT SEND ERROR Internal logic error. Power cycle the printer, and retry.

7023 SMART CARD CAM Mechanical positioning issue. Power cycle the printer, and retry.
ERROR
7024 OPTIONS CARD JAM Card is jammed in the Options Module, Clear the card path.
Feeder Cartridge.
7026 FLIPPER CARD JAM Card is jammed in the Flipper. Clear the card path.

7028 OPTIONS COVER OPEN This warning will be displayed if the cover This warning will be cleared when the
protecting the Options Module is opened. options cover is closed.
7029 FLIPPER ROTATION The Flipper has failed. Contact Zebra Technical Support.
ERROR
7032 SINGLE CARD FEED JAM Card is jammed in the Options Module, Clear the card path.
Single Card Feed Slot.
7033 FLIPPER BOARD ERROR The Flipper has failed. Contact Zebra Technical Support.
7034 REJECT BIN FULL The Reject Bin is full. Remove the cards from the bin, and reset
REMOVE CARDS the reject bin card count to 0 via the OCP
(Main Menu > Advanced Settings > Clear
Reject Bin).
7035 OPTIONS CARD JAM Card is jammed in the Options Module, Clear the card path.
Magnetic Encoder.
7036 - PRINT CARD JAM Card is jammed in Printer Module. Clear the card path.
7039

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 107

 4: Troubleshooting
Introduction

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

9001 MAG READ ERROR • Encoding error. a. Ensure that you are using the correct
• Defective magnetic stripe. card type.
b. Check that the cards are loaded with
the magnetic stripe in the correct
orientation.
c. Ensure that the cards are set-up
correctly in the printer driver
(coercivity setting).
d. Ensure that the data conforms to
ISO Specifications.
e. Retry reading.
9002 MAG WRITE ERROR • Encoding error. a. Ensure that you are using the correct
• Defective magnetic stripe. card type.
b. Check that the cards are loaded with
the magnetic stripe in the correct
orientation.
c. Ensure that the cards are set-up
correctly in the printer driver
(coercivity setting).
d. Ensure that the data conforms to
ISO Specifications.
e. Retry writing.
9004 NO MAG STRIPE Magnetic stripe not detected. a. Ensure that you are using the correct
card type.
b. Check that the cards are loaded with
the magnetic stripe in the correct
orientation.
15001 MISSING MAB An error occurred when reading the RFID a. Check print ribbon orientation.
Tag by the MAB (Media Authentication b. Verify part number of the print ribbon.
Board). c. Power cycle the printer, and retry.
15002 MAB FIRMWARE MISSING MAB (Media Authentication Board) Install the firmware.
Firmware is missing.
17002 LAMINATOR FAILED Laminator was detected by the printer, Contact Zebra Technical Support.
INITIALIZATION but was unable to communicate to it.
17003 LAMINATOR UNKNOWN An unknown error has occurred – this is a. Press RETRY on the OCP.
ERROR an indication of a FW problem and should b. Contact Zebra Technical Support.
not occur.

17004 MISSING LAMINATOR MAB An error occurred when trying to a. Power cycle the printer, and retry.
communicate to the Laminator MAB b. Contact Zebra Technical Support.
(Media Authentication Board).
17005 TOP LAMINATE FEED FAIL • Top laminate cartridge is not installed • Remove, reposition, and re-install the
properly. top laminate cartridge.
• Cartridge is not removed when that • Remove the top laminate cartridge.
side of the card is not being laminated.
• A mis-cut piece of laminate (rare) is • Remove the mis-cut piece of laminate.
obscuring the media sensor.
17006 BOTTOM LAMINATE FEED • Bottom laminate cartridge is not • Remove, reposition, and re-install the
FAIL installed properly. bottom laminate cartridge.
• Cartridge is not removed when that • Remove the bottom laminate
side of the card is not being laminated. cartridge.
17007 TOP LAMINATE • Improperly prepared registered Remove and recut laminate in the center
REGISTRATION ERROR laminate. of the index notch, re-install, and retry.
• Media misfeed.
• Patch length improperly set.
• Unexpected end of laminate roll
detected.
17008 LAMINATOR CARD FEED Printer has not fed the card far enough Open the Laminator and printer doors to
FAIL into laminator mechanism for infeed check for jammed/stuck cards.
rollers to grab it.

108 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 4: Troubleshooting
Introduction

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

17009 LAMINATOR EARLY CARD Card did not make it to the staging rollers. Remove the card and/or laminate that is
JAM stuck in the laminator staging/cutting
area.
17010 LAMINATOR MIDDLE Card and laminate have jammed inside Remove the oven, and inspect for stuck
CARD JAM heater assembly, often due to mis- cards.
positioned laminate patch sticking to
heated rollers.
17011 LAMINATOR LATE CARD Card did not unblock the exit sensor in a. Check for card jam in the exit area.
JAM the specified time. b. Assure that the sliding exit door is not
partially blocking the exit path.
17012 LAMINATOR POLL The laminator expects the printer to Power cycle the printer, and retry.
TIMEOUT periodically send commands to it within a
specified time period. If it fails to do so, it
assumes that something is wrong with
the communication link or that the printer
is down. This error may occur if the
printer-to-laminator communications is
having intermittent problems.
17013 LAMINATOR TOP HEATER Top heater did not turn on after being Replace the top halogen bulb.
FAIL instructed to do so. When the heater is
enabled, the controller will wait a certain
specified amount of time for it to attain
the set target temperature. If the heater
fails to reach the target in the specified
time, the TopHeaterFail fault will be set.
17014 LAMINATOR BOTTOM Bottom heater did not turn on after being Replace the bottom halogen bulb.
HEATER FAIL instructed to do so. When the heater is
enabled, the controller will wait a certain
specified amount of time for it to attain
the set target temperature. If the heater
fails to reach the target in the specified
time, the BotHeaterFail fault will be set.
17015 LAMINATOR TOP If the top roller temperature ever exceeds a. Power cycle the printer, and retry.
TEMPERATURE HIGH a fixed temperature threshold, the over b. If this error persists, contact Tech
temp error occurs. Support.
17016 LAMINATOR BOTTOM If the bottom roller temperature ever a. Power cycle the printer, and retry.
TEMPERATURE HIGH exceeds a fixed temperature threshold, b. If this error persists, contact Tech
the over temp error occurs. Support.
17017 LAMINATOR TOP CUTTER Top cutter blade is obstructed, or top If this error persists, contact Tech
STALL cutter mechanism is damaged. Support.
17118 LAMINATOR BOTTOM Bottom cutter blade is obstructed, or If this error persists, contact Tech
CUTTER STALL bottom cutter mechanism is damaged. Support.
17019 LAMINATOR TOP CUTTER Top cutter has failed. If this error persists, contact Tech
FAIL Support.
17020 LAMINATOR BOTTOM Bottom cutter has failed. If this error persists, contact Tech
CUTTER FAIL Support.
17021 LAMINATOR TOP TEMP The top temperature (thermopile) sensor If this error persists, contact Tech
SENSOR FAIL has failed. Support.
17022 LAMINATOR BOTTOM The bottom temperature (thermopile) If this error persists, contact Tech
TEMP SENSOR FAIL sensor has failed. Support.
17023 LAMINATOR FAN FAIL This should only happen if one or both Check for blocked vents.
cooling fans fail or the cooling vents near
the heated roller assembly are blocked or
the fan(s) have failed.
17024 LAMINATOR EEPROM The parameters stored in EEPROM have a. Press RETRY on the OCP when this
DEFAULT been reset to their default values. This error occurs.
will not normally happen, but could be b. Power cycle the printer, and retry.
seen with certain FW upgrades when
new parameters have been added by
Engineering. It could also indicate a
problem with the Laminator’s EEPROM.

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 109

 4: Troubleshooting
Introduction

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

17026 TOP AND BOTTOM The top and bottom laminates have Load new rolls of laminate.
LAMINATES OUT run out.
17027 TOP LAMINATE OUT The top laminate has run out. Load new roll of laminate.

17028 BOTTOM LAMINATE OUT The bottom laminate has run out. Load new roll of laminate.
17029 INVALID TOP LAMINATE Laminate does not match the printer. a. Verify the part number of the laminate
is correct on OCP.
b. Power cycle the printer, and retry.
17030 INVALID BOTTOM Laminate does not match the type a. Verify that the top and bottom
LAMINATE allowed in the laminator or top and/or laminate cassettes are installed in the
bottom has been swapped. correct locations.
b. Verify the part number of the laminate
is correct on OCP.
c. Power cycle the printer, and retry.
17031 BOTTOM LAMINATE • Improperly prepared registered Remove and recut laminate in the center
REGISTRATION ERROR laminate. of the index notch, re-install, and retry.
• Media misfeed.
• Patch length improperly set.
• Unexpected end of laminate roll
detected.
17038 LAMINATOR COVER OPEN This warning will be displayed if the cover This warning will be cleared when the
protecting the laminator is opened. laminator cover is closed.
17040 LAMINATOR INITIALIZING This warning will be displayed after the No action needed
laminator door is closed and laminate
spools are re-read/detected.
17041 LAMINATOR FIRMWARE LCB (Laminator Controller Board) Install the firmware.
MISSING Firmware is missing.
17042 LAMINATOR MAB Laminator MAB (Media Authentication Install the firmware.
FIRMWARE MISSING Board) Firmware is missing.

110 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 4: Troubleshooting
OCP Test Cards

4.2 OCP Test Cards

Test Card Images

GRADIENT BOXES DENSITY SETUP MONOCHROME ONLY

Test Card Descriptions

Image Title Description Use

GRADIENT 3 sets of light-to-dark grayscale For factory use only
BOXES ramps

DENSITY Mid-gray and maximum density Used to measure mid and max densities.
SETUP fields on a flat gray surface Also used to check the left/right offsets or
the centering of the image on the card.
MONOCHROME Barcode and text Used to verify monochrome print capability
ONLY

Also used to check the left/right offsets or the centering of the image on the card.

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 111

 4: Troubleshooting
Ethernet

4.3 Ethernet
• Indicators -- Detail

Link Speed Link Activity

• Link Speed Indicator (Orange)

Off No link (disconnected)

1 Blink The LED blinks once (one blink, pause, one blink, etc.) when a
10Base link has been established.
2 Blinks The LED blinks twice (two blinks, pause, two blinks, etc.) when
a 100Base link has been established.

• Link Activity Indicator (Green)

Off No link (disconnected)

On Network link has been established
Blinking Network activity has been detected

• Issues

If both LEDs are off, the printer has not detected the presence of a network cable. To solve
the problem:

• Verify that the network cable is appropriate and has an RJ-45 connector.

• Remove the network cable from the printer. Plug the network cable back in until you
hear a positive click. Check the other end of the cable in the same manner. If the
printer still does not detect a cable, then continue.

• Connect the printer to a known good network. If the printer is still unable to detect the
network cable, contact Technical Support for assistance.

112 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 5
Replacement Procedures for
the Printer

5.1 Introduction
The following sections describe removing both major assemblies and, where applicable,
subassemblies and/or components that are considered replaceable.

In general, only removal directions are presented; unless otherwise noted, replacement would
be performed by reversing the removal steps. Replacement instructions for some items are not
presented; removal and replacement of these items are considered too obvious to warrant a
detailed description.

Spare Kits are listed in Appendix E.

Electric Shock • Before performing any of the procedures in this section, set the printer
power to OFF (O) and disconnect the power cord.
still

Electrostatic Discharge • All replacement procedures must be performed at a static-

free work station, an anti-static wrist strap must be worn and properly terminated, or
other appropriate protection must be used.

Caution • Before beginning any of the procedures that follow, read completely through
the procedure. If you do not have the specified tools or if any step(s) seem beyond your
skill or experience level, do not attempt the procedure. You may cause additional
damage to the printer.

Note • Some of the photographs in this section may show additional parts removed in
addition to removals for the process being described.

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 113

 5: Replacement Procedures for the Printer
Required Tools

5.2 Required Tools

The following list specifies the tools required to perform the replacement procedures described
in this section. Naturally, not all tools are required for a particular procedure; specific tools are
called out in each step as appropriate.

1. Flat-blade Screwdrivers: from 1/16 inch (1.5 mm) to 1/4 inch (6.5 mm)
2. Phillips Screwdrivers: #0, #1, and #2
3. TORX T8, T9, and T10 (standard, 12-inch shaft, and/or ball-end; magnetic
tip recommended)
4. Fine-Point, Offset Fine-Point, and Needle-Nose Pliers
5. Small Diagonal Cutters or other cutter for cutting cable ties
6. 5.5 mm Nut Driver (this can also be used for securing push nuts)
7. 3-10 mm E-Ring Clip Tool
8. Small and Medium Spring Hooks
9. Adjustable Wrench
10. Multimeter

11. Loctite® 242

The following list specifies the Zebra Special-Purpose Tools required to calibrate specific
parts/assemblies reinstalled in selected procedures. Note that the Zebra Part Number is in
parentheses following the description.

1. Torque Tools for RTU Motor Calibration ZXP7 (P1037750-400)

comprised of High Torque Tool and Low Torque Tool
2. Print Head Cam Sync Fixture ZXP7 (P1037750-401)
3. Flipper Deck Level (P1037750-402)
4. Contact Station Upgrade Tool (P1037750-403)
5. AC Power Filter Release Tool (P1037750-404)
6. Mag Tensioning Spring Tool (P1051857)
7. Gate 507C Sonic Tension Meter, 74200507

114 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 5: Replacement Procedures for the Printer
Removal Sequence

5.3 Removal Sequence

The following three figures show the recommended removal sequence. For each item, follow
the diagram upward to see what must be removed for access. For example, to remove the
Control Panel Door Open Sensor, remove the Back Cover, the Options Cover, and the
Right Cover -- follow the red path.

5.6.3, Ribbon 5.6.1, Reject 5.6.6, Back 5.6.8, Options 5.6.4, Card
Drawer Bin Cover Cover Guides

5.6.14, Left 5.6.7, Rear 5.6.10, Right 5.6.9, OCP

Side Cover Feeder Cover Side Cover PCBA

5.6.15, Panel, 5.6.12, Print

Cover 5.6.11, Control
Plungers, and Panel Door
Springs Open Sensor

5.6.13, Door
Button and
Latch

5.6.16, Bottom
Cover

5.6.21, 5.6.20, Main

Ethernet PCBA PCBA

5.6.25, Ground
Plate

5.6.19, Printer

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 115

 5: Replacement Procedures for the Printer
Removal Sequence

Printer

5.6.19, Printer

5.6.22, Print 5.6.23, Feeder/

Engine Flipper/Options
Assembly

5.6.24, Feeder/
Flipper
Assembly

5.6.27, Feeder 5.6.28, Flipper 5.6.29, Options

Module Module Module

Feeder Module

5.6.27, Feeder 5.6.27.1, Drive

Module Assembly
Feeder

5.6.27.2,
Feeder Motor

116 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 5: Replacement Procedures for the Printer
Removal Sequence

Flipper Module

5.6.28, Flipper 5.6.28.1,

Module Flipper
Assembly

5.6.28.2, ESD 5.6.28.3, 5.6.28.4, 5.6.28.5, 5.6.28.8,

Brush Flipper PCBA Flipper Position Flipper Flipper Drive
Sensor Rotation Gear Motor

5.6.28.6, 85/
35T Gear

5.6.28.7,
Flipper
Rotation Motor

5.6.28.9,
Flipper Deck

5.6.28.10, 5.6.28.11, Card

Flipper Deck Present On
Platen Roller Flipper Sensor

Options Module

5.6.29, Options 5.6.29.1,

Module Options
Module

, 5.6.29.2, 5.6.29.7, MAG 5.6.29.9, MAG 5.6.29.10, Card 5.6.29.11,

SmartCard (or Non-MAG) Control PCBA Sensor Options Motor
Control PCBA Pressure Roller
Assembly

5.6.29.12, 5.6.29.8, MAG 5.6.29.13,

Drive Platen Head MAG Drive
Roller Platen Roller

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 117

 5: Replacement Procedures for the Printer
Procedure List

5.4 Procedure List

5.6.1 Reject Bin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 123
5.6.2 Feeder Cartridge Standard - - - - - - - - - - - - - - - - - - - - - - - - 125
5.6.2.1 Feeder Cartridge Cover - - - - - - - - - - - - - - - - - - - 126
5.6.2.2 Retainer for Feeder Cartridge - - - - - - - - - - - - - - - 127
5.6.3 Ribbon Drawer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 128
5.6.4 Card Guides - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 130
5.6.5 Shroud for Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 132
5.6.6 Back Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 133
5.6.7 Rear Feeder Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 134
5.6.8 Options Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 135
5.6.9 OCP PCBA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 137
5.6.10 Right Side Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 139
5.6.11 Control Panel Door Open Sensor - - - - - - - - - - - - - - - - - - - - 141
5.6.12 Print Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 142
5.6.13 Door Button and Latch - - - - - - - - - - - - - - - - - - - - - - - - - - - 144
5.6.14 Left Side Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 147
5.6.15 Panel, Plungers, and Springs - - - - - - - - - - - - - - - - - - - - - - - 148
5.6.16 Bottom Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 150
5.6.17 Feet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 151
5.6.18 Reject Bin Bracket - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 152
5.6.19 Printer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 153
5.6.20 Main PCBA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 157
5.6.21 Ethernet PCBA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 162
5.6.22 Print Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 163
5.6.22.1 Cooling Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - 163
5.6.22.2 Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - 164
5.6.22.3 Print Engine Ground Plate - - - - - - - - - - - - - - - - - 166
5.6.22.4 Printhead Assembly - - - - - - - - - - - - - - - - - - - - - - 167
5.6.22.5 Printhead Housing Assembly - - - - - - - - - - - - - - - 171
Printhead Latch Assembly - - - - - - - - - - - - - - - - - 172
Printhead Lift Spring Assembly - - - - - - - - - - - - - - 173
5.6.22.6 Ribbon Sensor - - - - - - - - - - - - - - - - - - - - - - - - - 175
5.6.22.7 Covers for Printhead - - - - - - - - - - - - - - - - - - - - - 176
Printhead Front Cover - - - - - - - - - - - - - - - - - - - - 176
Printhead Back Cover - - - - - - - - - - - - - - - - - - - - 178
5.6.22.8 Ribbon Spindles - - - - - - - - - - - - - - - - - - - - - - - - 179
5.6.22.9 Ribbon Supply Spindle Assembly - - - - - - - - - - - - 180
Media Authentication PCBA (MAB) - - - - - - - - - - - 180
Spindle Clutch Assembly - - - - - - - - - - - - - - - - - - 182
Ribbon Sync Sensor - - - - - - - - - - - - - - - - - - - - - 183
Spindle Clutch Assembly (continued) - - - - - - - - - 184
Antenna (Media Authentication PCBA) - - - - - - - - 185
Supply Spindle Motor - - - - - - - - - - - - - - - - - - - - - 186

118 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 5: Replacement Procedures for the Printer
Procedure List

5.6.22.10 Ribbon Take-Up Spindle Assembly - - - - - - - - - - - 188

Take-Up Spindle Assembly - - - - - - - - - - - - - - - - - 188
Take-Up Spindle Motor - - - - - - - - - - - - - - - - - - - - 189
Encoder Sensor - - - - - - - - - - - - - - - - - - - - - - - - 190
Take-Up Spindle Assembly (continued) - - - - - - - - 191
5.6.22.11 Flexible Rollers - - - - - - - - - - - - - - - - - - - - - - - - - 192
5.6.22.12 Ribbon Close Outs - - - - - - - - - - - - - - - - - - - - - - 194
5.6.22.13 Tricolor Ribbon Sensor - - - - - - - - - - - - - - - - - - - 196
5.6.22.14 Platen Drive Motor - - - - - - - - - - - - - - - - - - - - - - - 198
5.6.22.15 Drive System Platen Rollers - - - - - - - - - - - - - - - - 201
5.6.22.16 Printhead Lift Motor - - - - - - - - - - - - - - - - - - - - - - 204
5.6.22.17 Cam Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - 206
5.6.22.18 Print Engine Platen Rollers - - - - - - - - - - - - - - - - - 207
Printhead Lift Gears - - - - - - - - - - - - - - - - - - - - - - 207
Front Frame - - - - - - - - - - - - - - - - - - - - - - - - - - - 208
Exit Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - 209
Sync Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - 210
Pinch Rollers - - - - - - - - - - - - - - - - - - - - - - - - - - 211
Middle and Back Frame Separation - - - - - - - - - - 212
Platen Rollers - - - - - - - - - - - - - - - - - - - - - - - - - - 213
5.6.23 Feeder/Flipper/Options Assembly - - - - - - - - - - - - - - - - - - - - 219
5.6.24 Feeder/Flipper Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - 224
5.6.25 Ground Plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 227
5.6.26 Power Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 229
5.6.27 Feeder Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 231
5.6.27.1 Drive Assembly Feeder - - - - - - - - - - - - - - - - - - - 231
5.6.27.2 Feeder Motor - - - - - - - - - - - - - - - - - - - - - - - - - - 232
5.6.28 Flipper Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 234
5.6.28.1 Flipper Assembly - - - - - - - - - - - - - - - - - - - - - - - - 234
5.6.28.2 ESD Brush - - - - - - - - - - - - - - - - - - - - - - - - - - - - 235
5.6.28.3 Flipper PCBA - - - - - - - - - - - - - - - - - - - - - - - - - - 237
5.6.28.4 Flipper Position Sensor - - - - - - - - - - - - - - - - - - - 239
5.6.28.5 Flipper Rotation Gear - - - - - - - - - - - - - - - - - - - - - 240
5.6.28.6 85/35T Gear - - - - - - - - - - - - - - - - - - - - - - - - - - - 242
5.6.28.7 Flipper Rotation Motor - - - - - - - - - - - - - - - - - - - - 243
5.6.28.8 Flipper Drive Motor - - - - - - - - - - - - - - - - - - - - - - 244
5.6.28.9 Flipper Deck - - - - - - - - - - - - - - - - - - - - - - - - - - - 245
5.6.28.10 Flipper Deck Platen Roller - - - - - - - - - - - - - - - - - 250
5.6.28.11 Card Present On Flipper Sensor - - - - - - - - - - - - - 252
5.6.29 Options Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 253
5.6.29.1 Options Module - - - - - - - - - - - - - - - - - - - - - - - - - 253
5.6.29.2 SmartCard Control PCBA - - - - - - - - - - - - - - - - - - 254
5.6.29.3 MIFARE/Contact Encoder Module - - - - - - - - - - - - 255
5.6.29.4 PCBA for MIFARE Contact Encoder - - - - - - - - - - 258
5.6.29.5 Contact Station Module - - - - - - - - - - - - - - - - - - - 260

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 5: Replacement Procedures for the Printer
Procedure List

5.6.29.6 PCBA for Contact Station Module - - - - - - - - - - - - 263

5.6.29.7 MAG (or Non-MAG) Pressure Roller Assembly - - 265
5.6.29.8 MAG Head - - - - - - - - - - - - - - - - - - - - - - - - - - - - 269
5.6.29.9 MAG Control PCBA - - - - - - - - - - - - - - - - - - - - - - 271
5.6.29.10 Card Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - 272
5.6.29.11 Options Motor - - - - - - - - - - - - - - - - - - - - - - - - - - 274
5.6.29.12 Drive Platen Roller - - - - - - - - - - - - - - - - - - - - - - 275
5.6.29.13 MAG Drive Platen Roller - - - - - - - - - - - - - - - - - - 279

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 5: Replacement Procedures for the Printer
Kit List ( P1037750- )

5.5 Kit List ( P1037750- )

KIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION
001 MIFARE Contact Encoder (Upgrade Kit) . . . . . . .Appendix H
002 Contact Station (Upgrade Kit) . . . . . . . . . . . . . . .Appendix H
003 Mag Encode (Upgrade Kit) . . . . . . . . . . . . . . . . .Appendix H
004 Wired Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6.21
005 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
006 Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . .5.6.22.4
007 Housing for Printhead . . . . . . . . . . . . . . . . . . . . .5.6.22.5
008 Latch & Springs for Print Housing . . . . . . . . . . . .5.6.22.5
009 Covers for Printhead . . . . . . . . . . . . . . . . . . . . . .5.6.22.7
010 Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . .5.6.20
011 Lam SS (Upgrade Kit) . . . . . . . . . . . . . . . . . . . . .Appendix H
012 Lam DS (Upgrade Kit) . . . . . . . . . . . . . . . . . . . . .Appendix H
013 Options Module . . . . . . . . . . . . . . . . . . . . . . . . . .5.6.29
014 Operator Control Panel . . . . . . . . . . . . . . . . . . . .5.6.9
015 PCBA SmartCard Control . . . . . . . . . . . . . . . . . .5.6.29.2
016 PCBA Mag Control . . . . . . . . . . . . . . . . . . . . . . .5.6.29.9
017 MAG Head Replacement . . . . . . . . . . . . . . . . . .5.6.29.8
018 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
019 PCBA Flipper Module . . . . . . . . . . . . . . . . . . . . .5.6.28.3
020 Media Authentication PCBA. . . . . . . . . . . . . . . . .5.6.22.9
021 Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6.22.2
022 Power Switch/Entry Module . . . . . . . . . . . . . . . . .5.6.26
023 PCBA Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . .N/A
024 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
025 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
026 Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6.22.1
027 Electronics Cables . . . . . . . . . . . . . . . . . . . . . . .See applicable section(s)
028 Ribbon Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6.22.6
029 Print Engine Door Open Sensor . . . . . . . . . . . . .5.6.22.7
030 Module Contact Station . . . . . . . . . . . . . . . . . . . .5.6.29.5
031 Encoder Sensor for Ribbon Supply Spindle. . . . .5.6.22.9
032 Encoder Sensor for Ribbon Take-Up Spindle . . .5.6.22.10
033 Kit Sensor for Control Panel Door Open . . . . . . .5.6.11
034 Kit Flipper Position Sensor . . . . . . . . . . . . . . . . .5.6.28.4
035 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
036 Kit Cam Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .5.6.22.17
037 Kit Sync Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .5.6.22.18
038 Kit Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6.22.18
039 Kit Card Sensor Option Module . . . . . . . . . . . . . .5.6.29.10
040 Kit Ribbon Tricolor Sensor . . . . . . . . . . . . . . . . . .5.6.22.12
041 Kit Ribbon Supply Spindle Assembly . . . . . . . . . .5.6.22.9
042 Kit Motor for Ribbon Supply Spindle . . . . . . . . . .5.6.22.9
043 Kit Ribbon Close Outs . . . . . . . . . . . . . . . . . . . . .5.6.22.12

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 5: Replacement Procedures for the Printer
Kit List ( P1037750- )

044 Kit Ribbon Take-Up Spindle Assembly. . . . . . . . .5.6.22.10

045 Kit Motor for Ribbon Take-Up Spindle . . . . . . . . .5.6.22.10
046 Kit Cleaning Cartridges . . . . . . . . . . . . . . . . . . . .2.3.3, 2.3.4
047 Kit Pinch Roller Assemblies . . . . . . . . . . . . . . . . .5.6.22.18
048 Kit Pressure Roller Assembly Mag . . . . . . . . . . .5.6.29.7
049 Kit Flexible Rollers . . . . . . . . . . . . . . . . . . . . . . . .5.6.22.11
050 Kit Platen Rollers . . . . . . . . . . . . . . . . . . . . . . . . .5.6.22.18, 5.6.28.10, 5.6.29.12, 5.6.29.13
051 Kit All Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . .See applicable section(s)
052 PCBA MIFARE Contact Encoder . . . . . . . . . . . . .5.6.29.4
053 Kit Drive System Platen Rollers . . . . . . . . . . . . . .5.6.22.15
054 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
055 Kit Drive Motor Printhead Lift . . . . . . . . . . . . . . . .5.6.22.16
056 Kit Drive Motor Platen Rollers . . . . . . . . . . . . . . .5.6.22.14
057 Kit Drive Motors Flipper . . . . . . . . . . . . . . . . . . . .5.6.28.7, 5.6.28.8
058 Kit Encoder and Feeder Motor. . . . . . . . . . . . . . .5.6.27.2, 5.6.29.11
059 Kit Feeder Cartridge Standard . . . . . . . . . . . . . . .2.3.2
060 Kit Feeder Cover . . . . . . . . . . . . . . . . . . . . . . . . .5.6.2.1
061 Kit Drive Assembly Feeder . . . . . . . . . . . . . . . . .5.6.27.1
062 Kit Retainer for Feeder. . . . . . . . . . . . . . . . . . . . .5.6.2.2
063 Kit Print Engine Door Assembly . . . . . . . . . . . . . .5.6.12
064 Kit Cover Assembly Option Module . . . . . . . . . . .5.6.8
065 Kit Left & Right Cover Assemblies . . . . . . . . . . . .5.6.10, 5.6.14
066 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
067 Kit Skins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6.8, 5.6.10, 5.6.12, 5.6.14
068 Kit Print Engine Drawer . . . . . . . . . . . . . . . . . . . .5.6.3
069 Kit Door Button & Latch . . . . . . . . . . . . . . . . . . . .5.6.13
070 Kit PCBA for Contact Station . . . . . . . . . . . . . . . .5.6.29.6
071 Kit Bottom Panel . . . . . . . . . . . . . . . . . . . . . . . . .5.6.16
072 Kit Panel Plungers & Springs . . . . . . . . . . . . . . . .5.6.15
073 Kit Output Hopper . . . . . . . . . . . . . . . . . . . . . . . .2.3.2
074 Kit Reject Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6.1
075 Kit Flipper Assembly . . . . . . . . . . . . . . . . . . . . . .5.6.28
076 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
077 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
078 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
079 Kit Shroud for Options . . . . . . . . . . . . . . . . . . . . .5.6.5
080 Kit Ground Plates. . . . . . . . . . . . . . . . . . . . . . . . .5.6.25, 5.6.23, 5.6.22.3
081 Kit Springs Shaft for Print Engine Door . . . . . . . .5.6.12
082 Kit Feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6.17
083 Kit Ribbon Spindles . . . . . . . . . . . . . . . . . . . . . . .5.6.22.8
084 Kit Assorted Hardware . . . . . . . . . . . . . . . . . . . . .See applicable section(s)
085 Kit Packaging without Lam. . . . . . . . . . . . . . . . . .N/A
086 Kit Pressure Roller Assembly Non Mag . . . . . . . .5.6.29.7
087 Kit Module MIFARE Contact Encoder . . . . . . . . .5.6.29.3
088 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
089 Kit Packaging with Lam . . . . . . . . . . . . . . . . . . . .N/A
090 ZXP7 Service CD . . . . . . . . . . . . . . . . . . . . . . . . .N/A

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 5: Replacement Procedures for the Printer
Procedures: Reject Bin

5.6 Procedures:
5.6.1 Reject Bin

Note • This procedure uses Spare Kit #

P1037750-074: REJECT BIN

Step 1. Locate the Reject Bin (circled below).

Step 2. Slide the Reject Bin out of the Printer until it stops.

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 5: Replacement Procedures for the Printer
Procedures: Reject Bin

Step 3. Using two fingers, simultaneously, depress the two locking tabs (arrows below) that
prevent the Reject Bin from being removed.

Step 4. Slide the Reject Bin out of the Printer, and set it aside.

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 5: Replacement Procedures for the Printer
Procedures: Feeder Cartridge Standard

5.6.2 Feeder Cartridge Standard

Note • This procedure uses Spare Kit #

P1037750-059: FEEDER CARTRIDGE STANDARD

This is the replacement kit for the Standard Feeder Cartridge; i.e., the entire assembly.

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 5: Replacement Procedures for the Printer
Procedures: Feeder Cartridge Standard

5.6.2.1 Feeder Cartridge Cover

Note • This procedure uses Spare Kit #

P1037750-060: FEEDER COVER

Step 1. With a Flat-blade screwdriver, carefully press the pivot arm in (arrow below) to free
the tab and thereby releasing the Feeder Cartridge Cover.

Step 2. Set the Feeder Cartridge Cover aside.

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 5: Replacement Procedures for the Printer
Procedures: Feeder Cartridge Standard

5.6.2.2 Retainer for Feeder Cartridge

Note • This procedure uses Spare Kit #

P1037750-062: RETAINER FOR FEEDER

Step 1. Lift the Retainer slightly; then slide it forward, up, and out of the Feeder Cartridge;
see arrows below.

Step 2. Remove the Spring (under the Retainer).

Step 3. Set the Retainer and Spring aside.

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 5: Replacement Procedures for the Printer
Procedures: Ribbon Drawer

5.6.3 Ribbon Drawer

Note • This procedure uses Spare Kit #

P1037750-068: PRINT ENGINE DRAWER

Step 1. Open the Print Cover.

Step 2. If a ribbon is installed, remove the ribbon.

Step 3. Slide the Ribbon Drawer out of the Printer until it stops.

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 5: Replacement Procedures for the Printer
Procedures: Ribbon Drawer

Step 4. Depress the two locking tabs (one on each side) to free the Ribbon Drawer.

Step 5. Slide the Ribbon Drawer out of the Printer, and set it aside.

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 5: Replacement Procedures for the Printer
Procedures: Card Guides

5.6.4 Card Guides

Step 1. Remove the Ribbon Drawer; see Section 5.6.3.

Step 2. Locate the Card Guides.

NOTE • To facilitate reassembly, mark the Card Guides appropriately upon removal; e.g.,
left, top; and right, top.

Step 3. With a Flat-blade screwdriver, free the Left Card Guide; it snaps into place.

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 5: Replacement Procedures for the Printer
Procedures: Card Guides

Step 4. With a Flat-blade screwdriver, free the Right Card Guide; it snaps into place.

Step 5. Set the Card Guides aside.

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 5: Replacement Procedures for the Printer
Procedures: Shroud for Options

5.6.5 Shroud for Options

Note • This procedure uses Spare Kit #

P1037750-079: SHROUD FOR OPTIONS

Step 1. Open the Options Cover.

Step 2. Depress the two tabs (one on each side) to unlock the Shroud.

Step 3. Lift the Shroud up and out of the Printer, and set it aside.

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 5: Replacement Procedures for the Printer
Procedures: Back Cover

5.6.6 Back Cover

Step 1. With a TORX T10 driver, remove the three screws (SCR EJOT 30x10, 4 in-lb)
holding the Back Cover in place. Use an 8-inch tapered bit TORX T10 driver for
the screw on the left.

Step 2. Close the Print Cover.

Step 3. Remove the Back Cover, and set it aside.

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 5: Replacement Procedures for the Printer
Procedures: Rear Feeder Cover

5.6.7 Rear Feeder Cover

Step 1. With a TORX T10 driver, remove the left screw (SCR EJOT 30x10, 4 in-lb) holding
the Rear Feeder Cover in place.

Step 2. With a TORX T10 driver, remove the right screw (SCR EJOT 30x10, 4 in-lb) and
washer holding the Rear Feeder Cover in place.

Step 3. Remove the Rear Feeder Cover, and set it aside.

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 5: Replacement Procedures for the Printer
Procedures: Options Cover

5.6.8 Options Cover

Note • This procedure uses Spare Kit #
P1037750-064: COVER ASSEMBLY OPTION MODULE
P1037750-067: SKINS

Step 1. If not already done, remove the Cleaning Cartridge and Cleaning Cassette.

Step 2. With a TORX T10 driver, remove the two screws (SCR EJOT 30x10, 4 in-lb)
holding the Options Cover in place.

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 5: Replacement Procedures for the Printer
Procedures: Options Cover

Step 3. Disconnect the OCP cable connection.

Step 4. Remove the Options Cover, and set it aside.

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 5: Replacement Procedures for the Printer
Procedures: OCP PCBA

5.6.9 OCP PCBA

Note • This procedure uses Spare Kit #

P1037750-014: OPERATOR CONTROL PANEL

Step 1. With a TORX T10 driver, remove the five screws (SCR EJOT 30x10, 4 in-lb)
holding the Faceplate to the Options Cover;.

Step 2. Set the Faceplate aside.

Step 3. With a TORX T10 driver, remove the two screws (SCR EJOT 30x10, 4 in-lb)
holding the OCP PCBA to the Options Cover.

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 5: Replacement Procedures for the Printer
Procedures: OCP PCBA

Step 4. Remove the OCP PCBA.

Step 5. Disconnect the Plug at J2 (circled above).

Step 6. Set the OCP PCBA aside.

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 5: Replacement Procedures for the Printer
Procedures: Right Side Cover

5.6.10 Right Side Cover

Note • This procedure uses Spare Kit #
P1037750-065: LEFT & RIGHT COVER ASSEMBLIES
P1037750-067: SKINS

Step 1. From the front of the Printer: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 4 in-lb) holding the Right Cover in place.

Step 2. From the back of the Printer: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 4 in-lb) holding the Right Cover in place.

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 5: Replacement Procedures for the Printer
Procedures: Right Side Cover

Step 3. Disconnect the Control Panel Door Open Sensor at connector J12 on the FLIPPER
MODULE PCBA.

J12

Step 4. Carefully cut the cable tie to free the sensor cable.

Step 5. Remove the Right Cover.

Step 6. Set the Right Cover aside.

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 5: Replacement Procedures for the Printer
Procedures: Control Panel Door Open Sensor

5.6.11 Control Panel Door Open Sensor

Note • This procedure uses Spare Kit #

P1037750-033: SENSOR FOR CONTROL PANEL DOOR OPEN

Step 1. With a TORX T10 driver, remove the five screws (SCR EJOT 30x10, 4 in-lb)
holding the Inner Cover to the Right Cover.

Step 2. Remove the Inner Cover.

Step 3. With a TORX T8 driver, remove the two screws (SCR EJOT 35x6, 2.5 in-lb)
holding the Sensor in place; and set the Sensor (and cable) aside.

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 5: Replacement Procedures for the Printer
Procedures: Print Cover

5.6.12 Print Cover

Note • This procedure uses Spare Kit #
P1037750-063: PRINT ENGINE DOOR ASSY
P1037750-067: SKINS
P1037750-081: SPRINGS SHAFT FOR PRINT ENGINE DOOR

Step 1. If not already done, open the Print Cover.

Step 2. With a small Flat-blade screwdriver, carefully remove the left-side E-ring holding
the shaft in place.

Step 3. Slide the shaft out of the print cover brackets.

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 5: Replacement Procedures for the Printer
Procedures: Print Cover

Step 4. Free the two springs (right side and left side of the Print Cover). Note that you may
need to use needle-nose pliers.

Step 5. Slide the cover to the rear thereby freeing the left and right guide pins from their
respective guides.

Step 6. Set the Print Cover (and two springs) aside.

Replacement
Note that the springs go in the slots on the Print Cover when reassembling.

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 5: Replacement Procedures for the Printer
Procedures: Door Button and Latch

5.6.13 Door Button and Latch

Note • This procedure uses Spare Kit #

P1037750-069: DOOR BUTTON & LATCH

Step 1. With a TORX T10 driver, remove the six screws (SCR EJOT 30x10, 5.5 in-lb)
holding the Door Enclosure and Door Frame together.

Step 2. Separate the Door Enclosure from the Door Frame.

Step 3. Remove the Door Button (arrow above).

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 5: Replacement Procedures for the Printer
Procedures: Door Button and Latch

Step 4. With a TORX T10 driver, remove the two screws (SCR EJOT 30x10, 5.5 in-lb)
holding the Upper Bearings in place.

Step 5. Remove the Upper Bearings.

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 5: Replacement Procedures for the Printer
Procedures: Door Button and Latch

Step 6. With a small Flat-blade screwdriver, release and remove the two latch springs
(solid arrows below). There is a LEFT and RIGHT latch spring; note the
orientation of each spring.

Step 7. Remove the Latch (dashed arrow above), and set it aside.

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 5: Replacement Procedures for the Printer
Procedures: Left Side Cover

5.6.14 Left Side Cover

Note • This procedure uses Spare Kit #
P1037750-065: LEFT & RIGHT COVER ASSEMBLIES
P1037750-067: SKINS

Step 1. From the front of the Printer: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 4 in-lb) holding the Left Cover in place.

Step 2. From the back of the Printer: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 4 in-lb) holding the Left Cover in place.

Step 3. Remove the Left Cover, and set it aside.

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 5: Replacement Procedures for the Printer
Procedures: Panel, Plungers, and Springs

5.6.15 Panel, Plungers, and Springs

Note • This procedure uses Spare Kit #

P1037750-072: PANEL PLUNGERS & SPRINGS

Panel
Step 1. With a TORX T10 driver, remove the four front screws (SCR EJOT 30x10, 4 in-lb)
holding the Belt and Gear Panel in place.

Step 2. Remove the Belt and Gear Panel, and set it aside.

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 5: Replacement Procedures for the Printer
Procedures: Panel, Plungers, and Springs

Plunger and Spring Assemblies

Step 1. Press each Plunger in, and rotate it counterclockwise. This will free the assembly.

Step 2. Set the Plungers and associated Springs aside.

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 5: Replacement Procedures for the Printer
Procedures: Bottom Cover

5.6.16 Bottom Cover

Note • This procedure uses Spare Kit #

P1037750-071: BOTTOM PANEL

Step 1. With a TORX T10 driver, remove the eight screws (SCR EJOT 30x10, 4 in-lb)
holding the Bottom Cover in place.

Step 2. Carefully move the Bottom Cover away from the Printer. Note the green ground
wire attached.

Step 3. With a 5.5-mm Nut Driver, remove the nut holding the ground wires to the
ground lug; then remove the ground wire.

Step 4. Remove the Bottom Cover.

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 5: Replacement Procedures for the Printer
Procedures: Feet

5.6.17 Feet

Note • This procedure uses Spare Kit #

P1037750-082: FEET

Step 1. With a Flat-blade screwdriver, carefully loosen each Foot. Note that the feet are
attached with adhesive.

Step 2. Set the Feet aside.

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 5: Replacement Procedures for the Printer
Procedures: Reject Bin Bracket

5.6.18 Reject Bin Bracket

Note • This procedure uses Spare Kit #

P1037750-074: REJECT BIN

Step 1. Locate the Reject Bin Bracket (arrow below).

Step 2. With a TORX T10 driver, remove the four screws (SCR EJOT 30x10, 4 in-lb)
holding the Reject Bin Bracket in place.

Step 3. Remove the Reject Bin Bracket, and set it aside.

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 5: Replacement Procedures for the Printer
Procedures: Printer

5.6.19 Printer
The Printer is comprised of three assemblies: the Print Engine, the Feeder/Flipper Module, and
the Options Module. This section details the steps required to separate the Print Engine from
the Feeder/Flipper/Options Assembly.

PRINT ENGINE FEEDER/ OPTIONS

FLIPPER

Step 1. With a 5.5-mm Nut Driver, remove the two nuts (circled below) holding the print
engine ground wires in place.

Step 2. Remove the ground wires connecting the Print Engine with the Options Module.

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 5: Replacement Procedures for the Printer
Procedures: Printer

Step 3. For printers with a Mag Encoder and/or Smart Card Encoder: Disconnect
connectors J112 and/or J4 (arrows below). Note that these connectors have locking
tabs; use a small Flat-blade screwdriver to unlock the tabs.

J4 J112

Step 4. Disconnect connectors J5 and J7 from the FLIPPER MODULE PCBA

(arrows below).

J5
J7

Step 5. With a 5.5-mm Nut Driver, remove ground wires from the L-shaped ground plate
(circled above).

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 5: Replacement Procedures for the Printer
Procedures: Printer

Step 6. Turn the printer on its side so that you can access the Main PCBA.

Step 7. Disconnect connector J21 from the Main PCBA (arrow above).

Step 8. From the top of the Printer: With a long TORX T10 driver, remove the two
screws (SCR EJOT 30x10, 5.5 in-lb) holding the modules together. Use an 8-inch
tapered bit or ball-end TORX T10 driver for the lower screw.

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 5: Replacement Procedures for the Printer
Procedures: Printer

Step 9. From the front of the Printer: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 5.5 in-lb) holding the modules together.

Step 10. Lift the Feeder/Flipper/Options Assembly, and slide it to the right.

Step 11. Disconnect the two ground wires and cut the cable tie.

Step 12. Separate the Print Engine from the Feeder/Flipper/Options Assembly.

PRINT ENGINE FEEDER/ OPTIONS

FLIPPER

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 5: Replacement Procedures for the Printer
Procedures: Main PCBA

5.6.20 Main PCBA

Important • A configuration file, NVM_bkup_< printer serial number >.xml, is saved when
the driver and printer are first installed. If the Main PCBA is not functional, you can use that
file to restore the printer settings.

Before you replace the Main PCBA, save the printer configuration settings. Use the
ZXP Series 7 Service Tool to save and restore the settings.

• NVMEM (Non-Volatile Memory): This control is used to back up NVMEM to XML

for importing back into the printer. This does a full restore of all printer settings and
calibration data; e.g., ribbon torque, program values, MAC address, etc.

Use this control when replacing the Main PCBA (MCB):

Step 1. Click the Backup button to back up the printer configuration settings.

Step 2. Replace the board; see next page.

Step 3. If necessary, update the Firmware; see Firmware Update on page 161 for details.

Step 4. Click the Restore button to restore the settings.

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 5: Replacement Procedures for the Printer
Procedures: Main PCBA

Note • This procedure uses Spare Kit #

P1037750-010: MAIN LOGIC BOARD

Step 1. Disconnect all the connectors to the Main PCBA. Cut cable ties as required.

Step 2. With a Phillips #2 screwdriver, remove the three screws (M3x10, 4 in-lb) holding
the Main PCBA in place.

Step 3. With a Phillips #1 screwdriver, remove the five screws (M3x12, 4 in-lb) holding the
Shield and Main PCBA in place; and set the Main PCBA and Shield aside.

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 5: Replacement Procedures for the Printer
Procedures: Main PCBA

Main PCBA Connections

* J50, J51, and J52 are on the bottom side of the Main PCBA

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 5: Replacement Procedures for the Printer
Procedures: Main PCBA

PCBA Connections

Connector PCBA ID Functional Description

J1 ETHERNET INTERFACE Ethernet Daughterboard
J2 USB_PERIPH_PC USB peripheral interface from host PC
J3 SEN_RIBA Ribbon tri-color sensor (detector)
J4 SEN_RIBB Ribbon tri-color sensor (emitter)
J5 PH_PWR Power to printhead
J6 JTAG RESERVED
J7 DCPWR DC power input to board
J8 MTR_RIBT Ribbon take-up motor
J9 SEN_TENC Ribbon take-up encoder wheel sensor
J10 LAM_CTL Control signals to Laminator
J11 SEN_EXIT Exit sensor
J12 -- RESERVED
J13 -- RESERVED
J14 -- RESERVED
J15 -- RESERVED
J16 MTR_MCB Stepper motors driven by MCB
J17 -- RESERVED
J18 USB_HOST_SP RESERVED
J19 USRAUTH User Authentication
J20 BARCD Barcode Reader
J21 OCP Operator Control Panel
J22 MAB Media Authentication Board
J23 SEN_CAM RESERVED
J24 SEN_MCB Various sensors
J25 N/A N/A
J26 UHF/FELICA RESERVED
J27 FDFLIP_CTL Control signals to Flipper Board
J28 FDFLIP_PWR Power to Flipper Board
J29 PH_DATA Printhead Data
J30 USB_HOST_PANEL USB Dual Host cable
J31 -- RESERVED
J32 IP_DEBUG RESERVED
J33 EP_DEBUG RESERVED
J34 SEN_RIBA_NEW Ribbon tri-color sensor (emitter)
J35 SEN_RIBB_NEW Ribbon tri-color sensor (detector)
J36 THERM RESERVED
J50* OPSC SmartCard option board
J51* OPMAG Mag option board
J52* DIAG I/F Diagnostic test

* J50, J51, and 52 are on the bottom side of the Main PCBA

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 5: Replacement Procedures for the Printer
Procedures: Main PCBA

Firmware Update
Step 1. Download the latest firmware from the Zebra web site, http://zebra.com under
Drivers & Downloads.

Step 2. Use the ZXP Series 7 Service Tool, and select the Information section.

Step 3. Click on the Browse button.

Step 4. From the Browse window, “find” the firmware (BIN file type) that was downloaded
in Step 1.

Step 5. Click on the Update button to install the firmware.

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 5: Replacement Procedures for the Printer
Procedures: Ethernet PCBA

5.6.21 Ethernet PCBA

Note • This procedure uses Spare Kit #

P1037750-004: WIRED ETHERNET

Step 1. With a Phillips #0 screwdriver, remove the four screws (M2x8, 4 in-lb) holding the
Ethernet PCBA to the Main PCBA.

Step 2. Remove the Ethernet PCBA, and set it aside.

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 5: Replacement Procedures for the Printer
Procedures: Print Engine

5.6.22 Print Engine

5.6.22.1 Cooling Fan

Note • This procedure uses Spare Kit #

P1037750-026: COOLING FAN

Step 1. With a TORX T10 driver, remove the four screws (SCR EJOT 30x8, 4 in-lb)
holding the Cooling Fan in place.

Step 2. Remove the Cooling Fan, and set it aside.

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 5: Replacement Procedures for the Printer
Procedures: Print Engine

5.6.22.2 Power Supply

Note • This procedure uses Spare Kit #

P1037750-021: POWER SUPPLY

Step 1. Disconnect the input power and ground connections at the Power Switch;
circled below.

Step 2. Disconnect J7 (DCPWR) from the Main PCBA; arrow below.

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Step 3. With a TORX T10 driver, remove the four screws (SCR EJOT 30x10, 4 in-lb)
holding the Power Supply in place.

Step 4. Remove the Power Supply, and set it aside.

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5.6.22.3 Print Engine Ground Plate

Note • This procedure uses Spare Kit #

P1037750-080: GROUND PLATES

Step 1. With a TORX T10 driver, remove the three screws (SCR EJOT 30x10, 5.5 in-lb)
holding the Print Engine Ground Plate in place; see arrows below.

Step 2. With a 5.5-mm Nut Driver, remove all nuts and associated ground wires.

Step 3. Remove the Print Engine Ground Plate, and set it aside.

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5.6.22.4 Printhead Assembly

Note • This procedure uses Spare Kit #

P1037750-006: PRINTHEAD ASSEMBLY

Step 1. Pull the Printhead Assembly and Printhead Housing out of the Print Engine.

Step 2. Push the Printhead Assembly into the Printhead Housing, then pull it up and out of
the Printhead Housing.

Caution • Pulling the Printhead Assembly too far out of the Printhead Housing may break
the wire connected to the ground lug (circled below).

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Step 3. With a small Flat-blade screwdriver, carefully disconnect the Printhead Power and
Data Cable (arrows below), and then remove the Ground (circled below).

Step 4. Set the Printhead Assembly aside.Set the Printhead Assembly aside.

Replacement
Replacement is performed by reversing the removal steps

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Test and Adjustment

Printhead Serial Number and Resistance Change

Note • Access to Print Head options (Serial Number and Resistance) is controlled via
Advanced Security > Security Roles.

After replacing the Printhead, you will need to change the printhead serial number and
resistance value stored in the printer. The new value is located on the label applied to the
Printhead; e.g., R=3662.

Step 1. Select Start > Devices and Printers, right-click on the Zebra ZXP Series 7
Card Printer listing, and select Printer Properties > Device Information. Click on
the ZXP Toolbox button.

Step 2. From the ZXP Toolbox, select Configuration > Printer Settings.

Step 3. In the Printhead > Serial Number and Resistance fields (circled above), enter the
serial number and resistance of the replacement Printhead. The new resistance value
is located on the label applied to the Printhead; e.g., R=3380.

Step 4. Click on the Save Settings button.

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Power Adjustment

Step 1. Print a card.

Step 2. If card is too dark or too light in comparison with the previously used printhead,
access the ZXP Toolbox.

Select Start > Devices and Printers, right-click on the Zebra ZXP Series 7
Card Printer listing, and select Printer Properties > Device Information. Click on
the ZXP Toolbox button.

Step 3. From the ZXP Toolbox, go to Printer Settings, select Advanced Settings, then select
the Mechanical and Power Adjustment tab.

Step 4. In the Power Adjustment section (circled below), adjust the settings as follows:

• If the card is too dark, decrease the appropriate power settings (1% increments
recommended).
• If the card is too light, increase the appropriate power settings (1% increments
recommended).

Typically, the following adjustments should be set to the same value; individual
adjustments can be made as required:

- Yellow, Magenta, and Cyan

- K-resin front and K-resin back
- K-dye and Overlay (the overlay option should be disabled with a laminator)
- UV front and UV back

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5.6.22.5 Printhead Housing Assembly

Note • This procedure uses Spare Kit #
P1037750-007: HOUSING FOR PRINTHEAD
P1037750-008: LATCH AND SPRINGS FOR PRINT HOUSING

Printhead Housing
Step 1. Remove the Printhead Assembly from the Printhead Housing Assembly; see
Section 5.6.22.4.

Step 2. Pull the Printhead Power and Data Cable out of the Printhead Housing.

Step 3. Unplug the ribbon sensor cable-to-cable connection.

Step 4. Set the Printhead Housing Assembly aside.

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Printhead Latch Assembly

Step 1. When the slot is in the vertical position, the Printhead Latch is locked.

Step 2. With a Flat-blade screwdriver, rotate the slot 90o counter-clockwise to unlock
the Printhead Latch.

Step 3. Slide the Latch out of the housing, and remove the Spring.

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Printhead Lift Spring Assembly

Step 1. Remove the eight screws holding the Printhead Front Cover in place. Note the in-lb
torque difference for Steps a and b.

a. With a TORX T10 driver, remove the “outside” four screws (SCR EJOT
30x10, 4 in-lb).

b. With a TORX T10 driver, remove the “inside” four screws (SCR EJOT
30x10, 9 in-lb).

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Step 2. Locate the Printhead Lift Spring Assembly.

Step 3. Remove the spring, lift, pulley, and dowel.

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5.6.22.6 Ribbon Sensor

Note • This procedure uses Spare Kit #

P1037750-028: RIBBON SENSOR

Step 1. With a TORX T10 driver, remove the two screws (SCR EJOT 30x10, 4 in-lb)
holding the Ribbon Sensor Assembly (sensor housing and sensor) in the Printhead
Housing Assembly.

Step 2. Unplug the ribbon sensor cable-to-cable connection, and set the Ribbon Sensor
Assembly aside.

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5.6.22.7 Covers for Printhead

Note • This procedure uses Spare Kit #
P1037750-009: COVERS FOR PRINTHEAD
P1037750-029: PRINT ENGINE DOOR OPEN SENSOR

Printhead Front Cover

Step 1. Remove the eight screws holding the Printhead Front Cover in place.

a. With a TORX T10 driver, remove the “outside” four screws (SCR EJOT
30x10, 4 in-lb); see arrows below.

a. With a TORX T10 driver, remove the “inside” four screws (SCR EJOT
30x10, 9 in-lb); see arrows below.

Step 2. Remove the Printhead Front Cover.

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Step 3. Unplug the door open sensor cable-to-cable connection.

Step 4. With a TORX T8 driver, remove the screw (SCR EJOT 35x6, 4 in-lb) holding the
Door Open Sensor in place.

Step 5. Remove the Door Open Sensor, and set it aside.

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Printhead Back Cover

Step 1. Remove the screw holding the cable harness anchor in place.

Step 2. Cut the cable ties as required to free the cable harness.

Step 3. Disconnect J5 (printhead power) and J29 (printhead data) from the Main PCBA.

Step 4. Disconnect the Cooling Fan.

Step 5. With a TORX T10 driver, remove the four screws (SCR EJOT 30x10, 4 in-lb)
holding the Printhead Back Cover in place.

Step 6. Remove the Printhead Back Cover.

Step 7. Set the Front and Back Covers aside.

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5.6.22.8 Ribbon Spindles

Note • This procedure uses Spare Kit #

P1037750-083: RIBBON SPINDLES

Step 1. Open the Print Cover.

Step 2. Remove the Ribbon Drawer.

Step 3. With a TORX T10 driver, remove the screws (SCR M3x6, 4 in-lb) holding the
Spindles in place. When replacing the screws, use Loctite 242. In the figure below,
parts have been removed for clarity.

Step 4. Remove the Spindles, and set them aside.

Replacement
The spindles need to be rotated to engage the flat on the shaft.

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5.6.22.9 Ribbon Supply Spindle Assembly

Note • This procedure uses Spare Kit #
P1037750-020: MEDIA AUTHENTICATION PCBA
P1037750-031: ENCODER SENSOR FOR RIBBON SUPPLY SPINDLE
P1037750-041: RIBBON SUPPLY SPINDLE ASSEMBLY
P1037750-042: MOTOR FOR RIBBON SUPPLY SPINDLE ZXP

Media Authentication PCBA (MAB)

Step 1. Locate the Media Authentication PCBA.

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Step 2. Disconnect J4 and J5 (arrows below).

J4

J5

Step 3. With a TORX T10 driver, remove the two screws (SCR EJOT 30x10, 4 in-lb)
holding the Media Authentication PCBA in place; circled above.

Step 4. Remove the Media Authentication PCBA, and set it aside.

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Spindle Clutch Assembly

Step 1. Remove the retaining ring/clip (circled below).

Step 2. With a TORX T10 driver, remove the four screws (SCR EJOT 30x10, 4 in-lb)
holding the Bearing Plate in place; see arrows above.

Step 3. Remove the Bearing Plate, and set it aside.

Step 4. Remove the retaining clip; and then remove the washer, spring, pressure plate, felt
washer, gear, and felt washer.

washer
spring
pressure plate
felt washer
gear
felt washer

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Ribbon Sync Sensor

Step 1. Unplug the ribbon sync sensor cable-to-cable connection.

Step 2. With a TORX T8 driver, remove the two screws (SCR EJOT 35x6, 2.5 in-lb)
holding the Ribbon Sync Sensor in place.

Step 3. Remove the Ribbon Sync Sensor, and set it aside.

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Spindle Clutch Assembly (continued)

Step 1. With a rubber-faced hammer, carefully tap the shaft out of the Frame.

Step 2. Set the encoder wheel and shaft aside.

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Antenna (Media Authentication PCBA)

Step 1. With a TORX T10 driver, remove the two screws (SCR EJOT 30x6, 4 in-lb) holding
the Antenna in place; arrows below.

Step 2. Disconnect the cable plug (circled above).

Step 3. Remove the Antenna, and set it aside.

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Supply Spindle Motor

Step 1. With a TORX T10 driver, remove the two screws (SCR EJOT 30x10, 4 in-lb)
holding the Supply Spindle Motor in place. When replacing the screws, loosely
tighten; then fully tighten when replacing the Bearing Plate; see Page 182.

Step 2. Cut the cable ties as required to free the motor cable.

Step 3. Unplug the supply spindle motor cable-to-cable connection.

Step 4. Remove the Supply Spindle Motor, and set it aside.

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Replacement
Replacement is performed by reversing the removal steps

Test and Adjustment

Supply Spindle Motor
Use the ZXP Series 7 Service Partner Tool; see Appendix F.

Run Ribbon Torque Calibration on page 462.

Run Ribbon Damping Calibration on page 464.

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5.6.22.10 Ribbon Take-Up Spindle Assembly

Note • This procedure uses Spare Kit #
P1037750-032: ENCODER SENSOR FOR RIBBON TAKE-UP SPINDLE
P1037750-044: RIBBON TAKE-UP SPINDLE ASSY
P1037750-045: MOTOR FOR RIBBON TAKE-UP SPINDLE

Take-Up Spindle Assembly

Step 1. Remove the retaining ring/clip (circled below).

Step 2. With a TORX T10 driver, remove the three screws (SCR EJOT 30x10, 4 in-lb)
holding the Bearing Plate in place; see arrows above.

Step 3. Remove the Bearing Plate, and set it aside.

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Take-Up Spindle Motor

Step 1. Remove the gear (arrow below).

Step 2. With a TORX T10 driver, remove the three screws (SCR EJOT 30x10, 4 in-lb)
holding the Take-Up Spindle Motor in place; see circles above. When replacing the
screws, loosely tighten; then fully tighten after replacing the Bearing Plate.

Step 3. Cut the cable ties as required to free the motor cable.

Step 4. If not already done, unplug J8 from the Main PCBA; and disconnect the
ground wire.

Step 5. Remove the Take-Up Spindle Motor, and set it aside.

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Encoder Sensor
Step 1. With a TORX T8 driver, remove the two screws (SCR EJOT 35x6, 2.5in-lb) holding
the Encoder Sensor in place; see arrows below.

Step 2. Cut the cable ties as required to free the sensor cable.

Step 3. If not already done, unplug J9 from the Main PCBA.

Step 4. Remove the Encoder Sensor, and set it aside.

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Take-Up Spindle Assembly (continued)

Step 1. Remove the retaining ring/clip holding the encoder wheel in place.

Step 2. With a rubber-faced hammer, carefully tap the shaft out of the Frame.

Step 3. Set the encoder wheel and shaft aside.

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5.6.22.11 Flexible Rollers

Note • This procedure uses Spare Kit #

P1037750-049: FLEXIBLE ROLLERS

Step 1. Locate the Flexible Rollers.

Step 2. Press the left Flexible Roller down and to the rear of the Print Engine to release
the roller shaft.

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Step 3. Pull Flexible Roller up and out of the Print Engine.

Step 4. Repeat Step 2 and Step 3 for the right Flexible Roller.

Step 5. Set the Flexible Rollers aside.

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5.6.22.12 Ribbon Close Outs

Note • This procedure uses Spare Kit #
P1037750-043: RIBBON CLOSE OUTS
P1037750-040: RIBBON TRICOLOR SENSOR

Ribbon Close Outs

Step 1. Locate the two Closeouts (arrows below).

Step 2. From the front of the Print Engine: With a TORX T10 driver, remove the two
screws (SCR EJOT 30x10, 4 in-lb) holding the Ribbon Close Outs in place.

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Step 3. From the back of the Print Engine: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 4 in-lb) holding the Ribbon Close Outs in place. Note the
ground wires connections for reassembly.

Step 4. Carefully lift the Ribbon Close Outs and associated springs out of the Print Engine;
The Tricolor Ribbon Sensor is attached to the right Ribbon Close Out.

Step 5. Set the Ribbon Close Outs aside.

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5.6.22.13 Tricolor Ribbon Sensor

Step 1. With a TORX T8 driver, remove the screw (SCR EJOT 35x6, 2.5 in-lb) holding the
Tricolor Ribbon Sensor in place.

Step 2. Disconnect the plug at the Tricolor Ribbon Sensor.

Step 3. Remove the Tricolor Ribbon Sensor and set it aside.

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Replacement
Replacement is performed by reversing the removal steps

Test and Adjustment

Tricolor Ribbon Sensor
Use the ZXP Series 7 Service Partner Tool; see Appendix F.

Run Tricolor Sensor Calibration on page 453.

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5.6.22.14 Platen Drive Motor

Note • This procedure uses Spare Kit #

P1037750-056: DRIVE MOTOR PLATEN ROLLERS

Step 1. With a TORX T10 driver, remove the four screws (M3x6, 4 in-lb) holding the
Platen Drive Motor in place. When replacing the screws, follow the numbered
sequence below).

4 3

1 2

Step 2. Disconnect the plug at the motor.

Step 3. Remove the Platen Drive Motor, and set it aside.

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Test and Adjustment

Belt Tension Adjustment
For this test, you will need the Gate 507C Sonic Tension Meter, 74200507.

Step 1. Turn the Sonic Tension Meter power on (press the red Power button).

Step 2. Select measurement setting No02 (press the 2 button).

Step 3. Ensure the meter parameters (preset by Zebra Engineering) are set to:

M 001.1 g/m

W 006.0 mm/R

S 0029 mm

Step 4. Set the range to High (press and hold the Range button until the range selections
display, then use the UP and DOWN buttons to select the desired range).

Step 5. Press the green Measure button. The green light below the number pad will flash
indicating that measurement is in progress.

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Step 6. Align the first hole with the screw.

Step 7. Position/point the meter sensor approximately 5 mm from the belt.

Step 8. Tap the belt until you see the belt tension measurement display, and record the
first belt tension measurement.

Step 9. Rotate the pulley 120o, and align the second hole with the screw.

Step 10. Tap the belt until you see the belt tension measurement display, and record the
second belt tension measurement.

Step 11. Rotate the pulley 120o, and align the third hole with the screw.

Step 12. Tap the belt until you see the belt tension measurement display, and record the
third belt tension measurement.

Step 13. All three belt tension measurements should be between 5.5 to 7.0. If not, readjust
the motor (loosen the mounting screws, reposition the motor, and tighten the
mounting screws); and repeat Steps 5 through 13.

Step 14. This completes the calibration procedure.

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5.6.22.15 Drive System Platen Rollers

Note • This procedure uses Spare Kit #

P1037750-053: DRIVE SYSTEM PLATEN ROLLERS

Step 1. Remove the retaining clip (arrow below), and then remove the large pulley and belt.

Step 2. Note the belt routing; see outlines below.

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Step 3. Remove the retaining clips holding the five pulleys in place.

Step 4. Remove the five pulleys.

Step 5. With a TORX T10 driver, remove the screw (4-40 x 1/2, 4 in-lb), locknut, and
washer holding the Tensioner in place; circled above.

Step 6. Remove the Tensioner and belt.

Step 7. Remove the retaining clips holding the four gears in place.

Step 8. Remove the four gears and associated belts.

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Test and Adjustment

Tensioner Belt
For this test, you will need the Gate 507C Sonic Tension Meter, 74200507.

Step 1. Turn power on (press the red Power button).

Step 2. Select measurement setting No09 (press the 9 button).

Step 3. Ensure the meter parameters (preset by Zebra Engineering) are set to:

M 000.8 g/m

W 004.7 mm/R

S 0055 mm

Step 4. Set the range to Standard (press and hold the Range button until the range
selections display, then use the UP and DOWN buttons to select the desired range).

Step 5. Press the green Measure button. The green light below the number pad will flash
indicating that measurement is in progress.

Step 6. Position/point the meter sensor approximately 5 mm from the belt (arrow below).

Step 7. Tap the belt until you see the belt tension measurement display.

Step 8. The belt tension should measure between 0.5 to 1.5. If not, readjust the Tensioner;
and repeat Steps 5 through 8.

Step 9. This completes the calibration procedure.

Platen Drive Motor Belt

See Belt Tension Adjustment on page 199.

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5.6.22.16 Printhead Lift Motor

Note • This procedure uses Spare Kit #

P1037750-055: DRIVE MOTOR PRINTHEAD LIFT

Step 1. Remove the Gear; circled below.

Step 2. With a TORX T10 driver, remove the four screws (M3x6, 4 in-lb) and associated
washers holding the Printhead Lift Motor in place; arrows below. Note the
orientation of the motor.

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Step 3. Disconnect the cable plug at the motor.

Step 4. Remove the Printhead Lift Motor, and set it aside.

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5.6.22.17 Cam Sensor

Note • This procedure uses Spare Kit #

P1037750-036: CAM SENSOR

Step 1. With a TORX T8 driver, remove the two screws (SCR EJOT 35x6, 2.5 in-lb)
holding the Cam Sensor in place.

Step 2. Unplug the cam sensor cable-to-cable connection.

Step 3. Remove the Cam Sensor, and set it aside.

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5.6.22.18 Print Engine Platen Rollers

Note • This procedure uses Spare Kit #
P1037750-050: PLATEN ROLLERS
P1037750-038: EXIT SENSOR
P1037750-037: SYNC SENSOR
P1037750-047: PINCH ROLLER ASSEMBLIES

Printhead Lift Gears

Important • Before removal, note the orientation of each gear. If the orientation is not correct
when reinstalling the gears, the printer will not print or even synchronize.

Step 1. Locate the Gears.

3 4
1 6
2 5

Step 2. With a TORX T8 driver, remove the screws (35x6, 2.5 in-lb) holding
Gears 1 and 6 in place.

Step 3. Remove the retaining clips holding Gears 2 and 5 in place.

Step 4. With a TORX T10 driver, remove the screw (16mm, 4 in-lb) holding Gear 3
in place.

Step 5. With a TORX T10 driver, remove the screw (30x8, 4 in-lb) holding Gear 4
in place.

Step 6. Remove the Gears and Belts, and set them aside.

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Front Frame
Step 1. With a TORX T10 driver, remove the four screws (30x10, 4 in-lb) holding
the Front Frame in place.

Step 2. With a TORX T10 driver, remove the two screws (30x8, 4 in-lb) holding
the Front Frame in place.

Step 3. Carefully remove the Front Frame, and set it aside.

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Exit Sensor
Step 1. With a TORX T8 driver, remove the two screws (35x6, 2.5 in-lb) holding
the Exit Sensor in place; see arrows below.

Step 2. If not already done, unplug J11 from the Main PCBA.

Step 3. Remove the Exit Sensor, and set it aside.

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Sync Sensor
Step 1. With a TORX T8 driver, remove the two screws (35x6, 2.5 in-lb) holding
the Sync Sensor in place; see arrows below.

Step 2. Free the cable from the aluminum cable tie.

Step 3. Unplug the sync sensor cable-to-cable connection.

Step 4. Remove the Sync Sensor, and set it aside.

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Pinch Rollers
Step 1. Lift the two Pinch Rollers (arrows below) up and out of the Frame.

Step 2. Set the Pinch Rollers aside.

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Middle and Back Frame Separation

Step 1. With a TORX T8 driver, remove the three screws (30x10, 4 in-lb) holding
the Middle and Back Frames together; see arrows below.

Step 2. Separate the Frames.

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Step 3. Set the Middle Frame aside.

Platen Rollers
Step 1. Remove the five Platen Rollers.

Step 2. Set the Platen Rollers aside.

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Replacement
Printhead Lift Gears
The following pictures show the proper gear alignment for the print head lift gears on the front
of the printer. If they are not correct, then the printer will not print or even synchronize.

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Printhead Cam Alignment

The following steps show how to align the Printhead Cam. For this procedure, you will need
the Print Head Cam Sync Fixture ZXP7 (P1037750-401).

Step 1. From the back of the printer, align the timing mark on the Printhead Lift Cam to the
vertical (12 o’clock) position; see arrow below.

Step 2. From the front of the printer, align the timing mark on the Printhead Lift Cam (lower
arrow) with the mark on the Frame (upper arrow).

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Step 3. Install the Printhead Lift Cam Fixture. The orientation is critical as shown below.

Step 4. Install the Printhead Cam Sync Holding Fixture (set the lip of the fixture into the
access hole, pivot the fixture down, and then pull the fixture to anchor it).

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Step 5. Lock both fixtures in place with the two clips (arrows below).

Step 6. Rotate the gear until the D-notch is aligned with the flat on the shaft. Partially slide
the gear into place.

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Step 7. Press the cam shaft from the rear of the printer and the gear from the front of the
printer until the gear slides into place.

Step 8. With a TORX T10 driver, install the screw (30x8, 4 in-lb) holding the gear
in place.; see arrow below

Step 9. Remove the Print Head Cam Sync Fixture.

Step 10. Continue reassembly.

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5.6.23 Feeder/Flipper/Options Assembly

Note • This procedure uses Spare Kit #

P1037750-080: GROUND PLATES

Step 1. The Feeder/Flipper/Options Assembly is comprised of two modules: the Feeder/

Flipper Module and the Options Module.

FEEDER/FLIPPER OPTIONS

Step 2. From the bottom of the Options Module: With a 5.5-mm Nut Driver, remove the
two nuts (arrows below) holding the grounds in place; and remove the grounds.

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Step 3. From the back of the Options Module: With a 5.5-mm Nut Driver, remove the
three nuts (circled below) holding the grounds to the Grounding Plate; and
remove the grounds.

Step 4. From the bottom of the Options Module: With a TORX T10 driver, remove the
four screws (SCR EJOT 30x10, 5.5 in-lb) holding the Print Engine Ground Plate
in place.

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Step 5. Remove the Print Engine Ground Plate, and set it aside. Note that the back edge of
the Print Engine Ground Plate is tightly held under plastic clips; use moderate
pressure to free it.

Step 6. Disconnect connectors J1 and J2 from OPSC MODULE PCBA (arrows below).

J1

J2

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Step 7. Disconnect connectors J1 and J2 from OPMAG MODULE PCBA (arrows below).

J1

J2

Step 8. Disconnect connectors J1 and J10 from FLIPPER MODULE PCBA (arrows below).

J1

J10

Step 9. Free all the cables.

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Step 10. From the back of the Printer: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 5.5 in-lb) holding the Feeder/Flipper Module and the Options
Module together. Use an 8-inch tapered bit TORX T10 driver for the lower screw.

Step 11. From the front of the Printer: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 5.5 in-lb) holding the Feeder/Flipper Module and the Options
Module together.

Step 12. Lift and separate the Feeder/Flipper Module from the Options Module.

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5.6.24 Feeder/Flipper Assembly

The Feeder/Flipper Assembly is comprised of two Modules: Feeder and Flipper.

FEEDER

FLIPPER

Step 1. Disconnect connector J8from the FLIPPER MODULE PCBA.

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Step 2. From the front of the Assembly: With a TORX T10 driver, remove the four screws
(SCR EJOT 30x10, 5.5 in-lb) holding the Feeder and the Flipper together.

Step 3. Disconnect the two ground wires that go through the hole close to the top left
side screw.

Step 4. Separate the Feeder Module and the Flipper Module.

FEEDER FLIPPER

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Replacement
Replacement is performed by reversing the removal steps

Test and Adjustment

Feeder/Flipper Assembly
Use the ZXP Series 7 Service Partner Tool; see Appendix F.

Run Flipper Calibration on page 455.

Run Feeder Test (10 mil) on page 458.

Run Feeder Test on page 459.

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5.6.25 Ground Plate

Note • This procedure uses Spare Kit #

P1037750-080: GROUND PLATES

Step 1. With a 5.5-mm Nut Driver, remove the three nuts (arrows below) holding the
grounds to the Ground Plate; and remove the grounds.

Step 2. With a Phillips #1 screwdriver, remove the screw (M3x10, 5.5 in-lb) holding the
Ground Plate to the Power Supply.

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Step 3. Remove the two power connections. Note that the blue wire is on the
bottom connector.

Step 4. With a TORX T10 driver, remove the six screws (SCR EJOT 30x6, 4 in-lb) holding
the Ground Plate to the Frame.

Step 5. Set the Ground Plate aside.

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5.6.26 Power Switch

Note • This procedure uses Spare Kit #

P1037750-022: POWER SWITCH/ENTRY MODULE

See next page for alternate Power Switch removal method using AC Power Filter Release Tool
(P1037750-404) on page 114.

Step 1. Locate the Power Switch (circled below).

Step 2. With a Flat-blade screwdriver, release the locking tabs (dashed arrows below) on
both sides of the Power Switch.

Step 3. Slide the Power Switch forward, out of the mounting bracket; and set it aside.

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Alternate Method
Alternate Power Switch removal method using AC Power Filter Release Tool (P1037750-404)
on page 114.

Step 1. Locate the Power Switch (circled below).

Step 2. Slide the tool into place (arrow above) thereby releasing the locking tabs on both
sides of the Power Switch.

Step 3. Slide the Power Switch forward, out of the mounting bracket; and set it aside.

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5.6.27 Feeder Module

5.6.27.1 Drive Assembly Feeder

Note • This procedure uses Spare Kit #

P1037750-061: DRIVE ASSEMBLY FEEDER

This is the replacement kit for the Feeder Module; i.e., the entire assembly.

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5.6.27.2 Feeder Motor

Note • This procedure uses Spare Kit #

P1037750-058: ENCODER AND FEEDER MOTOR

Step 1. Locate the Feeder Motor (arrow below).

Step 2. With a TORX T10 driver, remove the four screws (SCR EJOT 30x10, 4 in-lb) and
washers holding the Feeder Motor and Motor Plate in place.

Step 3. Remove the Feeder Motor and Motor Plate.

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Step 4. With a TORX T10 driver, remove the two screws (SCR EJOT 30x8, 4 in-lb),
washers (#6 WASHER), and nuts (KEPS, M3) holding the Feeder Motor to
the Motor Plate.

Step 5. Remove the Feeder Motor and associated green ground wire from the Motor Plate,
and set them aside.

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5.6.28 Flipper Module

5.6.28.1 Flipper Assembly

Note • This procedure uses Spare Kit #

P1037750-075: FLIPPER ASSEMBLY

This is the replacement kit for the Flipper Module; i.e., the entire assembly.

Flipper Calibration
Run this calibration any time you work on the Flipper or suspect you have a misaligned flipper
deck; see Flipper Calibration on page 455 for details.

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5.6.28.2 ESD Brush

Step 1. Locate the ESD Brush (arrow below).

Step 2. Free the green ground wire from the cable tie (arrow below).

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Step 3. With a small Flat-blade screwdriver, carefully free the ESD Brush (circled below)
from the Frame. Note that the ESD Brush is held in place with adhesive.

Step 4. Set the ESD Brush aside.

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5.6.28.3 Flipper PCBA

Note • This procedure uses Spare Kit #

P1037750-019: PCBA FLIPPER MODULE

Step 1. Locate the Flipper PCBA (arrow below).

Step 2. Disconnect the plugs (J2, J3, J4, J9, J11, and J13) from the Flipper PCBA.

J2 J3 J4

J13

J11

J9

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Step 3. With a TORX T10 driver, remove the three screws (SCR EJOT 30x6, 4 in-lb)
holding the Flipper PCBA in place.

Step 4. Set the Flipper PCBA aside.

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5.6.28.4 Flipper Position Sensor

Note • This procedure uses Spare Kit #

P1037750-034: FLIPPER POSITION SENSOR

Step 1. With a TORX T9 driver, remove the two screws (SCR EJOT 35x6, 2.5 in-lb)
holding the Flipper Position Sensor in place.

Step 2. Remove the Flipper Position Sensor, and set it aside.

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5.6.28.5 Flipper Rotation Gear

Step 1. Remove the retaining clip (arrow below) holding the Flipper Rotation Gear in place.

Step 2. Remove the four wires from the Sensor connector P11.

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Step 3. Slide the Flipper Rotation Gear off the Shaft, the Ground Wire, and Sensor Wires.

Step 4. Remove the Flipper Rotation Gear, and set it aside.

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5.6.28.6 85/35T Gear

Step 1. With the Flipper Rotation Gear removed, the 85/35T Gear can be removed.

Step 2. Remove the retaining clip (arrow below) holding the 85/35T Gear in place.

Step 3. Remove the 85/35T Gear, and set it aside.

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5.6.28.7 Flipper Rotation Motor

Note • This procedure uses Spare Kit #

P1037750-057: DRIVE MOTORS FLIPPER

Step 1. Locate the Flipper Rotation Motor (circled below).

Step 2. With a TORX T10 driver, remove the two screws (SCR EJOT 30x10, 4 in-lb)
holding the Flipper Rotation Motor in place.

Step 3. Remove the Flipper Rotation Motor and the associated green ground wire, and set
them aside.

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5.6.28.8 Flipper Drive Motor

Note • This procedure uses Spare Kit #

P1037750-057: DRIVE MOTORS FLIPPER

Step 1. Locate the Flipper Drive Motor (circled below).

Step 2. With a TORX T10 driver, remove the two screws (SCR EJOT 30x10, 4 in-lb)
holding the Flipper Drive Motor in place. Note that the cable harness has been
removed for clarity.

Step 3. Remove the Flipper Drive Motor and the associated green ground wire, and set
them aside.

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5.6.28.9 Flipper Deck

Step 1. Remove the four Flipper Deck gears.

a. Remove the retaining clips holding Gears #1 and #2 in place; and remove
the gears.

b. Remove the retaining clip holding Gears #3 in place; and remove the gear.

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c. Remove the retaining clip holding Gears #4 in place; and remove the gear.

d. Set the four Flipper Deck gears aside.

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Step 2. With a TORX T10 driver, remove the three screws (SCR EJOT 30x10, 4 in-lb)
holding the Flipper Deck Bearing Plate in place. Note the orientation of the Flipper
Deck Bearing Plate.

Step 3. Remove the Flipper Deck Bearing Plate, and set it aside.

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Step 4. With a TORX T10 driver, remove the two screws (SCREW PLASTITE M3x12,
4 in-lb) holding the Bearing Block in place.

Step 5. Remove the Bearing Block, and set it aside.

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Step 6. Lift the Flipper Deck up and out of the Frame.

Step 7. Set the Flipper Deck aside.

Note: To remove the Pressure Roller, push the back end down and to the right to
free it from its holder.

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5.6.28.10 Flipper Deck Platen Roller

Note • This procedure uses Spare Kit #

P1037750-050: PLATEN ROLLERS

Step 1. With a TORX T10 driver, remove the three screws (SCR EJOT 30x8, 4.0 in-lb)
holding the Roller Shaft in place; arrows below.

Step 2. With a Phillips #2 screwdriver, remove the screw (arrow below) holding the ground
wire in place.

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Step 3. Remove the Roller Shaft Bracket.

Step 4. Slide the Platen Roller forward, far enough to free the shaft; then pull the Platen
Roller up and out of the Flipper Deck.

Step 5. Set the Platen Roller aside.

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5.6.28.11 Card Present On Flipper Sensor

Note • This procedure uses Spare Kit #

NOT AVAILABLE.

Step 1. With a TORX T8 driver, remove the three screws (SCR EJOT 35x6, 2.5 in-lb)
holding the Sensor in place; arrows below.

Step 2. Remove the Sensor, and set it aside.

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5.6.29 Options Module

5.6.29.1 Options Module

Note • This procedure uses Spare Kit #

P1037750-013: OPTIONS MODULE

This is the replacement kit for the Options Module; i.e., the entire assembly.

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5.6.29.2 SmartCard Control PCBA

Note • This procedure uses Spare Kit #

P1037750-015: PCBA SMART CARD CONTROL

Step 1. If not already done, disconnect connectors J1 and J2 from OPSC MODULE PCBA.

Step 2. With a TORX T10 driver, remove the four screws (SCR EJOT 30x8, 5.5 in-lb)
and washers holding the Smart Card Control PCBA in place.

Step 3. Remove the Smart Card Control PCBA, and set it aside.

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5.6.29.3 MIFARE/Contact Encoder Module

Note • This procedure uses Spare Kit #

P1037750-087: MODULE MIFARE CONTACT ENCODER

Step 1. Locate the MIFARE/Contact Encoder Module (circled below).

Step 2. Rotate the key counterclockwise to unlock the Encoder Module.

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Step 3. Push the Encoder Module forward to disconnect the plug (on the back of the
Encoder Module) from the connector (on the Encoder PCBA); then pull the Encoder
Module up and out of the Frame.

Step 4. Set the Encoder Module aside.

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Replacement
Replacement is performed by reversing the removal steps

Test and Adjustment

MIFARE/ Contact Encoder Module
Use the ZXP Series 7 Service Partner Tool; see Appendix F.

Run Smart Card Enable on page 469.

Run Smart Card Calibration on page 470.

Run Smart Card Contact Read/Write Test on page 471.

Run Smart Card Contactless Read/Write Test on page 472.

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5.6.29.4 PCBA for MIFARE Contact Encoder

Note • This procedure uses Spare Kit #

P1037750-052: PCBA MIFARE CONTACT ENCODER

Step 1. With a small Flat-blade screwdriver, release the three locking tabs (arrows below) to
free the Encoder Module PCBA.

Step 2. Carefully unplug the connectors (circled below).

Step 3. Remove the Encoder Module PCBA, and set it aside.

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Step 4. With a TORX T10 driver, remove the screw (SCR EJOT 30x8, 5.5 in-lb) holding
the SC MOD PCBA in place; arrow below.

Step 5. Carefully unplug the three connectors (circled below).

Step 6. Remove the SC MOD PCBA, and set it aside.

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5.6.29.5 Contact Station Module

Note • This procedure uses Spare Kit #

P1037750-030: MODULE CONTACT STATION

Step 1. Locate the Contact Station Module (circled below).

Step 2. Rotate the key counterclockwise to unlock the Contact Station Module.

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Step 3. Push the Contact Station Module forward to disconnect the plug (on the back of the
Encoder Module) from the connector (on the Encoder PCBA); then pull the Contact
Station Module up and out of the Frame.

Step 4. Set the Contact Station Module aside.

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Replacement
Replacement is performed by reversing the removal steps

Test and Adjustment

Contact Station Module
For these tests, you will need Contact Station Upgrade Tool (P1037750-403).

Use the ZXP Series 7 Service Partner Tool; see Appendix F.

Run Smart Card Enable on page 469.

Run Smart Card Calibration on page 470.

Run Smart Card Contact Read/Write Test on page 471.

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5.6.29.6 PCBA for Contact Station Module

Note • This procedure uses Spare Kit #

P1037750-070: PCBA FOR CONTACT STATION

Step 1. With a small Flat-blade screwdriver, release the three locking tabs (arrows below) to
free the Contact Station Module PCBA.

Step 2. Carefully unplug the connectors (circled below).

Step 3. Remove the Contact Station Module PCBA, and set it aside.

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Step 4. With a TORX T10 driver, remove the screw (SCR EJOT 30x8, 5.5 in-lb) holding
the SC MOD PCBA in place; arrow below.

Step 5. Carefully unplug the three connectors (circled below).

Step 6. Remove the SC MOD PCBA, and set it aside.

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5.6.29.7 MAG (or Non-MAG) Pressure Roller Assembly

Note • This procedure uses Spare Kit #
P1037750-048: PRESSURE ROLLER ASSY MAG
P1037750-086: PRESSURE ROLLER ASSY NON MAG

Step 1. Locate the Pressure Roller Assembly; circle below.

Step 2. With a TORX T10 driver, remove the screw (SCR EJOT 30x8, 5.5 in-lb) holding
the Pressure Roller Assembly in place; arrow below.

Step 3. Remove the Belt (circled above).

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Step 4. Pull the Pressure Roller Assembly forward, up, and out of the Frame.

Step 5. Set the Pressure Roller Assembly aside.

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Reassembly
Belt Tension Adjustment
For this test, you will need the Gate 507C Sonic Tension Meter, 74200507.

Step 1. Turn power on (press the red Power button).

Step 2. Select measurement setting No09 (press the 9 button).

Step 3. Ensure the meter parameters (preset by Zebra Engineering) are set to:

M 000.8 g/m

W 004.7 mm/R

S 0055 mm

Step 4. Set the range to Standard (press and hold the Range button until the range
selections display, then use the UP and DOWN buttons to select the desired range).

Step 5. Press the green Measure button. The green light below the number pad will flash
indicating that measurement is in progress.

Step 6. Position/point the meter sensor approximately 5 mm from the belt.

Step 7. Tap the belt until you see the belt tension measurement display.

Step 8. The belt tension should measure between 2.2 to 2.8. If not, readjust the motor
(loosen the mounting screws, reposition the motor, and tighten the mounting
screws); and repeat Steps 5 through 8.

Step 9. This completes the calibration procedure.

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Alternate Belt Tension Adjustment: For this adjustment, you will need the Mag Tensioning
Spring Tool (P1051857).

Step 1. Loosen the two motor mounting screws (arrows below).

Step 2. Hook the belt tensioning tool spring around the motor shaft (right arrow below).

Step 3. Hook the belt tensioning tool ring in the notch (left arrow above).

Step 4. Tighten the two motor mounting screws; see Step 1.

Step 5. Remove the Belt Tensioning Tool.

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5.6.29.8 MAG Head

Note • This procedure uses Spare Kit #

P1037750-017: MAG HEAD REPLACEMENT

Step 1. Locate the MAG Head (circle below).

Step 2. With a TORX T10 driver, remove the two screws (SCR EJOT 30x8, 5.5 in-lb)
holding the MAG Head in place; arrows below.

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Step 3. Lift the MAG Head out of the Frame just far enough to access the cable connector,
and disconnect the MAG Head plug (circle below).

Step 4. Set the MAG Head aside.

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5.6.29.9 MAG Control PCBA

Note • This procedure uses Spare Kit #

P1037750-016: PCBA MAG CONTROL

Step 1. From the back of the Options Module: With a TORX T10 driver, remove the five
screws (SCR EJOT 30x8, 5.5 in-lb) holding the MAG Control PCBA in place.

Step 2. Remove the MAG Control PCBA. Note the MAG Head Cable attached to
the MAG Control PCBA.

Step 3. Set the MAG Control PCBA aside.

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5.6.29.10 Card Sensor

Note • This procedure uses Spare Kit #:

P1037750-039: CARD SENSOR OPTION MODULE

Step 1. From the bottom of the Options Module: With an 8-inch tapered bit TORX T10
driver, remove the screw (SCR EJOT 30x8, 5.5 in-lb) holding the Card Sensor
in place.

Step 2. Free the cable from the cable hooks, and then carefully pull the cable and connector
out of the Frame.

Step 3. Set the Card Sensor aside.

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Replacement
Replacement is performed by reversing the removal steps

Test and Adjustment

Card Sensor
Use the ZXP Series 7 Service Partner Tool; see Appendix F.

Run ATM Feed Test on page 461.

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5.6.29.11 Options Motor

Note • This procedure uses Spare Kit #

P1037750-058: ENCODER AND FEEDER MOTOR

Step 1. With a TORX T10 driver, remove the two screws (SCR EJOT M3x8, 5.5 in-lb)
washers (#6 WASHER), and nuts (KEPS, M3) holding the Options Motor in place.
Note the green ground wire attached.

Step 2. Remove the Motor and associated green ground wire from the Motor Plate, and set
them aside.

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Procedures: Options Module

5.6.29.12 Drive Platen Roller

Note • This procedure uses Spare Kit #

P1037750-050: PLATEN ROLLERS

Step 1. Locate the Drive Platen Roller.

Step 2. From the front of the Options Module, remove the retaining clip (arrow below)
holding the Roller Shaft in place.

Step 3. With a TORX T10 driver, remove the two screws (SCR EJOT 30x8, 5.5 in-lb)
holding the Bearing Bracket in place; circled above. Set the Bearing Bracket aside.

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 5: Replacement Procedures for the Printer
Procedures: Options Module

Step 4. From the back of the Options Module, remove the retaining clip holding the Roller
Shaft in place.

Step 5. Remove the Belt (circled below) and Gear (arrow below).

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 5: Replacement Procedures for the Printer
Procedures: Options Module

Step 6. Slide the Drive Platen Roller forward to clear the Frame, and remove the Drive
Platen Roller.

Step 7. Set the Drive Platen Roller aside.

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 5: Replacement Procedures for the Printer
Procedures: Options Module

Test and Adjustment

Belt Tension Adjustment
For this test, you will need the Gate 507C Sonic Tension Meter, 74200507.

Step 1. Turn power on (press the red Power button).

Step 2. Select measurement setting No07 (press the 7 button).

Step 3. Ensure the meter parameters (preset by Zebra Engineering) are set to:

M 001.2 g/m

W 004.7 mm/R

S 0039 mm

Step 4. Set the range to High (press and hold the Range button until the range selections
display, then use the UP and DOWN buttons to select the desired range).

Step 5. Press the green Measure button. The green light below the number pad will flash
indicating that measurement is in progress.

Step 6. Position/point the meter sensor approximately 5 mm from the belt.

Step 7. Tap the belt until you see the belt tension measurement display.

Step 8. The belt tension should measure between 2.5 to 3.5. If not, readjust the motor
(loosen the mounting screws, reposition the motor, and tighten the mounting
screws); and repeat Steps 5 through 8.

Step 9. This completes the calibration procedure.

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 5: Replacement Procedures for the Printer
Procedures: Options Module

5.6.29.13 MAG Drive Platen Roller

Note • This procedure uses Spare Kit #

P1037750-050: PLATEN ROLLERS

Step 1. Locate the MAG Drive Platen Roller.

Step 2. From the front of the Options Module, remove the retaining clip (arrow below)
holding the Gear and the Roller Shaft in place. Remove the Gear.

Step 3. With a TORX T10 driver, remove the two screws (SCR EJOT 30x8, 5.5 in-lb)
holding the Bearing Bracket in place; circled above. Set the Bearing Bracket aside.

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 5: Replacement Procedures for the Printer
Procedures: Options Module

Step 4. Slide the MAG Drive Platen Roller forward to clear the Frame, and remove the
MAG Drive Platen Roller.

Step 5. Set the MAG Drive Platen Roller aside.

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 6
Replacement Procedures for
the Laminator

6.1 Introduction
The following sections describe removing both major assemblies and, where applicable,
subassemblies and/or components that are considered replaceable on the Laminator.

In general, only removal directions are presented; unless otherwise noted, replacement would
be performed by reversing the removal steps. Replacement instructions for some items are not
presented; removal and replacement of these items are considered too obvious to warrant a
detailed description.

Spares Kits are listed in Appendix E.

Electric Shock • Before performing any of the procedures in this section, set the printer
power to OFF (O) and disconnect the power cord.

Electrostatic Discharge • All replacement procedures must be performed at a static-

free work station, an anti-static wrist strap must be worn and properly terminated, or
other appropriate protection must be used.

Caution • Before beginning any of the procedures that follow, read completely through
the procedure. If you do not have the specified tools or if any step(s) seem beyond your
skill or experience level, do not attempt the procedure. You may cause additional
damage to the printer.

Note • Some of the photographs in this section may show additional parts removed in
addition to removals for the process being described.

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 6: Replacement Procedures for the Laminator
Required Tools

6.2 Required Tools

This section lists the tools required for the replacement procedures described in this section.
Naturally, not all tools are required for a particular procedure; specific tools are called out in
each step as appropriate.

• Flat-blade Screwdrivers, from 1/16 inch (1.5 mm) to 1/4 inch (6.5 mm)
• Phillips #0, #1 Screwdriver
• TORX T10, T15 Driver (standard, 8-inch shaft, and/or ball-end; magnetic
tip recommended)
• Adjustable Wrench
• Fine-Point, Offset Fine-Point, and Needle-Nose Pliers
• Small Diagonal Cutters or other cutter for cutting cable ties
• 5.5 mm Hex Driver (this can also be used for securing push nuts)
• 3-10 mm E-Ring Clip Tool
• Small and Medium Spring Hook Tools
• Cotton Gloves

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 6: Replacement Procedures for the Laminator
Removal Sequence

6.3 Removal Sequence

The following figures show the recommended removal sequence. For each item, follow the
diagram to see what must be removed for access.

To remove the Exit Rollers (6.6.31), first remove the 24V Heater Fans (6.6.14), and the 24V
Heater Fans (6.6.14); then open the Laminator Door, and remove the Laminator Heater
Assembly (6.6.12) and the Front Frame (6.6.22) -- follow the red paths.

6.6.14, 24V 6.6.16, Open

Heater Fans Laminator Laminator
Controller Door

6.6.15, Motor 6.6.19, Bottom 6.6.17, Media 6.6.10, Molded

and Plate Laminator Authentication Ribbon Spindle
Assembly Control Motor PCBA

6.6.18, Top 6.6.20, Staging 6.6.11, Square

Laminator Motor Corner Spindle
Control Motor

6.6.34, Card 6.6.21, Media 6.6.13, Halogen

Entry Sensor Authentication Bulbs
Cable Assembly Antenna PCBAs

6.6.37, Door 6.6.14, 24V

Sensor Cable Heater Fans
Assembly

, 6.6.12,
Laminator
Heater

6.6.14, 24V 6.6.31, Exit 6.6.22, Front

Heater Fans Rollers Frame

Next Page

Frame

Remove the Separate the

Baseplate from Frame from the
the Frame & Base
Base Assembly
Base

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 6: Replacement Procedures for the Laminator
Removal Sequence

Previous Page

6.6.16,
Laminator
Controller

6.6.24, Cassette
Latch Assembly
(Top & Bottom)

6.6.25,
Thermopiles
(Top & Bottom)

6.6.35, Card 6.6.26, Top 6.6.27, Bottom

Laminator Sensor Thermopile Thermopile
Cable Assembly Cable Cable

6.6.36, Card
Exit Sensor
Cable Assembly

6.6.32, Cutters 6.6.33, Laminate

(Upper & Lower) Ribbon Rollers
(Top & Bottom)

6.6.28, Flexible
Ribbed Rollers
(Left & Right)

6.6.30, Platen
Overrun Roller
(Top & Bottom)

6.6.29, Card
Staging Nip Rollers
(Left & Right)

6.6.23, Static
Brush

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 6: Replacement Procedures for the Laminator
Procedure List

6.4 Procedure List

6.6.1 Rear Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 288

6.6.2 Side Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 289
6.6.3 Lower Door - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 290
6.6.4 Door Assembly (Door and Hinges) - - - - - - - - - - - - - - - - - - - 292
6.6.5 Latch Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 295
6.6.6 Laminator / Printer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 297
6.6.7 Bottom Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 299
6.6.8 Feet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 300
6.6.9 Mounting Plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 301
6.6.10 Molded Ribbon Spindle - - - - - - - - - - - - - - - - - - - - - - - - - - - 303
6.6.11 Square Corner Spindle - - - - - - - - - - - - - - - - - - - - - - - - - - - 304
6.6.12 Laminator Heater Assembly - - - - - - - - - - - - - - - - - - - - - - - - 305
6.6.13 Halogen Bulbs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 306
6.6.14 24V Heater Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 309
6.6.15 Motor and Plate Assembly - - - - - - - - - - - - - - - - - - - - - - - - - 311
6.6.16 Laminator Controller PCBA - - - - - - - - - - - - - - - - - - - - - - - - 314
6.6.17 Media Authentication PCBA - - - - - - - - - - - - - - - - - - - - - - - - 316
6.6.18 Top Laminator Control Motor - - - - - - - - - - - - - - - - - - - - - - - 317
6.6.19 Bottom Laminator Control Motor - - - - - - - - - - - - - - - - - - - - - 318
6.6.20 Staging Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 319
6.6.21 Media Authentication Antenna PCBAs - - - - - - - - - - - - - - - - 320
6.6.22 Front Frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 322
6.6.23 Static Brush - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 323
6.6.24 Cassette Latch Assembly (Top & Bottom) - - - - - - - - - - - - - - 324
6.6.25 Thermopiles (Top & Bottom) - - - - - - - - - - - - - - - - - - - - - - - 332
6.6.26 Top Thermopile Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - 336
6.6.27 Bottom Thermopile Cable - - - - - - - - - - - - - - - - - - - - - - - - - 337
6.6.28 Flexible Ribbed Rollers (Left & Right) - - - - - - - - - - - - - - - - - 338
6.6.29 Card Staging Nip Rollers (Left & Right) - - - - - - - - - - - - - - - - 339
6.6.30 Platen Overrun Roller (Top & Bottom) - - - - - - - - - - - - - - - - - 340
6.6.31 Exit Rollers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 341
6.6.32 Cutters (Upper & Lower) - - - - - - - - - - - - - - - - - - - - - - - - - - 342
6.6.33 Laminate Ribbon Rollers (Top & Bottom) - - - - - - - - - - - - - - - 346
6.6.34 Card Entry Sensor Cable Assembly - - - - - - - - - - - - - - - - - - 347
6.6.35 Card Laminator Sensor Cable Assembly - - - - - - - - - - - - - - - 348
6.6.36 Card Exit Sensor Cable Assembly - - - - - - - - - - - - - - - - - - - 349
6.6.37 Door Sensor Cable Assembly - - - - - - - - - - - - - - - - - - - - - - 350

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 6: Replacement Procedures for the Laminator
Kit List ( P1037750- )

6.5 Kit List ( P1037750- )

KIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION

500 Kit Lam Door ZXP7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.4
501 Kit Lam Lower Door ZXP7 . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.3
502 Kit Lam Bottom Panel ZXP7 . . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.7
503 Kit Lam Door Hinges ZXP7 . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.4
504 Kit Lam Electronics Cables ZXP7 . . . . . . . . . . . . . . . . . . . . . See applicable section(s)
505 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
506 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
507 Kit Packaging for Lam Only ZXP7 . . . . . . . . . . . . . . . . . . . . . N/A

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 6: Replacement Procedures for the Laminator
Kit List ( P1037750- )

Kit List ( P105936G- )

KIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION

500 N/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
501 N/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
502 N/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
503 KIT, ASSY, FAN, 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.14
504 KIT, PCBA, LAM, MA, ANT, UPPER . . . . . . . . . . . . . . . . . . . Section 6.6.21
505 KIT, LAM, UPPER CAS. LATCH . . . . . . . . . . . . . . . . . . . . . . Section 6.6.24
506 KIT, LAM, LOWER CAS. LATCH . . . . . . . . . . . . . . . . . . . . . . Section 6.6.24
507 KIT, TOOL, THUMB DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
508 KIT, ASSY, CUTTER, LOWER . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.32
509 KIT, HEATER, HALOGEN, 78MM, 150W, 120V . . . . . . . . . . Section 6.6.13
510 KIT, PCBA, LAMINATOR CONTROLLER . . . . . . . . . . . . . . . Section 6.6.16
511 KIT, ASSY, MOTOR, 17PM . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.15
512 KIT, MTR, BI-STP, PM42L-048, RIGHT, 8IN . . . . . . . . . . . . . Section 6.6.18
513 KIT, MTR, BI-STP, PM42L-048, LEFT, 8IN . . . . . . . . . . . . . . Section 6.6.19
514 KIT, MTR, BI-STP, PM42L-048, RIGHT, 6IN . . . . . . . . . . . . . Section 6.6.20
515 KIT, STATIC BRUSH, 60MM . . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.23
516 KIT, CASSETTE, LAMINATE, TOP . . . . . . . . . . . . . . . . . . . . Section 2.3.6
517 KIT, CASSETTE, LAMINATE, BOTTOM . . . . . . . . . . . . . . . . Section 2.3.6
518 KIT, MODULE, THERMOPILE . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.25
519 KIT, ASSY, HEATER, LAM . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.12
520 KIT, PCBA, MEDIA AUTH, ZXP LAM . . . . . . . . . . . . . . . . . . Section 6.6.17
521 KIT, ROLLER, RIBBED, FLEXIBLE . . . . . . . . . . . . . . . . . . . . Section 6.6.28
522 KIT, ASSY, CUTTER, UPPER . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.32
523 KIT, ROLLER, RIB, LAMINATE . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.33
524 N/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
525 KIT, PLATEN, OVERRUN . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.30
526 KIT, ASSY, EXIT ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6.6.31
527 KIT, SPINDLE, RIBBON, MOLDED . . . . . . . . . . . . . . . . . . . . Section 6.6.10
528 KIT, SPINDLE, SQUARE CORNER. . . . . . . . . . . . . . . . . . . . Section 6.6.11
529 N/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
530 KIT, CBL ASY, LAM-THERMOPILE, TOP . . . . . . . . . . . . . . . Section 6.6.26
531 KIT, CBL ASY, LAM-THERMOPILE, BTM . . . . . . . . . . . . . . . Section 6.6.27
532 KIT, CBL ASSY, SENSOR CARD, ENTRY . . . . . . . . . . . . . . Section 6.6.34
533 KIT, CABLE ASSY, SENSOR CARD, LAM . . . . . . . . . . . . . . Section 6.6.35
534 KIT, CBL ASSY, SENSOR CARD, EXIT . . . . . . . . . . . . . . . . Section 6.6.36
535 N/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
536 KIT, PCBA, LAM, MA, ANT, LOWER . . . . . . . . . . . . . . . . . . . Section 6.6.21
537 KIT, CBL ASY, SNSR REFL, LAM, DOOR. . . . . . . . . . . . . . . Section 6.6.37

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 6: Replacement Procedures for the Laminator
Procedures:

6.6 Procedures:
6.6.1 Rear Cover
Step 1. Open the Laminator Doors (Upper and Lower).

Step 2. With a TORX T10 driver, remove the two screws (SCR EJOT 30x10, 5.5 in-lb)
holding the Rear Cover in place.

Step 3. Set the Rear Cover aside.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.2 Side Cover

Step 1. From the front of the Laminator: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 5.5 in-lb) holding the Side Cover in place.

Step 2. From the back of the Laminator: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 5.5 in-lb) holding the Side Cover in place.

Step 3. Remove the Side Cover, and set it aside.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.3 Lower Door

Note • This procedure uses Spare Kit #

P1037750-501: KIT LAM LOWER DOOR

Step 1. With a TORX T10 driver, remove the seven screws (SCR EJOT 30x10, 5.5 in-lb)
holding the Inner Panel to the Lower Door.

Step 2. Set the Inner Panel aside.

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 6: Replacement Procedures for the Laminator
Procedures:

Step 3. With a small Flat-blade screwdriver, carefully remove the clip holding the lower
hinge pin in place.

Step 4. Slide the Hinge Pin out of the Laminator.

Step 5. Set the Lower Door aside.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.4 Door Assembly (Door and Hinges)

Note • This procedure uses Spare Kit #
P1037750-500: KIT LAM DOOR
P1037750-503: KIT LAM DOOR HINGES

Step 1. From the back of the Laminator: Disconnect the Door Sensor at J9 on the Main
PCBA; circled below. Cut cable ties as required to free the door sensor cable.

Step 2. With a TORX T10 driver, remove the screw (SCR EJOT 30x10, 5.5 in-lb) holding
the Door Assembly in place; arrow below.

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 6: Replacement Procedures for the Laminator
Procedures:

Step 3. From the front of the Laminator: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 5.5 in-lb) holding the Door Assembly in place.

Step 4. Slide the Door Assembly to the rear, up, and away from the Laminator.

Step 5. Remove the Door Assembly.

Step 6. Ensure the Door is in the closed position.

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 6: Replacement Procedures for the Laminator
Procedures:

Step 7. With a small Flat-blade screwdriver, carefully remove the clip holding the upper
hinge pin in place.

Step 8. Slide the upper hinge pin out of the Door Assembly. This should release the
hinge springs.

Step 9. Separate the Door from the Hinges.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.5 Latch Assembly

Step 1. With a TORX T10 driver, remove the six screws (SCR EJOT 30x10, 5.5 in-lb)
holding the Inner Cover to the Door.

Step 2. Separate the Inner Cover and the Door (they snap together).

Step 3. Remove the Button (circled above), and set it aside.

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 6: Replacement Procedures for the Laminator
Procedures:

Step 4. With a TORX T10 driver, remove the two screws (SCR EJOT 30x8, 5.5 in-lb)
holding the bearing caps in place.

Step 5. Remove the Latch, two springs, and two bearing caps; and set them aside.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.6 Laminator / Printer

This section describes how to separate the Laminator from the Printer.

Step 6. Open the Print Cover; and remove the Ribbon Drawer; see Section 5.6.3.

Step 7. Remove the Belt and Gear Panel; see Section 5.6.15.

Step 8. Remove the Printer Back Cover; see Section 5.6.6.

Step 9. Disconnect J8 (AC Power), J14 (Data), and J15 (DC Power).

J8 J15

J14

Step 10. With a Phillips Screwdriver, remove the screw (circled below) to free the grounds.

Step 11. Remove thew screw (arrow above) holding the Laminator to the Printer.

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 6: Replacement Procedures for the Laminator
Procedures:

Step 12. From the front of the Printer: With a TORX T10 driver, remove the three screws
(SCR EJOT 30x10, 5.5 in-lb) holding the Laminator and Printer together.

Step 13. Separate the Laminator from the Printer.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.7 Bottom Panel

Step 1. From the front of the Laminator: With a TORX T10 driver, remove the screw
(SCR EJOT Washerhead 30x10, 5.5 in-lb) as shown.

Step 2. From the bottom of the Laminator: With a TORX T10 driver, remove the four
screws (SCR EJOT 30x10, 5.5 in-lb) as shown.

Step 3. Set the Bottom Panel aside.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.8 Feet

Note • This procedure uses Spare Kit #

P1037750-082: KIT FEET

Step 1. With a Flat-blade screwdriver, carefully loosen each Foot. Note that the feet are
attached with adhesive.

Step 2. Set the Feet aside.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.9 Mounting Plate

Step 1. From the bottom of the Laminator: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x8, 5.5 in-lb) as shown.

Step 2. From the rear of the Laminator: With a TORX T10 driver, remove the two screws
(SCR EJOT #4, 1/4, 5.5 in-lb) as shown.

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 6: Replacement Procedures for the Laminator
Procedures:

Step 3. From the front of the Printer: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 5.5 in-lb) as shown.

Step 4. Set the Mounting Plate aside.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.10 Molded Ribbon Spindle

This procedure uses Spares Kit #

105936G-527: KIT, SPINDLE, RIBBON, MOLDED

Step 1. With a TORX T10 driver, remove the screw (arrow below) holding the Molded
Ribbon Spindle in place.

Step 2. Slide the Molded Ribbon Spindle off the spindle shaft.

Step 3. Set the Molded Ribbon Spindle aside.

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6.6.11 Square Corner Spindle

Note • This procedure uses Spares Kit #

105936G-528: KIT, SPINDLE, SQUARE CORNER

Step 1. With a TORX T10 driver, remove the screw (arrow below) holding the Square
Corner Spindle in place.

Step 2. Slide the Square Corner Spindle off the spindle shaft.

Step 3. Set the Square Corner Spindle aside.

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6.6.12 Laminator Heater Assembly

Note • This procedure uses Spares Kit #

105936G-519: KIT, ASSY, HEATER, LAM

Hot Surface • Halogen Bulbs produce intense heat. Use caution when handling the
Laminator Heater Assembly

Step 1. Remove the four thumbscrews (circled below) holding the Laminator Heater
Assembly in place.

Step 2. Slide the Laminator Heater Assembly out of the Laminator.

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6.6.13 Halogen Bulbs

Note • This procedure uses Spares Kit #

105936G-509: KIT, HEATER, HAL, 78MM, 150W, 120V

Removal
Step 1. With a TORX T10 driver, remove the screw (circled below) holding the Laminator
Heater Cover in place.

Step 2. Remove the Laminator Heater Cover.

Step 3. Locate the Halogen Bulb to be replaced; then with a TORX T10 driver, loosen the
two screws holding the socket (and Halogen Bulb) in place.

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Step 4. Rotate the socket maximum counterclockwise, slide the socket out of the heater, and
move the socket and its associated wires out of the way.

Step 5. Note that the ceramic end of the Halogen Bulb is visible and accessible.

Step 6. Grasp the ceramic end, slide the bulb out of the heater, and set it aside.

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Replacement
Replacement is performed by reversing the removal steps.

After installing the replacement Halogen Bulb(s), use a Multimeter to verify that both bulbs
are making proper connection.

Top Bulb Bottom Bulb

connector connector
pins pins

Step 1. With a Multimeter, measure the resistance across the Top Bulb connector pins.

Step 2. Resistance should range between 8 ohms and 15 ohms.

Step 3. With a Multimeter, measure the resistance across the Bottom Bulb connector pins.

Step 4. Resistance should range between 8 ohms and 15 ohms.

Step 5. If the resistance is our of range, re-seat the Halogen Bulb(s), and repeat the
resistance measurement.

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6.6.14 24V Heater Fans

Exhaust Fan (Upper)

Note • This procedure uses Spares Kit #

105936G-503: KIT, ASSY, FAN, 24V, ZXP

Step 1. With a TORX T10 driver, remove the two screws holding the Exhaust Fan (circled
below) in place. Note the orientation of the fan.

Step 2. Cut the associated cable ties, disconnect the fan plug from the Laminator
Controller PCBA (J12), and remove the Exhaust Fan.

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Intake Fan (Lower)

Note • This procedure uses Spares Kit #

105936G-503: KIT, ASSY, FAN, 24V, ZXP

Step 1. With a TORX T10 driver, remove the two screws holding the Intake Fan (circled
below) in place. Note the orientation of the fan.

Step 2. Cut the associated cable ties, disconnect the fan plug from the Laminator
Controller PCBA (J3), and remove the Intake Fan.

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6.6.15 Motor and Plate Assembly

Note • This procedure uses Spares Kit #

105936G-511: KIT, MOTOR, 17PM, ZXP

Step 1. With a TORX T10 driver, remove the three screws (circled below) holding the
Bracket to the Frame.

Step 2. Move the Bracket out of the way.

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Step 3. With a TORX T10 driver, remove the four screws (circled below) holding the Motor
and Plate Assembly in place.

Step 4. Carefully free the Motor and Plate Assembly from the Frame. Ensure that all gears
and shafts remain in place.

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Step 5. With a TORX T10 driver, disconnect the Ground Wire.

Step 6. Cut the associated cable ties, disconnect the motor plug from J20, and remove the
Motor and Plate Assembly.

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6.6.16 Laminator Controller PCBA

Note • This procedure uses Spares Kit #

105936G-510: KIT, PCBA, LAMINATOR, CONTROLLER

Step 1. Unplug all the Laminator Controller PCBA cable connectors and ground
connections. To avoid confusion when reinstalling, mark all disconnected plugs
and associated connectors.

Step 2. With a TORX T10 driver, remove the four mounting screws (circled above) holding
the Laminator Controller PCBA in place.

Step 3. Set the Laminator Controller PCBA aside.

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Main PCBA Connections

J2

J8
J15

J22

J21

J20
J4
J18
J19
J6
J17
J7
J12
J3
J13
J5

J14

J1 J10 J23 J24 J11 J25 J26 J27 J9

Connector Description Connector Description

J1 Host Serial TTL J15 DC to DC Power Conversion
J2 Top and Bottom Halogen Lamps J16 N/A
J3 Fan J17 Top Laminator Control Motor
J4 JTAG Interface J18 Staging Motor
J5 Fan J19 Bottom Laminator Control Motor
J6 Top Thermopile J20 Roller Drive Motor
J7 Bottom Thermopile J21 Bottom Cutter
J8 External AC Power J22 Top Cutter
J9 Laminator Door Sensor J23 Top Laminator Sensor
J10 Debug Serial TTL J24 Bottom Laminator Sensor
J11 Background Debug J25 Card Exit Sensor
J12 Fan J26 Card Laminator Sensor
J13 RFID Control PCBA I/F J27 Card Entey Sensor
J14 HOST I2C -

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6.6.17 Media Authentication PCBA

Note • This procedure uses Spares Kit #

105936G-520: KIT, PCBA, MEDIA AUTH, ZXP LAM

Step 1. Unplug the three Media Authentication PCBA cable connectors and ground
connection. To avoid confusion when reinstalling, mark all disconnected plugs
and associated connectors.

Step 2. With a TORX T10 driver, remove the two mounting screws (arrows above) holding
the Media Authentication PCBA in place.

Step 3. Set the Media Authentication PCBA aside.

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6.6.18 Top Laminator Control Motor

Note • This procedure uses Spares Kit #

105936G-512: KIT, MTR, BI-STP, PM42L-048, RGT, 8

Step 1. With a TORX T10 driver, remove the two screws holding the Top Laminator
Control Motor in place. Note that the left-hand screw connects a ground wire.

Step 2. If not already disconnected, disconnect the motor plug from J17.

Step 3. Cut the associated cable ties, and remove the Top Laminator Control Motor.

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6.6.19 Bottom Laminator Control Motor

Note • This procedure uses Spares Kit #

105936G-513: KIT, MTR, BI-STP, PM42L-048, LFT, 8

Step 1. With a TORX T10 driver, remove the two screws holding the Bottom Laminator
Control Motor in place. Note that the left-hand screw connects a ground wire.

Step 2. If not already disconnected, disconnect the motor plug from J19.

Step 3. Cut the associated cable ties, and remove the Bottom Laminator Control Motor.

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Procedures:

6.6.20 Staging Motor

Note • This procedure uses Spares Kit #

105936G-514: KIT, MTR, BI-STP, PM42L-048, RGT, 6

Step 1. With a TORX T10 driver, remove the two screws holding the Staging Motor in
place. Note that the left-hand screw connects a ground wire.

Step 2. If not already disconnected, disconnect the motor plug from J18.

Step 3. Cut the associated cable ties, and remove the Staging Motor.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.21 Media Authentication Antenna PCBAs

Upper PCBA

This procedure uses Spares Kit #

105936G-504: KIT, PCBA, LAM, MA, ANT, UPPER

Step 1. Locate the upper Media Authentication Antenna PCBA.

Step 2. With a Phillips #1 Screwdriver, remove the two screws holding the Media
Authentication Antenna PCBA in place. Note that the left-hand screw connects a
ground wire.

Step 3. Remove the Media Authentication Antenna PCBA.

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Procedures:

Lower PCBA

Note • This procedure uses Spares Kit #

105936G-536: KIT, PCBA, LAM, MA, ANT, LOWER

Step 1. Locate the lower Media Authentication Antenna PCBA.

Step 2. With a Phillips #1 Screwdriver, remove the two screws holding the Media
Authentication Antenna PCBA in place. Note that the left-hand screw connects a
ground wire.

Step 3. Remove the Media Authentication Antenna PCBA.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.22 Front Frame

Removal
Step 1. With a TORX T10 driver, remove the seven mounting screws (circled below)
holding the Front Frame in place.

Step 2. Remove the Front Frame. Note that five Torsion Springs (arrows above) are
released when the Front Frame is removed.

Replacement
See Section 6.6.24, Replacement, on page 327 for details.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.23 Static Brush

Note • This procedure uses Spares Kit #

105936G-515: KIT, STATIC BRUSH, 60MM

Step 1. Slide the Static Brush out of its mounting slot.

Step 2. Set the Static Brush aside.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.24 Cassette Latch Assembly (Top & Bottom)

Note • This procedure uses:
Spares Kit # 105936G-505: KIT, LAM, UPPER CAS. LATCH
Spares Kit # 105936G-506: KIT, LAM, LOWER CASS LATCH

Removal
Step 1. Locate the Cassette Latch Assemblies.

Step 2. With a Spring Hook Tool, carefully release the upper Cassette Torsion Spring
(circled below), and slide the Cassette Latch and spring out of the Frame.

Step 3. With a Spring Hook Tool, carefully release the lower Cassette Torsion Spring, and
slide the Cassette Latch and spring out of the Frame.

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Procedures:

Step 4. With a TORX T10 driver, remove the two screws (circled below) holding the Latch
Plate in place.

Step 5. With a small Flat-blade screwdriver, carefully lift and free the Latch Plate. Note that
some force may be required.

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 6: Replacement Procedures for the Laminator
Procedures:

Step 6. Rotate the Laminator Levers in the direction indicated, lifting the levers up and
over the stops. Continue until rotation stops; then remove the levers.

Step 7. Set the Laminator Levers, Latch Plate, Cassette Latches, and Cassette Torsion
Springs aside.

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 6: Replacement Procedures for the Laminator
Procedures:

Replacement
Step 1. Install a screw (SCR,PH,TORX,PLAST,4-.50) in the hole in the Front Frame.

Step 2. Position the Torsion Spring against the screw Note that this Torsion Spring was
released when the Front Frame was removed; see Section 6.6.22.

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Procedures:

Step 3. With a TORX T10 driver, install the seven mounting screws (circled below) that
hold the Front Frame in place.

Step 4. Remove the screw installed in Step 1. Ensure that the Torsion Spring is properly
aligned on the Exit Roller Bushing.

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Procedures:

Step 5. Install the Laminator Latches.

Step 6. Release the top and bottom Cassette Torsion Springs.

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 6: Replacement Procedures for the Laminator
Procedures:

Step 7. Set the Laminator Levers in place, rotate the levers in the direction indicated, lifting
the levers up and over the stops. Continue until rotation stops.

Step 8. Reinstall the Latch Plate.

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Procedures:

Step 9. With a TORX T10 driver, re-install the two screws holding the Latch Plate in place.

Step 10. Release the top and bottom Cassette Torsion Springs.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.25 Thermopiles (Top & Bottom)

Top Thermopile

Note • This procedure uses Spares Kit #

105936G-518: KIT, MODULE, THERMOPILE

Step 1. Slide out the metal plate.

Step 2. Slide out the Thermopile.

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Step 3. Carefully disconnect the Thermopile from the plug.

Step 4. Set the Thermopile aside.

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 6: Replacement Procedures for the Laminator
Procedures:

Bottom Thermopile

Note • This procedure uses Spares Kit #

105936G-518: KIT, MODULE, THERMOPILE

Step 1. Slide out the metal plate.

Step 2. Slide out the Thermopile.

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Procedures:

Step 3. Carefully disconnect the Thermopile from the plug.

Step 4. Set the Thermopile aside.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.26 Top Thermopile Cable

Note • This procedure uses Spares Kit #

105936G-530: KIT, CBL ASY, LAM-THERMOPILE, TOP

Step 1. Remove the Top Thermopile; refer to Section 6.6.25 on page 332.

Step 2. Locate the Top Thermopile Cable (arrow below).

Step 3. Carefully slide the Top Thermopile Cable out of the Laminator.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.27 Bottom Thermopile Cable

Note • This procedure uses Spares Kit #

105936G-531: KIT, CBL ASY, LAM-THERMOPILE, BTM

Step 1. Remove the Bottom Thermopile; refer to Section 6.6.25 on page 332.

Step 2. Locate the Bottom Thermopile Cable (arrow below).

Step 3. Carefully slide the Bottom Thermopile Cable out of the Laminator.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.28 Flexible Ribbed Rollers (Left & Right)

Note • This procedure uses Spares Kit #

105936G-521: KIT, ROLLER, RIBBED, FLEXIBLE

For this procedure you will need to free (i.e., remove the four mounting screws), but not
disconnect, the Laminator Controller PCBA.

Step 1. Carefully remove the Flexible Rib Roller(s); see arrows below.

Step 2. Set the Flexible Rib Roller(s) aside.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.29 Card Staging Nip Rollers (Left & Right)

Note • This procedure uses Spares Kit #

105936G-524: KIT, ROLLER, NIP, CARD STAGING

For this procedure you will need to free (i.e., remove the four mounting screws), but not
disconnect, the Laminator Controller PCBA

Step 1. Carefully remove the Card Staging Nip Roller(s); see arrows below.

Step 2. Set the Card Staging Nip Roller(s) aside.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.30 Platen Overrun Roller (Top & Bottom)

Note • This procedure uses Spares Kit #

105936G-525: KIT, PLATEN, OVERRUN

For this procedure you will need to remove (both free and disconnect) the Laminator
Controller PCBA.

Step 1. Remove the clip(s) holding the Platen Overrun Roller(s) in place; circled below.

Step 2. Remove the Platen Overrun Roller(s). Do not remove the gear.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.31 Exit Rollers

Note • This procedure uses Spares Kit #

105936G-526: KIT, ASSY, EXIT ROLLER

Step 1. Remove the clip from the bottom Exit Roller, and slide the gear off the shaft;
circled below.

Step 2. Remove the top Exit Roller. Note that this releases a Torsion Spring. Also note that
this roller has bushings.

Step 3. Remove the bottom Exit Roller.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.32 Cutters (Upper & Lower)

Upper Cutter

Note • This procedure uses Spares Kit #

105936G-522: KIT, ASSY, CUTTER, UPPER

For this procedure you will need to free (i.e., remove the four mounting screws), but not
disconnect, the Laminator Controller PCBA.

Step 1. Locate the Upper Cutter (front view, Front Frame removed).

Step 2. Disconnect the cutter plug at J22 and the sensor plug at J23 (arrows below).

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Step 3. Carefully slide the Upper Cutter out of its pressure-fit mount.

Step 4. Set the Upper Cutter aside.

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 6: Replacement Procedures for the Laminator
Procedures:

Lower Cutter

Note • This procedure uses Spares Kit #

105936G-508: KIT, ASSY, CUTTER, LOWER

For this procedure you will need to free (i.e., remove the four mounting screws), but not
disconnect, the Laminator Controller PCBA.

Step 1. Locate the Lower Cutter (front view, Front Frame removed).

Step 2. Disconnect the cutter plug at J21 and the sensor plug at J24 (arrows below).

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Step 3. Carefully slide the Lower Cutter out of its pressure-fit mount.

Step 4. Set the Lower Cutter aside.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.33 Laminate Ribbon Rollers (Top & Bottom)

Note • This procedure uses Spares Kit #

105936G-523: KIT, ROLLER, RIB, LAMINATE

Step 1. Locate the Laminate Rib Roller (top and/or bottom); circled below.

Step 2. Remove the corresponding Cutter(s); see Section 6.6.32 on page 342.

Step 3. Remove the Laminate Rib Roller(s).

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.34 Card Entry Sensor Cable Assembly

Note • This procedure uses Spares Kit #

105936G-532: KIT, CBL ASSY, SENSOR CARD, ENTRY

Step 1. Locate the Card Entry Sensor Cable Assembly; circled below.

Step 2. With a TORX T10 driver, remove the screw holding the Sensor in place.

Step 3. Carefully slide the Sensor and Cable straight out of the Laminator.

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 6: Replacement Procedures for the Laminator
Procedures:

6.6.35 Card Laminator Sensor Cable Assembly

Note • This procedure uses Spares Kit #

105936G-533: KIT, CABLE ASSY, SENSOR CARD, LAM

Step 1. Locate the Card Laminator Sensor Cable Assembly; circled below.

Step 2. With a TORX T10 driver, remove the screw holding the Sensor in place.

Step 3. Carefully slide the Sensor and Cable straight out of the Laminator.

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Procedures:

6.6.36 Card Exit Sensor Cable Assembly

Note • This procedure uses Spares Kit #

105936G-534: KIT, CBL ASSY, SENSOR CARD, EXIT

Step 1. Locate the Card Exit Sensor Cable Assembly; circled below.

Step 2. With a TORX T10 driver, remove the screw holding the Sensor in place.

Step 3. Carefully slide the Sensor and Cable down and out of the Laminator.

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Procedures:

6.6.37 Door Sensor Cable Assembly

Note • This procedure uses Spares Kit #

105936G-537: KIT, CBL ASY, SNSR REFL, LAM, DOOR

Step 1. With a small Flat-blade screwdriver, release the locking tab (circled below) to free
the Door Sensor.

Step 2. Cut the associated cable ties, disconnect J9 from the Laminator Controller PCBA,
and remove the Door Sensor Cable Assembly.

Step 3. Set the Door Sensor Cable Assembly aside.

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 7
Preventive Maintenance

Caution • PROTECT YOUR FACTORY WARRANTY!

The recommended maintenance procedures must be performed to maintain the factory

N

warranty. Other than the recommended cleaning procedures described in this manual,
allow only Zebra authorized technicians to service the Printer.

NEVER loosen, tighten, adjust, or bend, etc., a part or cable inside the printer.

NEVER use a high-pressure air compressor to remove particles from the printer.

7.1 Cleaning the Printer

NOTE • To order a Printer Cleaning Kit, go to http://www.zebra.com/supplies.

Clean the Printer using the Cleaning Cards provided in the Printer Cleaning Kit specified in
the Note above. The regular use of these cards will clean and maintain important parts of the
printer, including the Printhead, Transport Rollers, and optional Magnetic Encoder Station.

Printer usage (total number of cards printed and total number of cards laminated) can be found
on the printer’s Properties, Device Information tab. To access the Device Information tab,
select Start > Devices and Printers. Right click on the Zebra ZXP Series 7 Card Printer
listing, and select Printer properties > Device Information.

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 7: Preventive Maintenance
Cleaning the Printer

7.1.1 When to Clean

Cleaning requirements vary according to the environment. For a typical office environment,
the recommended cleaning cycle is:

• Card Path cleaning should occur every 5,000 cards.

• Feeder Path cleaning should occur every 5,000 cards.

7.1.2 Initiate the Cleaning Process

Step 1. Press the MENU button on the Operator Control Panel (OCP). The OCP will display
the Main Menu.
Step 2. Scroll through the Main Menu, and select Advanced Settings. The OCP will display
the Advanced Settings Menu.
Step 3. Scroll through the Advanced Settings Menu, and select Clean Printer. The OCP will
display the Clean Printer Menu.

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 7: Preventive Maintenance
Cleaning the Printer

7.1.3 Clean the Card Path

NOTE • Do not use previously used cleaning cards.

Step 1. From the Clean Printer Menu, select CLEAN CARD PATH.
Step 2. Use the Printer Cleaning Card, and follow the OCP instructions.
Step 3. Open print cover, open ribbon drawer, remove ribbon, and then press Next.
Step 4. Close ribbon drawer, close print cover, and then press Next.
Step 5. Insert long cleaning card in Manual Feed Slot, and then press Clean.

Step 6. Wait while cleaning process completes. The card will eject through same slot.
Step 7. Flip the cleaning card, reinsert it in the Manual Feed Slot, and then press Clean.
Step 8. Wait while cleaning process completes. The card will eject through same slot.
Step 9. Replace the ribbon, and press Next.
Step 10. The OCP will return to the Clean Printer Menu.

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 7: Preventive Maintenance
Cleaning the Printer

7.1.4 Clean the Feeder Path

NOTE • Do not use previously used cleaning cards.

Step 1. From the Clean Printer Menu, select CLEAN FEEDER.

Step 2. Use the Feeder Cleaning Card, and follow the OCP instructions.
Step 3. Remove all cards from feeder cartridge, and then press Next.
Step 4. Insert short cleaning card in top slot, then press Clean.
Step 5. Press yellow button in feeder cartridge to release pusher plate, and then press Next.

Step 6. Wait while cleaning process completes. The card will eject through same slot.
Step 7. Flip the cleaning card, reinsert it in top slot, and then press Clean.
Step 8. Wait while cleaning process completes. The card will eject through same slot.
Step 9. The OCP will return to the Clean Printer Menu.
Step 10. Load the cards back into the feeder cartridge.

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 7: Preventive Maintenance
Cleaning the Printer

7.1.5 Polish the Printhead

NOTE • Use is password protected and limited to Zebra-authorized service personnel.

The Advanced Cleaning button in the Clean Printer section of the ZXP Toolbox provides
access to printhead polishing. When printhead polishing is enabled in the ZXP Toolbox,
printhead polishing can be done via the OCP.

Step 1. Enable printhead polishing in the ZXP Toolbox

Step 2. Press the MENU button on the Operator Control Panel (OCP). The OCP will display
the Main Menu.
Step 3. Scroll through the Main Menu, and select Advanced Settings. The OCP will display
the Advanced Settings Menu.
Step 4. Scroll through the Advanced Settings Menu, and select Clean Printer. The OCP will
display the Clean Printer Menu.
Step 5. Open the printer cover and ribbon drawer, remove the ribbon, and press Next.
Step 6. Close the ribbon drawer and printer cover, and press Next.
Step 7. Insert a Polishing Card (grit up) in the Manual Feed Slot, and press Clean.

Step 8. Wait until the cleaning process completes. The card will be ejected through the
same slot.
Step 9. Replace the ribbon, and press Next to return to the Advanced Settings Menu.

NOTE • Card Path Cleaning (Page 353.) is recommended after printhead polishing to remove any
loose debris from the printer.

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Cleaning the Laminator

7.2 Cleaning the Laminator

NOTE • To order a Laminator Cleaning Kit, go to http://www.zebra.com/supplies.

7.2.1 When to Clean

Cleaning requirements vary according to the environment. For a typical office environment,
the recommended cleaning cycle is:

• Laminator Card Path cleaning should occur every 5,000 cards.

• Laminator Roller cleaning should occur every 5,000 cards.

• Laminator Oven (Heater Rollers) cleaning should occur every 20,000 cards.
.

7.2.2 Initiate the cleaning process:

NOTE • To avoid a long wait while the heated rollers cool to 60oC, perform cleaning before the
rollers heat; i.e., when first turned on and the rollers are still cold.

Step 1. Press the MENU button on the Operator Control Panel (OCP). The OCP will
display the Main Menu.
Step 2. Scroll through the Main Menu, and select Advanced Settings. The OCP will
display the Advanced Settings Menu.
Step 3. Scroll through the Advanced Settings Menu, and select Clean Printer. The OCP
will display the Clean Printer Menu.

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7.2.3 Clean the Laminator Card Path

Step 1. From the Clean Printer Menu, select CLEAN LAM CARD PATH to run the Laminator
Cleaning Routine; and follow the OCP instructions.
Step 2. Wait until the oven temperature falls below 60oC.
Step 3. If you have laminate installed, open the laminator covers, remove the laminate (top
and bottom cassettes), and close the covers.
Step 4. Open the print cover (to raise the printhead), then press Next.
Step 5. Insert the Laminator Cleaning Card into the Manual Feed Slot, then press Clean.

Step 6. Wait while the cleaning process completes.

Step 7. The card will be ejected into the output hopper.
Step 8. The OCP will return to the Clean Printer Menu.
Step 9. If you want to clean the Laminator Media Rollers at this time, see Clean the
Laminator Media Rollers on page 358; otherwise, do Step 10.
Step 10. Open the laminator covers, install the laminate (top and bottom spools), and close
the covers.
Step 11. Close the print cover.

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7.2.4 Clean the Laminator Media Rollers

Step 1. From the Clean Printer Menu, select CLEAN LAM ROLLERS to run the Laminator
Media Roller Cleaning Routine; and follow the OCP instructions.
Step 2. Wait until the oven temperature falls below 60oC.
Step 3. Open the laminator covers, remove the laminate (top and bottom cassettes), and
leave both covers open.
Step 4. Prepare a Cleaning Swab for use.
Step 5. Locate the top roller (circled below) for the upper cassette.

Step 6. When ready, press Next; and then press Top.

Step 7. Clean the top media roller by moving the swab tip side-to-side until roller stops
turning. Only use moderate pressure.

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Step 8. For dual-sided laminators only: Locate the bottom roller (circled below) for the
lower cassette.
Step 9. Prepare a second Cleaning Swab.
Step 10. Locate the bottom roller (circled below) for the lower cassette.

Step 11. When ready, press Bottom.

Step 12. Clean the bottom media roller by moving the swab tip side-to-side until the roller
stops turning. Only use moderate pressure.
Step 13. Press Exit to conclude the laminator rollers cleaning process.
Step 14. The OCP will return to the Clean Printer Menu.
Step 15. Install the laminate (top and bottom spools), and close the covers.

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7.2.5 Clean the Laminator Oven (Heater Rollers)

Step 1. From the Clean Printer Menu, select CLEAN LAM OVEN; and follow the
OCP instructions.
Step 2. Wait until the oven temperature falls below 60oC.
Step 3. Open the laminator covers.
Step 4. Remove the four thumb screws (circled below) holding the Heater Assembly
in place.
Step 5. Slide the Heater Assembly out of the Laminator (arrow below).

Caution • For the next step, you may have to wait until the Heater Assembly can be
handled comfortably.

Step 6. When ready, press Next.

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Step 7. Prepare the Laminator Hot Roller Cleaning Card for use.
Step 8. Insert the cleaning card between the heater rollers (arrow below).

Step 9. Pull the card all the way through the Heater Assembly.

Step 10. Remove the card from the Heater Assembly.

Step 11. Turn the card over, and repeat Step 8, Step 9, and Step 10.
Step 12. Press Next to conclude the laminator oven cleaning process.
Step 13. The OCP will return to the Clean Printer Menu.

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Step 14. Reinstall the Heater Assembly.

a. Remove the Thumb Drive Tool (circled below).

b. While carefully sliding the Heater Assembly into place, use the Thumb Drive
Tool to slowly rotate the gears counterclockwise (dashed arrow) until the gears
mesh and the Heater Assembly seats properly.

c. Install and tighten the four thumb screws removed in Step 4.

Step 15. Close the laminator covers.

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Dual Cleaning Cartridge

7.3 Dual Cleaning Cartridge

Important • It is recommended that you replace the Dual Cleaning Cartridge rollers every
time you install a new ribbon.

Two new card cleaning rollers are included with each ribbon or may be purchased separately.
To order additional rollers, go to http://www.zebra.com/supplies.

Installation of the Dual Cleaning Cartridge is described in Installing the Dual Cleaning
Cartridge on page 29 and is not repeated in detail here.

7.4 Manual Feed Cleaning Cassette

Important • It is recommended that you replace the Manual Feed Cleaning Cassette roller
every 5000 cards

Manual feed card cleaning rollers must be purchased separately. To order additional rollers, go
to http://www.zebra.com/supplies.

Installation of the Cleaning Cassette is described in detail in Installing the Cleaning Cassette
on page 31 and is not repeated here.

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ZXP Series Toolbox

8.1 Introduction
Important • Use of the ZXP Series Toolbox is intended only for advanced users and
system administrators.

The ZXP Series Toolbox provides advanced configuration capabilities and tools to manage the
operation of the printer. Note that the ZXP Series Toolbox works in conjunction with the
printer driver.

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Access

8.2 Access
To access the ZXP Series Toolbox from the printer driver, select Start > Devices and Printers.
Then right-click on the Zebra ZXP Series 7 Card Printer listing, and select Properties >
Device Information. Click on the ZXP Toolbox button (circled below).

The ZXP Series Toolbox can also be accessed via Start > All Programs > Zebra ZXP Series 7
Card Printer > ZXP Toolbox.

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Information

8.3 Information
8.3.1 Printer
Printer information cannot be edited or changed by the user; however, this information may be
useful for Zebra trained and certified personnel in diagnosing or evaluating printer status.

• Status shows the current operational state of the Printer; e.g., Ready, Offline, etc.

• Firmware and Driver lists the versions of the Firmware, Laminator, MAB, and
Laminator MAB and the version of the Driver.

• Other shows the Interface, the Laminator serial number, the Printer serial number, and
Available Memory.

• Options shows the options installed -- Magnetic encoding, Contact smartcard, Contactless
smartcard, and Laminator type.

• Network Configuration information includes the IP address, Gateway, Subnet mask, and
MAC address.

• OCP shows the Language displayed in the Operator Control Panel and the LCD contrast
level selected.

• Odometer shows the number of Cards printed and the number of Printhead lines printed.

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8.3.2 Printer Sensors

Printer Sensors information cannot be edited or changed by the user; however, this information
may be useful for Zebra trained and certified personnel in diagnosing or evaluating printer
sensor status.

• Sensor States displays “live” sensor states.

• Sensor Values displays “live” sensor values.

• Ribbon Take-up Motor lists various electrical characteristics of the motor.

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8.3.3 Media
Media characteristics cannot be edited or changed by the user; however, this information may
be useful for Zebra trained and certified personnel in diagnosing or evaluating media status.

• Ribbon Details include Type, Initial size, Description, and Images remaining.

• Top Laminate Details include Type, Initial size, Description, and Patches remaining.

• Bottom Laminate Details include Type, Initial size, Description, and Patches remaining.

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8.3.4 Laminator
Laminator information cannot be edited or changed by the user; however, this information
may be useful for Zebra trained and certified personnel in diagnosing or evaluating
laminator status.

• Status information includes Status, Warnings, and Faults; Top surface and Bottom surface
temperatures; and Line Voltage.

• Sensors shows the state of each laminator sensor.

• Odometer shows Total up time, Top bulb on time, Bottom bulb on time, the number of
Cards processed, and the number of Cards laminated.

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Configuration

8.4 Configuration
8.4.1 Job Log

Note • Access to this feature is controlled via Advanced Security > Security Roles.

The Job Log is a utility that builds a database of card transactions in the printer’s host
computer. The Job Log records the data encoded on the card’s magnetic stripe, together with
date, time, and the printer’s serial number.

The data set can be uploaded at any time to a central archive, thus providing a means for
security officers to validate a card by comparing it with tamper-proof real data.

• Enable logging - If this box is checked, the logging feature is enabled.

• Log File Definition - Choose one of the following options:

- If the “Create new log file each day” box is not checked, the data is saved to a log file
of your choice (Filename).

- If the “Create new log file each day” box is checked, the data is saved to log file
ZXPLog with the day’s date.

In addition to the Filename, you may wish to enter a special field Separator Character. The
default field Separator Character is the “|” character.

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• Log File Contents - The Log File Contents group selects the data to be logged in the file
you specified above. The data will be logged in the order displayed on the screen, each
field being separated by the character specified in the Logfile Definition, Separator.

Log File Contents selections include:

- Time: Logs the time a which the card was sent to the printer in the HH:MM:SS
format. The 24-hour clock is used, so 13:00:00 = 1:00 pm, and 05:00:00 = 5:00 am.

- Date: Logs the date the card was sent to the printer in the YY:MM:DD format.

- Printer serial number: Logs the serial number of the printer that printed the card.

- Static text: Adds to the record text in the box at right, 16 characters maximum.

- IP address: Logs the IP address of the PC that sent the card to the printer.

- Magnetic Track 1, 2, 3 Data: Logs the data sent to the printer to be encoded on
the card’s magnetic stripe.

- Application will send data with “~L=xxx” TextOut: Allows third-party

applications to send data to be logged in much the same way as they would send
magnetic data.

- Spooler job number: Logs the number which the card print job was assigned in the
Windows print spooler.

- User name: Logs the username of the person submitting the card print job.

- ZML Job ID: Logs the UUID; or, in a Windows environment, the GUID.

The Save Job Log Settings button saves the Job Log settings.

The Save Printer Log Files button creates the following XML Log Files:

- GetLogCleanHistory.xml
- GetLogErrors.xml
- GetLogEventHistory.xml
- GetLogServiceHistory.xml

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8.4.2 Save/Restore

Note • Access to this feature is controlled via Advanced Security > Security Roles.

When you set up a printer, you should save the printer and driver configuration settings; then,
when you restore or add additional printers, you can use the saved configuration to ensure
configuration consistency.

Note that the Saved/Restored Settings (circled below) are for the Printer only.

• The Save button saves the Driver Settings and/or Printer Settings in an XML file format.

- The printer configuration settings are stored as P_<filename>

- The driver configuration settings are stored as D_<filename>

• The Restore button restores the Driver Settings and/or Printer Settings.

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8.4.3 Firmware and Lookup Tables

Note • Access to this feature is controlled via Advanced Security > Security Roles.

The Firmware and Lookup Tables screen allows you to install firmware and check for
firmware updates. This screen also allows you to download and select custom
Lookup Tables.

Caution • Do not turn power OFF while the printer is downloading and configuring the
new firmware.

• Select Firmware to Download: Use this option to install the firmware downloaded from
the Zebra web site at http://zebra.com under Support & Downloads.

1. Click the Download button.

2. From the Browse window, locate the downloaded firmware (BIN file type); and click
the Open button.
3. Read the ZXP Toolbox caution message. If you are satisfied with the download, click
the OK button to install the firmware; otherwise, click the Cancel button to abandon
the firmware installation.

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• Check Firmware Updates: To use this option, you must have an internet connection.

1. Click the Check Updates button; then enter the Server name, User name, and
Password in the Ftp Login pop-up; and click the OK button.
2. Observe the firmware update file(s) displayed in the Filename listing; then select the
desired update file from the list; and click the Download File button.
3. As the file is downloaded, observe the % complete bar.
4. Click the OK button when the Download completed pop-up appears.
5. Read the ZXP Toolbox caution message. If you are satisfied with the download,
click on the OK button to install the firmware; otherwise, click the Cancel button to
abandon the firmware installation.

• Lookup Tables: A Look-Up Table (LUT) is used to transform a range of input colors
into a range of output colors. Use this Toolbox option to save and install LUTs, either
Default or Custom.

To save the current LUT, either Default or Custom:

1. Click on the Save Installed LUT to Host button.

2. From the Browse window, name the LUT, and specify the desired saved-file ___location
e.g., C:\ProgramData\ZXP Series 7\LUTs.
3. Click on the Save button.

To install a Custom LUT:

1. Click on the Custom LUT radio button.

2. Click on the Download selected LUT button.
3. From the Browse window, locate and select the Custom LUT; e.g.,
C:\ProgramData\ZXP Series 7\LUTs\ <filename >.
4. Click on the Open button.
5. Click the OK button when the LUT installed successfully pop-up appears.

To install/reinstall the Default LUT:

1. Click on the Default LUT radio button.

2. Click on the Download selected LUT button.
3. Click the OK button when the LUT installed successfully pop-up appears.

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8.4.4 Printer Settings

The Printer Settings screen allows you to change the OCP settings, set the network
configuration parameters, change print performance settings, adjust the print offset and image
fill, and change the printhead serial number and resistance.

Note • Access to Print Adjustment and Print Head options is controlled via Advanced
Security > Security Roles.

• OCP: This section allows you to change the Language displayed in the Operator Control
Panel (English, French, Spanish, German, Portuguese, or Italian) and adjust the LCD
Contrast level selected (the level ranges from 20 to 50).

• Network Configuration: This section allows you to change the various network
configuration parameters (DHCP, SNMP, IP address, Gateway, and Subnet mask). Note
that the MAC address cannot be changed.

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• Print Performance Setting: Performance options from the dropdown menu include:

- No error recovery (None): The printer provides high throughput with a hands-off
error recovery policy. This allows the host to have full control over how failed jobs
are retried, if at all. In this mode, there can be more than one job in the system at any
time. If there is any job in the system (i.e., printer or laminator) and an error occurs,
the job will not be automatically retried by the system after the error is cleared. In
addition, jobs already in the printer that were sent after the job that had the error are
aborted. Jobs ahead of the one with the error are not affected and are allowed to
proceed to completion if possible. This mode would be used in applications requiring,
for example, uniquely-serialized cards and having no automated means of validating
the mating of a job to a card.

- Standard error recovery (Medium): The printer provides high throughput with a
reasonable-effort error recovery policy. In this mode, there can be more than one job
in the system at any time. If a job suffers an error it will be automatically retried after
the error is cleared. Card jams, for example, are handled this way – after the printer is
opened, the jammed card removed, and the printer closed and re-initialized, a fresh
card is fed and the job reprocesses without host intervention. Jobs ahead of the job
that had the error are not affected and are allowed to proceed to completion if
possible. Jobs behind the one with the error are paused until the error is cleared, and
then they also proceed to completion.

- Full error recovery (High): The printer provides reduced throughput so that it can
recover any job automatically. In this mode, only one job is allowed into the system at
a time; and if a job errors anywhere in the system, the job will automatically be retried
by the system after the error is cleared.

• Print Adjustment

Adjust the Print X offset and Print Y offset sliders to position the image on the card. The
Print X offset slider values range from -150 to +150. The Print Y offset slider values range
from -300 to +300. Note that changing the offset can cause the printer to print off the edge
of the card and cause ribbon ripping.

Image Fill is used to resize the image (smaller or larger) to best fit the card.

• Print Head (Access is controlled via Security Roles)

- Serial Number: When you replace the printhead, change this field to match the serial
number of the replacement printhead.

- Resistance (Minimum: 2200 ohms, Maximum: 3300 ohms): When you replace the
printhead, change this value to match the resistance of the replacement printhead.
Note that the values must be the same for the algorithms to work properly. This value
is located on a sticker on the printhead; e.g., R = 3000.

The Save Settings button saves any changes you have made to this screen.

The Advanced Setting button provides access to service-related tests and adjustments; see
following pages for details.

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Important • Access to the Advanced Settings section is password protected and limited to
Zebra-authorized service personnel. The password will be given during training, or contact
Zebra Technical Support.

1. Click on the Advanced Settings button.

2. Read the ZXP Toolbox pop-up.

3. Click the OK button.

4. Enter the Password.

5. Click the OK button.

If you entered the correct password, you will be taken to the Advanced Settings section
on Page 379.

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Advanced Settings

Note • These tabs are password protected via the Advanced Settings selection. The password
will be given during training, or contact Zebra Technical Support.

The Advanced Settings section includes the following tabs:

• Diagnostics Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380

• Mechanical and Power Adjustment Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
• Laminator Adjustments Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
• Native Debug Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
• Advanced Configuration Request Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
• Smart Card Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

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Diagnostics Tab

The Diagnostics screen provides troubleshooting capabilities to assist Service Technicians in

analyzing printer problems.

To run a diagnostic function:

1. Locate the Function (Motor, Calibration, Fan, etc.).

2. Select the Command from the associated dropdown menu.
3. Select any additional options.
4. Click the Run (or On) button. Note that each On button has a corresponding
Off button; no options are available.
5. Follow any special instructions.
6. Observe the printer action and associated Status window. Note that if an error occurs
while executing the command, an error message will be displayed.
7. Close the status window when complete.

Click the Exit button to close Advanced Settings and return to the main Toolbox.

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Diagnostic Tab Details:

• Motor: These diagnostic commands allow you to test each motor’s functionality. For
all commands except ribbon takeup, direction is selectable (forward or reverse) and speed
is variable (100 Rpm -1500 Rpm).

- card feed: Turns on/off the card feed motor (remove the card hopper prior to
running this option).
- head lift: Enables or disables the head lift motor.
- engine card x: Enables or disables the engine card x motor.
- flipper x: Enables or disables the flipper x motor.
- options x: Enables or disables the options x motor.
- options mag x: Enables or disables the options mag x motor.
- smart card: Drives the smartcard contact array into position.
- ribbon: Advances the color ribbon (remove the ribbon prior to running this option).
- ribbon takeup: Takes up used color ribbon (remove ribbon prior to running this
option). Note that clicking on Warm up button warms up the ribbon takeup motor
prior to torque calibration.

• Fan: Enables or disables the printhead fan.

• Other Commands: These commands are used to validate the system operation for
troubleshooting purposes.

- initialize:

• flipper: initializes the flipper.

- flipper_rotate:

• flipper to home: Rotates the flipper to the home position.

• flipper to hopper: Rotates the flipper to the feeder.
• flipper to reject: Rotates the flipper to reject bin.
• flipper to 180: Rotates the flipper 180 degrees.

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• Transport: These commands move cards throughout the transport path to ensure/confirm
proper operation of card motors, transport rollers, and sensors.

- hopper:
• flipper: Transfers a card from the card input hopper to the flipper (place a card in
the hopper prior to running this option).
- atm:
• flipper: Transfers a card from the Manual Feed Slot to the flipper (place a card in
the Manual Feed Slot prior to running this option).
- options:
• flipper: Transfers the card from the options module to the flipper.
- flipper:
• options: Transfers the card from the flipper to the options module.
• reject: Transfers the card from the flipper to the reject bin.
• output: Transfers the card from the flipper to the card output hopper.

• Calibration

- tricolor: Determines the ribbon tricolor sensor calibration parameters (Red, Green,
and Blue). Before running this calibration, remove the ribbon.

• Sensor: These commands enable or disable the various sensors.

- door: Use this command to enable or disable the door sensor. This command is
not intended be used as a stand-alone command, but as one step of a multi-step
calibration process.
- contactless: For use by any agencies that perform radio/EMI certification testing.
- rfid 0: For use by any agencies that perform radio/EMI certification testing.
- rfid 1: For use by any agencies that perform radio/EMI certification testing.

• Panel: These commands advance the selected panel (yellow, magenta, cyan, black, or
overlay) to a position in front of the printhead thereby ensuring functionality of the
Ribbon Take-up Sensor, Ribbon Payout Sensor, and Tricolor Sensor.

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Mechanical and Power Adjustment Tab

This screen allows you to make selected mechanical and power adjustments.

• Power Adjustment (Minimum: 80%, Maximum: 120%) allows you increase or decrease
the relative temperature applied to the specified panel; i.e., Yellow, Magenta, UV back,
etc. Note that 100% is the default value.

Power adjustments are percentages of the pre-determined fixed energy value assigned to
each color panel. As the value goes up, the density of that color panel will increase; and, as
the value goes down, the density of that color panel will decrease. Note that if the relative
power levels for each color panel are adjusted individually by differing amounts, the color
balance of full color images will change.|

• Mechanical Adjustment:

Ribbon offset -- This adjustment determines the distance from the printhead dot line
to the center of the gap interrupt sensor used to sense the ribbon sync mark (or resin
black panel). This adjustment can be used to control the offset from the start of a color
panel to where the printing begins. To increase this offset, make the sensor adjustment
larger; and vice versa. (Minimum: 1 mm, Maximum: 12 mm).

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• Image Trim

Mono -- This slider adjustment allows you to stretch or compress the monochrome
image independently of the color ribbon settings.

K Panel -- This slider adjustment allows you to stretch or compress the K panel
image independently of the YMC panel settings thereby providing precision
placement of the K panel image relative to the YMC image.

The Restore Factory Defaults button resets the mechanical and power adjustments to the
factory default settings.

The Backup NVM button saves the printer settings stored in non-volatile memory to your
computer.

The Restore NVM button restores the printer settings stored on your computer to your
printer’s non-volatile memory.

The Apply button applies and saves the settings. Advanced Configuration remains open.

Click on the Exit button to close Advanced Settings and return to the main Toolbox.

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Laminator Adjustments Tab

This tab is used for making minor adjustments to laminate length and/or position, adjust
temperature and speed, and saving the changed settings to laminator memory.

• Roller Temperature Offset (oC) is adjusted via two sliders, one for the top roller and one
for the bottom roller. The range is -10 to 10, in increments of 1, for both adjustments.
Click the Send button to save the adjustment.

• Lamination speed Offset (mm/sec) allows you increase or decrease the relative
lamination speed. The range is -8 to 8, in increments of 0.5. Click the Send button to save
the adjustment.

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• Margins and patch placement (mm):

This adjustment allows you to set the margins of the laminate (i.e., size the patch) and
position the patch on the card.

Card

LEM TEM

Patch placement adjust

- Top Leading Edge Margin can be adjusted from -2 to 2. Note that this adjustment
positions the leading edge of the laminate with respect to the leading edge of the card.

- Bottom Leading Edge Margin can be adjusted from -2 to 2. Note that this
adjustment positions the leading edge of the laminate with respect to the leading
edge of the card.

- Trailing Edge Margin (both) can be adjusted from -3 to 3. Note that adjusting the
trailing edge margin increases or decreases the length of both laminate patches.

- Patch Placement Adjust (both) can be adjusted from -3 to 3. Note that this
adjustment positions the laminate with respect to both top and bottom of the card.

Click the Send button to save the adjustment(s).

• Misc Commands

- The Restore Factory Defaults button restores this tab’s factory default values.

- The Media Calibration button calibrates the laminate sensor to see the leading
edge of the laminate. That data is used to determine the patch length and placement
on the card. Install full clear laminate before performing this adjustment.

The Read All Parameters from EEPROM button loads all the laminator parameters from
the EEPROM.

The Save All Parameters to EEPROM button saves all the laminator parameters to
the EEPROM.

Click the Exit button to close Advanced Settings and return to the main Toolbox.

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Configuration

Native Debug Tab

The Native Debug tab allows you to send commands to the LAMINATOR.

This tab is intended for experienced users who have detailed knowledge of the Laminator
Control Board (LCB) debug commands. To use this tab:

1. Press the Start button first, BEFORE you send a command.

2. Type the command in the Command line.
3. Press the Send button, and observe the response.
4. Press the Stop button when done sending commands.

For example: A few commands that you could use are LM - displays the LCB lamination
mode, RM - displays the LCB run mode, UPTIME - displays the LCB odometer;
TLT - displays the top laminator temperature; and VER - displays the LCB firmware
version, CPLD version, and top/bottom temperature sensor version.

To read the top laminator temperature, click the Start button; type TLT in the Command line;
click the Send button, and then click the Stop button.

Contact Zebra Technical Support for the complete list of the commands.

Click on the Exit button to close Advanced Settings and return to the main Toolbox.

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Configuration

Advanced Configuration Request Tab

Note • This tab is password protected via the Advanced Settings selection. The password will
be given during training, or contact Zebra Technical Support.

This screen (intentionally not shown) allows you to select secure action commands to alter the
printer’s advanced configuration.

1. To use this tool, contact Zebra Level 3 Technical Support for assistance in changing
advanced configurations.
2. E-mail the XML file to the address given by Zebra Level 3 Technical Support.
3. Once in contact with Zebra Level 3 Technical Support, they will instruct you on how
to do an e-mail exchange of a secure one-time XML file that will allow you to make
one-time printer secure configuration changes.

Click on the Exit button to close Advanced Settings and return to the main Toolbox.

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Configuration

Smart Card Tab

Note • This tab is password protected via the Advanced Settings selection. The password will
be given during training, or contact Zebra Technical Support.

This screen allows you to enable / disable the Smart Card.

Click on the Exit button to close Advanced Settings and return to the main Toolbox.

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Cleaning

8.5 Cleaning
8.5.1 Clean Printer
The Clean Printer screen gives you the option to clean the printer via the Toolbox; refer to
Section 7, for cleaning via the OCP.

• Card Path: The Card Path cleaning interval can be adjusted depending on the printer
operation environment. The default cleaning interval is every 5,000 cards. A running
card count is displayed indicating the number of cards printed since last cleaning. Click
on the Clean button so start the cleaning process. For details, see Clean the Card Path
on page 353.

• Feeder Path: The Feeder Path cleaning interval can be adjusted depending on the
printer operation environment. The default cleaning interval is every 5,000 cards. A
running card count is displayed indicating the number of cards printed since last cleaning.
Click on the Clean button so start the cleaning process. For details, see Clean the Feeder
Path on page 354.

The Restore Defaults button resets the cleaning interval settings to the factory defaults.

The Save button saves any changes you have made to this screen.

The Advanced Clean... button provides access to the printhead polishing function. Use is
password protected and limited to Zebra-authorized service personnel; see next page
for details.

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Cleaning

Advanced Cleaning

Note • Use of Advanced Cleaning is password protected and limited to Zebra-authorized

service personnel.

The Advanced Cleaning screen gives you the option to polish the printhead via the Toolbox.

• Configure Printhead Polishing: Click on the appropriate to radio button to enable or

disable printhead polishing. Click on the Save button to save the setting. When enabled,
printhead polishing can also be done via the OCP; see Section 7 for details.

• Polish Printhead: Printhead polishing should occur every 5,000 cards. A running card
count is displayed indicating the number of cards printed since last polishing. Click on the
Clean button so start the polishing process; see next page for details.

• Pre-warning Interval: Used to set a threshold to alert the user that polishing will be
required soon; e.g., after the next 250 cards have been printed.

The Restore Defaults button resets the cleaning interval settings to the factory defaults.

The Save button saves any changes you have made to this screen.

Click on the Close button to return to the Clean Printer screen.

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Cleaning

Printhead Lapping
When you click on the Clean button, instructions will appear in the following sequence:

1. Open the printer cover and ribbon drawer, remove the ribbon, and then click the
Next button.
2. Close the ribbon drawer and printer cover, and then click the Next button.
3. Insert a Lapping Card (grit up) in the Manual Feed Slot, and click the Clean button.
4. Wait until the cleaning process completes. The card will be ejected through the
same slot.
5. Observe the message, Printhead cleaning has been completed successfully.
6. Click on the Close button to conclude the printhead cleaning process.
7. Reinstall the ribbon.

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Cleaning

8.5.2 Clean Laminator

The Clean Laminator screen gives you the option to clean the laminator via the Toolbox; refer
to Section 7, for cleaning via the OCP.

• Laminator Card Path cleaning interval can be adjusted depending on the printer
operation environment. The default cleaning interval is every 5,000 cards. A running card
count is displayed indicating the number of cards printed since last cleaning. Click on the
Clean button so start the cleaning process. For details, see Clean the Laminator Card Path
on page 357.

• Laminator Roller cleaning interval can be adjusted depending on the printer operation
environment. The default cleaning interval is every 5,000 cards. A running card count is
displayed indicating the number of cards printed since last cleaning. Click on the
Clean button so start the cleaning process. For details, see Clean the Laminator Media
Rollers on page 358.

• Laminator Oven (Heater Rollers) cleaning interval can be adjusted depending on the
printer operation environment. The default cleaning interval is every 20,000 cards. A
running card count is displayed indicating the number of cards printed since last cleaning.
Click on the Clean button so start the cleaning process. For details, see Clean the
Laminator Oven (Heater Rollers) on page 360.

The Restore Defaults button resets the cleaning interval settings to the factory defaults.

The Save button saves any changes you have made to this screen.

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Print Test Card

8.6 Print Test Card

1. View the Test Card Library. Use the scrollbar to view all the selections.

2. Set the front side:

a. Select (click on) a card from the Test Card Library.
b. Click the Set As Front button.
c. View the selected card in the Preview. Note that to remove the selected card from
the Preview, click the Set As Front button.
d. To change the selection, repeat Step a through Step c.

3. Set the back side: Same as Step 2, except click the Set As Back button.
4. When satisfied with your selection, click on the Print Sample Card button (circled
above) to print the sample card.

• The Print Configuration Test Card button provides printer configuration data on a card.

• The Reprint Last Card button sends a command to the printer to print the last card.

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Technology

8.7 Technology
8.7.1 Magnetic Encoding
The Magnetic Encoding screen allows the user to test various magnetic encoding options. For
more information on magnetic encoding, refer to Appendix C.

• Settings

Track 1, Track 2 and Track 3 settings will be enabled only for Custom mag
encoding format.

Note that this section is grayed our for ISO mode.

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Technology

• Encode/Read Data

Note • Access to this feature is controlled via Advanced Security > Security Roles.

Coercivity: Select either High or Low.

Track selection:

- For reading: Click the checkboxes to select Track 1, Track 2, and/or Track 3; click the
Read button, and validate the data read.

- For encoding: Click the checkboxes to select Track 1, Track 2, and/or Track 3; enter
the data to be written; and click the Encode button.

The Printing Preferences button takes you to Printing Preferences used to set selected driver
configuration parameters; see Changing the Printing Preferences on page 77.

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Technology

8.7.2 Smart Card (contact and contactless encoding)

The Smart Card screen allows the user to test various smart card encoding options. For more
information on smart card encoding, refer to Appendix D.

• Card Readers:

- Select the card reader from the drop-down menu.

- Card Option: Select either Contact or Contactless.

• Card Types:

- Select the appropriate card type from the drop-down menu.

- Place a card in the Feeder Cartridge, and click Feed Card button.

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Technology

• Card Types (continued):

- Input Data includes address, length, input, and PIN.

• Writing Data: Set the address, set the length, enter data in Input field, and click
the Write button.
• Reading Data: After writing data (above), click the Read button. “Read
successful” and the value read from the smart card will be displayed in the
Messages section.
• Click the Set PIN button to set the security code for the card.
• Click the Write Raw Data button to write “raw data” to a card.

- The Get ATR button returns the ATR (Answer To Reset) result from the card reader.
This is useful for identifying the type of smart card inserted into the printer.

- The Eject Card button ejects the card.

- Click the Show output as hex format checkbox to show the output in hex format
in Messages.

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 8: ZXP Series Toolbox
Advanced Security

8.8 Advanced Security

8.8.1 Configure Security
Important • To manage this Advanced Security section, you are required to be the
administrator of the computer or have administrative privileges.

• Toolbox Password

Enabling driver password protection prevents unauthorized persons from changing the
printer configuration settings. Access to various Toolbox screens can be selectively
disabled based on the Windows User Login.

The user will be prompted with this password when the Toolbox is launched.

- To enter a new password:

1. Enter the new password on the New password field. The password is case
sensitive, eight characters minimum.

2. Repeat the password in the Confirm password field.

3. Click the Apply button.

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Advanced Security

• Toolbox Password (continued)

- To change the password:

1. Enter your password in the Old password field.

2. Enter the new password in the New password and the Confirm password fields.
3. Click the Apply button.

- To deactivate password protection:

1. Enter your password in the Old password field.

2. Leave the New password and the Confirm password fields blank.
3. Click the Apply button.

• Last Print Job Options

- The Erase job data after transmission option erases the job data after it has been
transmitted to the printer.

- The Enable PRINT soft key in OCP option allows the print job to remain in memory
for multiple prints via the OCP.

The Save button saves the selection.

• Error Messages

Select the checkbox to suppress error message display from the driver.

• Passkey

The Enable Passkey button provides access to advanced security settings; i.e., Host
Authentication, Data Encryption, and Printer Lock Key; see next page for details.

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Advanced Security

Passkey

Important • Keep your pass-phrase in a secure ___location. If you forget it, you will not be able
to unlock your printer without assistance from Zebra.

The Enable Passkey button provides access to advanced security settings; i.e., Host
Authentication, Data Encryption, and Printer Lock Key.

The Printer passkey is generated from a security pass-phrase (see next page for details). It is
saved in the printer and is used to enable Host Authentication, Data Encryption, and Printer
Lock Key. Use this section to set the pass-phrase and enable secure communications.

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Advanced Security

Important • Keep your pass-phrase in a secure ___location. If you forget it, you will not be able
to unlock your printer without assistance from Zebra.

• To enter a new Pass-phrase:

1. Click the Enable Passkey button (circled previous page).
2. Observe the Printer Passkey window. The New/Change Pass-phrase and Host
Authentication and Data Encryption sections are enabled.

3. Click the Activate printer passkey checkbox.

4. Enter the new pass-phrase on the New pass-phrase field. The pass-phrase is case
sensitive, twenty characters minimum, spaces permitted.
5. Repeat the password in the Confirm pass-phrase field.
6. Click the Apply button.

• To change the Pass-phrase:

1. Enter your current pass-phrase in the Current pass-phrase field.

2. Enter the new pass-phrase in the New pass-phrase field and the Confirm
pass-phrase field.
3. Click the Apply button.

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Advanced Security

Host Authentication and Data Encryption:

• To access the Printer Keys Section:

1. Click the Keys button (circled below), enter the correct pass-phrase, and click OK.

2. Observe the Printer Keys window. Note that this window has two sections: Host
Authentication and Data Encryption.

3. Click the Enable radio buttons (arrows above) to enable the Host Authentication and
Data Encryption functionality.

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Advanced Security

• To set Host Authentication:

Note • The key should be 8 characters minimum. Note that the Key Strength field reflects the
strength of the key entered. Strength varies from Very weak to Very strong.

Click the Enter Key button, and enter the Host Authentication Key (either manually or
auto-generated), and click the Apply button. In the following example, the Auto
Generate Key was used.

• To set Data Encryption:

Note • The key should be 8 characters minimum. Note that the Key Strength field reflects the
strength of the key entered. Strength varies from Very weak to Very strong.

Click the Enter Key button, and enter the Data Encryption Key (either manually or
auto-generated), and click the Apply button. In the following example, the Auto
Generate Key was used.

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Advanced Security

8.8.2 Security Roles

Important • To manage this section, you are required to be the administrator of the local
computer or have administrative privileges.

Use this section to establish security roles; i.e., grant and restrict access to various ZXP Series
Toolbox features. The list of users in the drop-down menu (e.g., Guest, HelpAssistant, Local
User, localfix, etc.) is derived from the list of users on the system.

• To set security access roles:

1. Select a user from the drop-down menu.

2. Use the arrow buttons (>, >>, <, and <<) to make specific features available to or
restrict specific features from the selected user role.
3. When satisfied with the selection, click the Save button.

At the next log in, the user will only see, or have access to, the features previously granted.

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Print Viewer

8.9 Print Viewer

When a PRN file is printed, printer drivers are bypassed; but the print spooler is still required
since communication to the printer is via the print spooler. This diagnostic utility can be used
to ensure that your printer is working properly by isolating it from driver-related and issues.

Print PRN file

• To send a PRN file to the printer:

1. Click the Print button to print the default PRN file.

- or -

Click the Browse button to select and print a PRN file of your choice.

2. From the Browse window, locate and select the PRN file.
3. Click the Open button.
4. View the PRN file.
5. Click the Print button.

Successfully printing the PRN file indicates that the printer and data communications to
the printer are set up and configured properly.

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 APPENDIX A
Printer Configurations

The Part Number of a particular ZXP Series 7 Printer is shown on a label affixed to the
backplate (or rear enclosure) of the printer; that Part Number identifies the specific
configuration for that printer.

The chart on the next page shows the configurations that are available.

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 A: Printer Configurations

Printer Part Numbers

PART NUMBER DESCRIPTION

Z 7 _ - _ _ _ _ _ _ _ _ _ _ _ _ Base Unit
_ _ 1 - _ _ _ _ _ _ _ _ _ _ _ _ Single-Sided Printer
_ _ 2 - _ _ _ _ _ _ _ _ _ _ _ _ Dual-Sided Printer
_ _ 3 - _ _ _ _ _ _ _ _ _ _ _ _ Dual-Sided Printer with Single-Sided Laminator
_ _ 4 - _ _ _ _ _ _ _ _ _ _ _ _ Dual-Sided Printer with Dual-Sided Laminator
Smart Card Options
_ _ _ - 0 _ _ _ _ _ _ _ _ _ _ _ None
_ _ _ - A _ _ _ _ _ _ _ _ _ _ _ Contact Encoder + Contactless MIFARE
_ _ _ - E _ _ _ _ _ _ _ _ _ _ _ Contact Station
Mag Encoders
_ _ _ - _ 0 _ _ _ _ _ _ _ _ _ _ None
_ _ _ - _ M _ _ _ _ _ _ _ _ _ _ ISO HiCo/LoCo Mag S/W Selectable
Security Options
_ _ _ - _ _ 0 _ _ _ _ _ _ _ _ _ None
_ _ _ - _ _ A _ _ _ _ _ _ _ _ _ Enclosure Lock
Interface
_ _ _ - _ _ _ C _ _ _ _ _ _ _ _ USB and 10/100 Ethernet
Software/Kit
_ _ _ - _ _ _ _ 0 _ _ _ _ _ _ _ None
_ _ _ - _ _ _ _ D _ _ _ _ _ _ _ Media Starter Kit (includes: 1 YMCKO ribbon kit, 200 PVC cards)
Miscellaneous
_ _ _ - _ _ _ _ _ 0 0 0 _ _ _ _ None
_ _ _ - _ _ _ _ _ 0 0 G _ _ _ _ TAA Compliant
Country Code (others available)
_ _ _ - _ _ _ _ _ _ _ _ 0 0 _ _ None
_ _ _ - _ _ _ _ _ _ _ _ C N _ _ China
_ _ _ - _ _ _ _ _ _ _ _ J P _ _ Japan
_ _ _ - _ _ _ _ _ _ _ _ U S _ _ Americas Regional
_ _ _ - _ _ _ _ _ _ _ _ E M _ _ EMEA Regional
_ _ _ - _ _ _ _ _ _ _ _ A U _ _ Australia
_ _ _ - _ _ _ _ _ _ _ _ T W _ _ Taiwan
_ _ _ - _ _ _ _ _ _ _ _ A P _ _ Asia/Pacific
Custom Code
_ _ _ - _ _ _ _ _ _ _ _ _ _ 0 0 Reserved

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 Appendix B
Network Operations

Introduction
Card printers can be connected to an Ethernet network in three ways.

Printer Sharing
In printer sharing, the printer is connected locally to the host computer and configured to be
shared to other client computers. Client computers connect to the printer over the network
through the host computer.

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External Print Server

A stand alone device that acts as a server on the network specifically for receiving print jobs
and passing them to the printer. Client computers connect to the print server over a network.

Internal Print Server

Similar to an external print server, except the print server is integrated into the printer. This
removes the need for a separate power supply and separate device drivers. This is the simplest
way to network a printer.

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Setting Up a Network Printer

Use this procedure if you have already installed an ethernet printer on your system (refer
to Section 2), and you want to install a second ethernet printer on the network via the
Microsoft Add Printer Wizard.

Step 1. Click on the Start button, then select Devices and Printers.

Step 2. Observe the Devices and Printers window.

Step 3. Click on the Add a printer option in the Taskbar (arrow above).

Step 4. Observe the What type of printer do you want to install window.

Step 5. Select Add a local printer (arrow above), and click the Next button.

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Step 6. Observe the Choose a printer port window.

Step 7. Select the Create a new port radio button (1st arrow above).

Step 8. From the dropdown menu, select Zebra ZXP Series 7 Card ... (2nd arrow above).

Step 9. Click on the Next button.

Step 10. Observe the Port Name window.

Step 11. Enter the IP address of your printer in the Enter Printer IP Address text box
(circled above).

Step 12. Click on the OK button.

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Step 13. Observe the Install the printer driver window.

Step 14. Select the Manufacturer and the Printer (arrows above).

Step 15. Click on the Next button.

Step 16. Observe the Which version of the driver do you want to use window.

Step 17. Select the Use the driver that is currently installed radio button (arrow above).

Step 18. Click the Next button.

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 B: Network Operations

Step 19. Observe the Type a printer name window.

Step 20. Enter the printer name: use the default name, or add more information to indicate the
printer ___location; e.g., Ed’s Printer, Mike’s Office, Room 33, etc.

Step 21. Click the Next button.

Step 22. Observe the You’ve successfully added ... window.

Step 23. If appropriate, select the Set as the default printer checkbox (arrow above).

Step 24. Click on the Finish button to complete the Add Printer Wizard.

You have successfully installed the network printer.

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 B: Network Operations

Printer Pooling
Setting Up Printer Pooling
Printer Pooling is a standard feature of Windows, which lets you spread the printed output
across a pool of several printers. In this example, we will install and setup the three network
printers to be used for pooling.

Step 1. Before proceeding to pool the printers, test them individually, and be sure they are
configured similarly. Specifically, check the following:
• Ribbon panel configuration (ribbon type, and what prints on which side of
the card).
• Mag encoding configuration.
• Black extraction configuration (if applicable).

Step 2. Access the Ports Tab.

To access the Ports tab, select Start > Devices and Printers. Right click on the Zebra
ZXP Series 7 USB Card Printer listing. Select Properties > Ports tab.

Step 3. Select the three network printers by selecting the associated checkbox (circle above).

Step 4. Ensure that Enable printer pooling and Enable bidirectional support checkboxes are
selected (arrows above).

Step 5. Click the Apply button, then click the OK button.

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Using the Printer Pool

Important • Send print jobs to the printer pool, not to an individual printer.

When the first printer has taken as many jobs as it can handle (that being two jobs - one to be
printed immediately, the other waiting), the following jobs “spill over” to the second printer,
and then to the third printer.

Note that if you are only printing two jobs, they would both go to the first printer. Pooling is
a spill-over methodology. It does not balance printer usage.

Once the pool has been set up, maintenance and configuration changes should be done
through the menus for each individual printer, not through the pool (which can produce
undesirable results).

Important • The effect of any maintenance and/or changes can (and should) be tested by
sending print jobs separately to each printer, not to the pool.

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 APPENDIX C
Magnetic Card Encoder

Introduction
This Appendix includes operation and maintenance requirements for Printers with the optional
magnetic card stripe encoder.

The magnetic encoder can be set for either high coercivity (HiCo) or low coercivity (LoCo).
Use the printer driver to change the encoder setting.

HiCo vs. LoCo:

• HiCo cards are used for the majority of applications; e.g., credit cards, ID cards, access
control cards, etc. HiCo magnetic stripes are usually black and are encoded with a strong
magnetic field for long and durable card life.

• LoCo cards are used for short-term applications; e.g., season passes, hotel room keys, etc.
LoCo magnetic stripes are usually brown in color and are encoded with a low intensity
magnetic field.

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Driver Setting (Printing Preferences)

To access Printing Preferences, select Start > Devices and Printers. Right click on the Zebra
ZXP Series 7 Card Printer in the listing. Select Printing Preferences.

Initial Setup
Step 1. Select the Encoding tab.

Step 2. Make your selection(s) for Magnetic encoding:

• Magnetic encoder verification: When selected, the protocol is (1) Write mag
data; (2) Verify mag data; (3) If this fails, verify again; (4) If the second verify
fails, rewrite and verify; (5) If this cycle fails, eject the card.

• Coercivity: Selections are High or Low

• Magnetic encoding type: Selections are ISO, AAMVA, CUSTOM,

and BINARY; see page 423 for details.

Step 3. Click on the Apply button, then click the OK button.

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Printing Options
For printing and encoding on cards with the mag stripe up, use the Print front image on back
side option; and select Yes from the dropdown menu (circled below).

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Card Loading Orientation

Note • ONLY USE cards that comply with ISO 7810 and 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.

Place the cards in the Feeder Cartridge in the correct orientation as shown (with the magnetic
stripe to the left and to the rear). Ensure that the cards are seated properly the hopper.

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Functional Check
To check the operation of the mag encoder, you will need the ZXP Toolbox. Select Start >
Devices and Printers. Then right-click on the Zebra ZXP Series 7 Card Printer listing, and
select Properties > Device Information > ZXP ToolBox.

Step 1. From the main Toolbox window, select Technology > Magnetic Encoding.

Step 2. Coercivity: Depending on the Card Type used, select either High or Low.

Step 3. For encoding: Click on the checkboxes to select Track 1, Track 2, and/or
Track 3; enter the data to be written; if not already done, place a magnetic stripe card
in the Feeder Cartridge; and click on the Encode button.

Step 4. When encoding is complete, the card will be ejected into the Output Hopper.

Step 5. Move the card from the Output Hopper to the Feeder Cartridge.

Step 6. For reading / validating: Click on the checkboxes to select Track 1, Track 2,
and/or Track 3; click on the Read button.

Step 7. When reading is complete, the card will be ejected into the Output Hopper.

Step 8. The data encoded will be read and displayed.

Step 9. Validate the data encoded in Step 3.

Step 10. This completes the Mag Encoder Functional Check.

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Magnetic Encoding Type

ISO (Default)
The encoder reads and writes standard ISO track data formats in standard ISO track locations.
The following shows the three standard ISO tracks.

Track 1 -- 210 BPI

Track 2 -- 75 BPI
Track 3 -- 210 BPI

Each track can be encoded and decoded with ASCII characters in the standard default ISO
data formats:

Track Density Bits per Character Length LRC Start End Start sentinel
(bpi) character parity (characters) parity sentinel sentinel offset

1 210 7 Odd 76 Even % ? 0.293" (7.4 mm)

2 75 5 Odd 37 Even ; ? 0.293" (7.4 mm)

3 210 5 Odd 104 Even ; ? 0.293" (7.4 mm)

The magnetic encoder can read or encode up to 3 tracks of digital information onto CR-80
cards incorporating a HiCo or LoCo magnetic stripe in the ISO 7811 format.

Encoding for the three tracks uses the ISO 7811 format.

• Track 1 uses 210 BPI (bits per inch) encoding in the International Air Transport
Association (IATA) format of 79 alphanumeric characters, at 7 bits per character.
• Track 2 uses 75 BPI encoding to store 40 numeric characters at 5 bits per character in
American Banking Association (ABA) format.
• Track 3 uses 210 BPI encoding of 107 numeric characters at 5 bits per character in
THRIFT format.

The ISO data formats include a preamble (all zeros), a start character, data (7-bit or 5-bit as
specified by ISO), a stop character, and a longitudinal redundancy check (LRC) character. The
7-bit data format has 6 bits of encoded data and a parity bit. The 5-bit data format has 4 bits of
encoded data and a parity bit.

The ISO data formats include a data field separator (or delimiter) that allows parsing of the
encoded track data. An example of separate data fields would be the ABA data format
(Track 2) that includes a Primary Account Number (PAN) field and an account information
field (for expiration date, country code, etc.).

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 C: Magnetic Card Encoder

AAMVA
The data stored on magnetic stripes on American driver's licenses is specified by the American
Association of Motor Vehicle Administrators (AAMVA).

Alpha-numeric characters on Tracks 1 and 3, numerals only on Track 2.

Track Density Bits per Character Length LRC Start End Start sentinel
(bits per character parity (characters) parity sentinel sentinel offset
inch) inches (mm)

1 210 7 Odd 79 Even % ? 0.293" (7.4)

2 75 5 Odd 37 Even ; ? 0.293" (7.4)

3 210 7 Odd 79 Even % ? 0.293" (7.4)

CUSTOM
If a custom format is desired, the ISO standard format may be used as a starting point. The
standard format can then be modified by assigning different values to any or all of the density,
character, and sentinel attributes. (If any of these attributes is missing, its corresponding
value in the standard ISO format will be substituted.)

BINARY
The binary option allows the user to specify directly the value for each bit on the mag stripe:.

In this “direct binary” mode, it is the host’s responsibility to fully populate the magnetic stripe;
i.e., the hex data provided by the host must include the leading zeroes, start sentinel, data, end
sentinel, LRC, and trailing zeroes. Note that the magnetic stripe is encoded from the right-
hand end as viewed from the “stripe” side, with the stripe uppermost. The least significant bit
of the data is encoded first.

A sufficient number of leading zeroes should be prepended to offset the start sentinel by
approximately 0.3" (7.5 mm) from the right-hand end, as in the ISO format. Care should be
taken to ensure that the payload data does not exceed the capacity of the tracks at their
specified recording densities. (In the binary mode, out-of-range data is not recorded, and no
error condition will result.)

A CR-80 size card has a nominal capacity of 252 bits per track at 75 BPI, and 708 bits at
210 BPI. These capacities equate approximately to 31 hex bytes (248 binary bits) and 88 hex
bytes respectively.

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 423

 C: Magnetic Card Encoder

Encoder Macro Commands

With ZXP Series 7 Card Printers, we provide support for pass-through magnetic
encoding commands.

The application developer or user can use a preamble or Macro to indicate to the driver that the
data following the Preamble or Macro is to be mag encoded.

The user can have encoding and printing data on the same card, and the driver will filter out
the encoding data from the printing data. The user does not have to know job control syntax or
ZMotif commands to send mag encoding commands to the printer.

Supported Macro commands are:

1. C01<Track1 Data>
C02<Track2 Data>
C03<Track3 Data>

2. ${1<Track1 data>}$
${2<Track2 data>}$
${3<Track3 data>}$

3. ~1=<Track1 data>
~2=<Track2 data>
~3=<Track3 data>

424 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 APPENDIX D
Smart Card Options

Introduction
This Appendix contains information on the additional operations of a Printer equipped with
one or more of the available Smart Card options.

Smart Cards can have a built-in microcomputer and/or memory to store fingerprints, voice
recognition patterns, medical records, and other such data. All other printer operations remain
the same as the standard models.

Encoding data onto Smart Cards and reading the data previously encoded on them is totally
under control of the application software; no operator action is required.

If you experience any problems with encoding or reading data, refer to the service manual or
other documentation for the application software.

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 425

 D: Smart Card Options

Contact Smart Cards

Contact Smart Cards have a pad of contacts on the surface of the card that connect to the
circuitry embedded into the card.

The printer responds to commands that position the card at the contact ___location, where the
printer connects to the contacts on the Smart Card. Data to be encoded onto the Smart Card,
and data read from the Smart Card, can interface via a connector on the printer’s rear panel
(External Contact Station), or encoding/decoding can be performed by logic on the printer’s
Main PCBA (Contact Encoder).

All other printer operations remain the same as the standard models.

Card Loading Orientation for Contact Smart Cards

Place the cards in the Feeder Cartridge in the correct orientation as shown (with the gold-
plated Smart Card contacts at the top of the card and facing to the right). Ensure that the cards
are seated properly the hopper.

426 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 D: Smart Card Options

Contact Station
Interface
When a command to the printer interface sends a card to the External Contact Station, the
printer connects the External Contact Station to the female DB-9 connector on the rear of
the printer.

DB-9 Connector ___location for

External Contact Station

An attached external Smart Card Programmer can be used to program Smart Card chips. The
following table shows the Smart Card Contact Points.

DB-9 Pin Connections

Pin Smart Card Contact Points Pin Smart Card Contact Points
1 C1 (VCC) 6 C6 (Vpp)
2 C2 (Reset) 7 C7 (I/O)
3 C3 (Clock) 8 C8 (RFU)
4 C4 (RFU) (GND when chip
9
5 C5 (GND) is at station)

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 427

 D: Smart Card Options

Contactless Smart Cards

Rather than using a contact pad, Contactless Smart Cards use various short-range radio
technologies to “connect” to the printer. The printer moves the card to an antenna ___location
on the card path, and the encoding or decoding occurs. All other printer operations remain
the same.

Card Loading Orientation for Contactless Smart Cards

For Contactless Smart Cards, orientation is not a consideration.

Printing on Contactless Smart Cards

There are no restrictions when designing material to be printed on Contactless Smart Cards.

428 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 APPENDIX E
Spare Part Kits and
Upgrade Kits

Introduction
This Appendix lists the Spare Part Kits, Special Tools, and Upgrade Kits available for the
Zebra ZXP Series 7 Card Printer.

The list for Laminator Spare Part Kits starts on Page 445.

Before ordering, be sure to check the Partner Zone on www.zebra.com for the latest spare part
kits listing.

Printer
Kit # Description
P1037750-001 KIT, UPGRADE, MIFARE CONTACT ENCODER
P1037750-002 KIT, UPGRADE, CONTACT STATION
P1037750-003 KIT, UPGRADE, MAG ENCODER
P1037750-004 KIT, WIRED ETHERNET PCBA
P1037750-005 RESERVED
P1037750-006 KIT, PRINTHEAD ASSY
P1037750-007 KIT, PRINTHEAD HOUSING
P1037750-008 KIT, PRINTHEAD HOUSING LATCH & SPRINGS
P1037750-009 KIT, PRINTHEAD COVERS
P1037750-010 KIT, MAIN LOGIC BOARD (MLB)
P1037750-011 KIT, UPGRADE LAM SS
P1037750-012 KIT, UPGRADE LAM DS
P1037750-013 KIT, OPTIONS MODULE

Continued on next page

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 429

 E: Spare Part Kits and Upgrade Kits

Kit # Description
P1037750-014 KIT, OPERATOR CONTROL PANEL
P1037750-015 KIT, PCBA MIFARE CONTACT ENCODER
P1037750-016 KIT, PCBA MAG CONTROL
P1037750-017 KIT, MAG HEAD REPLACEMENT
P1037750-018 RESERVED
P1037750-019 KIT, PCBA FLIPPER MODULE
P1037750-020 KIT, MEDIA AUTHENTICATION PCBA
P1037750-021 KIT, POWER SUPPLY
P1037750-022 KIT, POWER SWITCH/ENTRY MODULE
P1037750-023 RESERVED
P1037750-024 RESERVED
P1037750-025 RESERVED
P1037750-026 KIT, COOLING FANS
P1037750-027 KIT, ELECTRONICS CABLES
P1037750-028 KIT, RIBBON SENSOR
P1037750-029 KIT, PRINT ENGINE DOOR OPEN SENSOR
P1037750-030 KIT, CONTACT STATION MODULE
P1037750-031 KIT, ENCODER SENSOR FOR RIBBON SUPPLY SPINDLE
P1037750-032 KIT, ENCODER SENSOR FOR RIBBON TAKE-UP SPINDLE
P1037750-033 KIT, SENSOR FOR CONTROL PANEL DOOR OPEN
P1037750-034 KIT, FLIPPER POSITION SENSOR
P1037750-035 RESERVED
P1037750-036 KIT, CAM SENSOR
P1037750-037 KIT, SYNC SENSOR
P1037750-038 KIT, EXIT SENSOR
P1037750-039 KIT, CARD SENSOR OPTIONS MODULE
P1037750-040 KIT, RIBBON TRICOLOR SENSOR
P1037750-041 KIT, RIBBON SUPPLY SPINDLE ASSEMBLY
P1037750-042 KIT, MOTOR FOR RIBBON SUPPLY SPINDLE
P1037750-043 KIT, RIBBON CLOSE OUTS
P1037750-044 KIT, RIBBON TAKE-UP SPINDLE ASSEMBLY
P1037750-045 KIT, MOTOR FOR RIBBON TAKE-UP SPINDLE
P1037750-046 KIT, CLEANING CARTRIDGES
P1037750-047 KIT, PINCH ROLLER ASSEMBLIES
P1037750-048 KIT, MAG PRESSURE ROLLER ASSEMBLY
P1037750-049 KIT, FLEXIBLE ROLLERS
P1037750-050 KIT, PLATEN ROLLERS
P1037750-051 KIT, ALL DRIVE BELTS
P1037750-052 RESERVED
P1037750-053 KIT, DRIVE SYSTEM PLATEN ROLLERS
P1037750-054 RESERVED
P1037750-055 KIT, DRIVE MOTOR PRINTHEAD LIFT
P1037750-056 KIT, DRIVE MOTOR PLATEN ROLLERS
P1037750-057 KIT, DRIVE MOTORS FLIPPER
P1037750-058 KIT, ENCODER AND FEEDER MOTOR
P1037750-059 KIT, FEEDER CARTRIDGE STANDARD
P1037750-060 KIT, FEEDER COVER
P1037750-061 KIT, DRIVE ASSEMBLY FEEDER

Continued on next page

430 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 E: Spare Part Kits and Upgrade Kits

Kit # Description
P1037750-062 KIT, RETAINER FOR FEEDER
P1037750-063 KIT, PRINT ENGINE DOOR ASSEMBLY
P1037750-064 KIT, COVER ASSEMBLY OPTION MODULE
P1037750-065 KIT, LEFT & RIGHT COVER ASSEMBLIES
P1037750-066 KIT, KEY & LOCK REPLACEMENT
P1037750-067 KIT, SKINS
P1037750-068 KIT, PRINT ENGINE DRAWER
P1037750-069 KIT, DOOR BUTTON & LATCH
P1037750-070 KIT, PCBA FOR CONTACT STATION
P1037750-071 KIT, BOTTOM PANEL
P1037750-072 KIT, PANEL PLUNGERS & SPRINGS
P1037750-073 KIT, OUTPUT HOPPER
P1037750-074 KIT, REJECT BIN
P1037750-075 KIT, FLIPPER ASSEMBLY
P1037750-076 KIT, FRONT, CENTER & REAR FRAME
P1037750-077 KIT, MODULE CHASSIS
P1037750-078 KIT, INLET AND EXIT DUCTS WITH GASKETS
P1037750-079 KIT, SHROUD FOR OPTIONS
P1037750-080 KIT, GROUND PLATES
P1037750-081 KIT, SPRINGS SHAFT FOR PRINT ENGINE DOOR
P1037750-082 KIT, FEET
P1037750-083 KIT, RIBBON SPINDLES
P1037750-084 KIT, ASSORTED HARDWARE
P1037750-085 KIT, PACKAGING WITHOUT LAM
P1037750-086 KIT, PRESSURE ROLLER ASSY NON MAG
P1037750-087 KIT, MODULE MIFARE CONTACT ENCODER
P1037750-088 KIT, FEEDER CARTRIDGE SECURITY
KIT, PACKAGING WITH LAM (Kit includes Shipping Carton and
P1037750-089
Packing Material for a ZXP7 Printer with attached Laminator)
P1037750-090 RESERVED

P1037750-400 Kit Torque Tools for RTU Motor Calibration ZXP7

P1037750-401 Kit Print Head Cam Sync Fixture ZXP7
P1037750-402 Kit Flipper Deck Level
P1037750-403 Kit Contact Station Upgrade Tool
P1037750-404 Kit AC Power Filter Release Tool
P1037750-405 Kit Mag Tensioning Spring Tool

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 431

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag

1 P1037750-067 Skins - Left Cover
2 P1037750-067 Skins - Pr Eng Cvr
3 P1037750-067 Skins - Opt Dr Cvr
4 P1037750-067 Skins - Right Cover

432 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag QTY

1 P1037750-039 Opt Mod Card Sensor 1
2 P1037750-074 Reject Bin 1
3 P1037750-033 Cont Pnl Door Sens 1
4 part of P1037750-046 Clean Cartr 1
5 P1037750-069 Door Button & Latch 1

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 433

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag QTY

1 P1037750-063 Pr. Eng. Door Assy 1
2 P1037750-079 Shroud for Options 1
3 P1037750-059 Feeder Cart. Std 1
4 P1037750-060 Feeder Cover 1
5 P1037750-065 R Cover Assy 1
6 P1037750-014 Oper. Control Panel 1
7 P1037750-064 Option Mod Cvr Assy 1
8 P1037750-068 Print Engine Drawer 1
9 P1037750-074 Output Hopper 1
10 P1037750-065 L Cover Assy 1

434 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag QTY

1 P1037750-008 PH Latch & Springs 1
1 P1037750-008 PH Latch & Springs 1
2 P1037750-007 Printhead Housing 1
3 P1037750-028 Ribbon Sensor 1
4 P1037750-006 Printhead Assembly 1
5 P1037750-009 Printhead Covers 1
6 P1037750-046 Cleaning Cartr. 1
6 P1037750-046 Cleaning Cartr. 1
7 P1037750-083 Ribbon Spindles 1
7 P1037750-083 Ribbon Spindles 1

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 435

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag QTY

1 P1037750-075 Flipper Assy 1
2 P1037750-072 Plungers & Springs 1
2 P1037750-072 Plungers & Springs 1
3 P1037750-036 Cam Sensor 1

436 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag QTY

1 P1037750-034 Flipper Pos Sensor 1

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 437

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag QTY

1 P1037750-077 Opt Module Chassis 1
2 P1037750-013 Options Module 1
3 P1037750-055 Printhead Lift Mot 1
4 p/o P1037750-076 Front Frame 1
5 p/o P1037750-076 Center Frame 1
6 p/o P1037750-076 Rear Frame 1

438 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag QTY

1 P1037750-043 Ribbon Close Out L 1
1 P1037750-043 Ribbon Close Out R 1
2 P1002628-002.PRT 1
3 P1037750-037 Sync Sensor 1
4 P1037750-047 Pinch Roller (R) 1
5 211420-102.PRT 1
6 P1037750-047 Pinch Roller (L) 1
7 P1037750-038 Exit Sensor 1
8 P1002628-002.PRT 1
9 P1037750-040 Rbn Tricolor Sensor 1

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 439

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag QTY

(All are included in P1037750-050, Platen Rollers)
1 P1012731.PRT 1
2 p/o P1016593.ASM 1
3 p/o P1011518-001.ASM 1
4 p/o 211421-001.ASM 4
5 p/o 211420-001.ASM 1

440 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag QTY

1 P1037750-015 Mifare / Contac PCB 1
2 P1037750-016 Mag Control PCBA 1
3 P1037750-019 Flipper Module PCBA 1
4 P1037750-020 Media Auth. PCBA 1
5 P1037750-026 Printhead Fans 1
6 P1037750-021 Power Supply 1
7 P1037750-022 Power Switch/Entry 1
8 P1037750-057 Flipper Drive Motor 1

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 441

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag QTY

1 P103750-057 Flipper Drive Motors 1
1 P103750-057 Flipper Drive Motors 1
2 P1037750-041 Supply Spindle Assy 1
3 P1037750-044 Takeup Spindle Assy 1
4 P1037750-045 Ribbon Takeup Motor 1
5 P103750-056 Platen Rollers Motor 1
6 P1037750-042 Ribbon Supply Motor 1
7 P1037750-058 Enc & Feeder Motor 1

442 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag QTY

1 p/o P1037750-080 Ground Plates 1
2 P1037750-010 Main Logic Board 1
3 P1037750-071 Bottom Panel 1
4 P1037750-082 Feet 1
5 P1037750-081 Prt Eng Door Shaft 1

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 443

444 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002
 E: Spare Part Kits and Upgrade Kits

Laminator

Kit # Description
P1037750-500 LAM DOOR
P1037750-501 LAM LOWER DOOR
P1037750-502 KIT, LAM BOTTOM PANEL
P1037750-503 KIT, LAM DOOR HINGES
P1037750-504 KIT, LAM ELECT CABLES
P1037750-505 RESERVED
P1037750-506 RESERVED
P1037750-507 PACKAGING FOR LAMINATOR ONLY

105936G-500 KIT, BEAM, ZXP, LAMINATOR

105936G-501 KIT, ASSY, CRUCIFORM, ZXP
105936G-502 KIT, ZXP LAM LOCK
105936G-503 KIT, ASSY, FAN, 24V, ZXP (Upper & Lower)
105936G-504 KIT, PCBA, LAM, MA, ANT, UPPER
105936G-505 KIT, LAM, UPPER CAS. LATCH, ZXP
105936G-506 KIT, LAM, LOWER CASS LATCH, ZXP
105936G-507 KIT, TOOL, THUMB DRIVE
105936G-508 KIT, ASSY, CUTTER, LOWER
105936G-509 KIT, HEATER, HAL, 78MM, 150W, 120V (Top & Bottom)
105936G-510 KIT, PCBA, LAMINATOR CONTROLLER
105936G-511 KIT, MOTOR, 17PM, ZXP
105936G-512 KIT, MTR, BI-STP, PM42L-048, RGT, 8 (Top Laminator Control Motor)
105936G-513 KIT, MTR, BI-STP, PM42L-048, LFT, 8 (Bottom Laminator Control Motor)
105936G-514 KIT, MTR, BI-STP, PM42L-048, RGT, 6 (Staging Motor)
105936G-515 KIT, STATIC BRUSH, 60MM
105936G-516 KIT, CASSETTE, LAMINATE, TOP
105936G-517 KIT, CASSETTE, LAMINATE, BOTTOM
105936G-518 KIT, MODULE, THERMOPILE (Top & Bottom)
105936G-519 KIT, ASSY, HEATER, LAM
105936G-520 KIT, PCBA, MEDIA AUTH, ZXP LAM
105936G-521 KIT, ROLLER, RIBBED, FLEXIBLE (Left & Right)
105936G-522 KIT, ASSY, CUTTER, UPPER
105936G-523 KIT, ROLLER, RIB, LAMINATE (Top & Bottom)
105936G-524 KIT, ROLLER, NIP, CARD STAGING (Left & Right)
105936G-525 KIT, PLATEN, OVERRUN
105936G-526 KIT, ASSY, EXIT ROLLER (Top & Bottom)
105936G-527 KIT, SPINDLE, RIBBON, MOLDED
105936G-528 KIT, SPINDLE, SQUARE CORNER
105936G-529 KIT, ASSY, ZXP LAM DOOR LATCH
105936G-530 KIT, CBL ASY, LAM-THERMOPILE, TOP
105936G-531 KIT, CBL ASY, LAM-THERMOPILE, BTM
105936G-532 KIT, CBL ASSY, SENSOR CARD, ENTRY
105936G-533 KIT, CABLE ASSY, SENSOR CARD, LAM
105936G-534 KIT, CBL ASSY, SENSOR CARD, EXIT
105936G-535 KIT, UPGRADE, ZXP LAM LOCK
105936G-536 KIT, PCBA, LAM, MA, ANT, LOWER
105936G-537 KIT, CBL ASY, SNSR REFL, LAM, DOOR

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 445

 E: Spare Part Kits and Upgrade Kits

+--

ITM Item Tag QTY

1 P1037750-500 Laminator Door 1
2 P1037750-501 Lam Lower Door 1

446 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 E: Spare Part Kits and Upgrade Kits

ITM Item Tag QTY

1 P1037750-503 Lam Door Hinges 2
2 P1037750-502 Lam Bottom Panel 1

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 447

448 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002
 APPENDIX F
ZXP Series 7 Service Tool

Introduction
This appendix contains an overview of the ZXP Series 7 Service Tool. This tool is intended for
use by Zebra-trained and certified service personnel when performing selected repair and/or
upgrade procedures.

The Service Tool provides the following functions:

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Debug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487

P1036102-002 Zebra ZXP Series 7 Card Printer Service Manual 449

 F: ZXP Series 7 Service Tool

Test
The Test tab lists a series of tests that can be performed either individually to validate a
specific function or collectively as a final operational check of a printer.

To use the Test tab:

Step 1. Either manually enter the printer serial number in the Serial Number text box; or
place the cursor in the text box, and press the Esc key (the serial number will be
entered automatically).

Step 2. The Test tab is now functional:

a. Select the desired test.

b. Click on the Start button.

c. Follow the on-screen instructions.

d. When the test is completed, note the test results (Test Passed or Test Failed).

Step 3. When finished with the Service Tool, select File > Exit from the Menu Bar.

450 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002

 F: ZXP Series 7 Service Tool

Functional Tests
Important • Ensure the printer is in the READY state prior to performing any of the
following procedures.

Test 1: Program Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452

Test 2: Tricolor Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Test 3: Media Coupler Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Test 4: Flipper Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
Test 7: Feeder Test (10 mil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Test 8: Feeder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Test 9: Reject Bin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
Test 10: ATM Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Test 11: Ribbon Torque Calibration . . . . . . . . . . . . . . . . . . . . . . . . . 462
Test 12: Ribbon Damping Calibration . . . . . . . . . . . . . . . . . . . . . . . . 464
Test 13: MAG Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
Test 14: MAG Write Test HiCo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Test 15: MAG Write Test LoCo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
Test 16: Smart Card Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
Test 17: Smart Card Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
Test 18: Smart Card Contact Read/Write Test . . . . . . . . . . . . . . . . . . 471
Test 19: Smart Card Contactless Read/Write Test . . . . . . . . . . . . . . . 472
Test 20: Wired Ethernet Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
Test 21: Wireless Ethernet Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Test 22: Overlay Density Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 476
Test 23: Offset Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Test 24: Print Speed Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Test 25: Monochrome Quality Test . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Test 26: Print Test (Thin Cards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Test 27: Print Test (Flat Field) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
Test 28: Image Quality Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
Test 29: Laminate Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . 484
Test 30: Laminate Offset Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 485
Test 31: Lamination Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
Test 32: Print Stats Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486

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Test 1: Program Values

This procedure displays the printhead resistance, the printhead serial number, and the ribbon
registration value. Use this procedure to change these values when the printhead is replaced.
Resistance values range from 2200 to 3300; registration settings range from 1 to 12.

Note that Program Values will also program the printer serial number if it is not already
programmed or is zero. It cannot change the printer serial number once it is programmed.

Start

SecureAction
Device SN =
N ResetPrinterSerial
Expected SN?
Number

Set Serial Number

Enter Printhead
Info

Set Printhead
Serial Number

Set Printhead
Resistence

Set Ribbon Sensor

Offset

Save Backup

End

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Test 2: Tricolor Sensor Calibration

This procedure calibrates the RGB values of the Tricolor Sensor for proper ribbon panel
color detection.

Verify Sensor
Start
Values

Disable Mech Init Red < 400 & N

Red > 0

Y
Remove
Ribbon
Green < 400 & N
Green > 0

RunCalibrationRoutine
Y
Tricolor

Blue < 400 & N

Blue > 0

Success? N
Y

Y
Green – Blue < N
70
Get Sensor Values

Y
Y

Blue – Red < N

Verify Sensor 70
Values

Y
Y

Red - Green < N

Passing? N 70

Y
Y

Y Pass Fail
Save Backup

Enable Mech Init Enable Mech Init

Pass Fail

Failure may indicate that the tricolor sensor needs replacement.

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Test 3: Media Coupler Test

This test verifies that the color ribbon’s RFID tag can be read.

For this test, ensure that a color ribbon is installed in the printer.

Start

Load Color
Ribbon

Initialize System:
PrintMechanism

Get Ribbon
Params

initialSize = 0 N

panelsRemaining =
N
65535

Fail Pass

Failure may indicate a bad or missing RFID tag, a bad Antenna, or a bad Media Authentication
PCBA (MAB).

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Test 4: Flipper Calibration

This procedure sets the flipper deck “home” position for proper flip operation. If you
experience flipper or card jams, you may want to recalibrate the flipper.

For this procedure, you will need the Flipper Deck Level (P1037750-402) fixture; see next
page for fixture installation.

Start

RotateFlipper:
N
RotateToHome

RunCalibrationRoutine:
CardFlipper – N
MotorCurrentOff
Y

Insert Flipper
Calibration
Tool

RunCalibrationRoutine:
CardFlipper – N
MotorCurrentOn
Y

Remove
Flipper
Calibration
Tool

RunCalibrationRoutine:
CardFlipper – N
SaveCalibration
Y

Save Backup

Pass Fail

Failure may indicate misaligned flipper deck.

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Flipper Deck Level Fixture Installation

Install and remove the “Flipper Calibration Tool” when instructed to do so during the test.

Step 1. Remove the Dual Cleaning Cartridge (see Section 2.3.3), remove the Shroud (see
Section 5.6.5), then remove the Options Cover (see Section 5.6.8).

Step 2. Locate the Dual Cleaning Cartridge slot; circled below.

Step 3. Slide the fixture into he Dual Cleaning Cartridge slot.

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Step 4. Ensure that the locking tabs reach underneath the edge of the Frame.

Step 5. Lower both locking levers.

Step 6. Removal is performed by reversing the installation steps.

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Test 7: Feeder Test (10 mil)

This test passes the cards from the feeder, through the printer, to the output hopper.

For this test, you will need ten 10-mil PVC cards. DO NOT REUSE the 10-mil cards when
doing this test; they are susceptible to warping and may cause jams in the printer.

Start

Remove
Ribbon & Load
Cards

N=0

Hopper To
N
Flipper

Flipper To
N
Options

Options To
N
Flipper

Rotate
N
Flipper 180

Flipper To
N+1 N
Options

Options To
N
Flipper

Rotate
N
Flipper Home

Flipper To
N
Output

N N = count?

Pass Fail

Failure may indicate a problem with the card feeder, card path, or flipper (calibration).

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Test 8: Feeder Test

This test passes the cards from the feeder, through the printer, to the output hopper.

For this test, you will need ten 30-mil PVC cards.

Start

Remove
Ribbon & Load
Cards

N=0

Hopper To
N
Flipper

Flipper To
N
Options

Options To
N
Flipper

Rotate
N
Flipper 180

Flipper To
N+1 N
Options

Options To
N
Flipper

Rotate
N
Flipper Home

Flipper To
N
Output

N N = count?

Pass Fail

Failure may indicate a problem with the card feeder, card path, or flipper (calibration). An
error could also mean that there is a faulty sensor in the card path. Where the card gets stuck
would suggest which sensor to check.

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Test 9: Reject Bin Test

This test passes the cards from the feeder, through the options module, to the reject bin. When
complete, remove the cards from the reject bin.

For this test, you will need three 30-mil PVC cards.

Start

Load Cards
into Feeder

Empty Reject
Bin

ClearRejectBinCounter

N=0

FeedSource =
CardFeeder

Destination =
Reject

N+1 PositionCard

JobError?

N
N

N = count?

Empty Reject
Bin

ClearRejectBinCounter

Pass Fail

Failure may indicate a problem with the flipper (calibration), the card path, or the ground
wire connection on the reject bin. An error could also mean that there is a faulty sensor in the
card path. Where the card gets stuck would suggest which sensor to check.

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Test 10: ATM Feed Test

This test passes the card from the ATM (single card feed) slot through the printer, to the
output hopper.

For this test, you will need three 30-mil PVC cards.

Start

N=0

FeedSource =
ATMSlot

Destination = Eject

N+1 PositionCard

JobError?

Y
N
N

N = count?

Pass Fail

Failure may indicate a problem with the ATM sensor (card sensor) or the card path. An error
could also mean that there is a faulty sensor in the card path. Where the card gets stuck would
suggest which sensor to check.

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Test 11: Ribbon Torque Calibration

This procedure warms the motor, calculates the voltage to turn the motor at 33.3 RPM for
both low-torque and high-torque tools. The procedure then calculates the slope and offset
of the motor.

For this procedure, you will need the and the Torque Tools for RTU Motor Calibration ZXP7
(P1037750-400) comprised of High Torque Tool and Low Torque Tool. See next page for
tool placement.

Start

Insert Ribbon

Disable MechInit

Low Torque
Calibration

High Torque
Calibration

PerformCalibration
TorqueCalc

M0 within
N
Limits?

K0 within
N
Limits?

Save Backup

Enable MechInit Enable MechInit

Pass Fail

Failure may indicate a bad motor or associated gears.

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Torque Tool Installation:

Install the Torque Tool on the ribbon take-up spool as shown.

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Test 12: Ribbon Damping Calibration

This procedure calibrates the BEMF value for the ribbon motor.

For this procedure, you will need a 25% full supply ribbon roll.

Start

Insert Ribbon

Disable MechInit

PerformCalibration
RibbonDamping

Error = 6 or
Y
Error = 5006?

BEMF = 0? Y

Save Backup

Enable MechInit Enable MechInit

Pass Fail

Failure may indicate a bad motor or associated gears.

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Ribbon Roll Example:

Note the almost-empty supply roll (arrow below).

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Test 13: MAG Calibration

This procedure performs three encoding jobs so that the printer can perform self-calibration.

Note that the printer self calibrates the MAG option every time it does a MAG encoding job.
This test performs an initial calibration for the option.

For this test, you will need three PVC HiCo MAG cards.

Start

MAG installed? Y

Load Media

Set MagCoercivity
= High

Set Mag Write

Verification = On

N=0

Send MAG Only

Job to printer

Get Job Status

Job Error? Y

N N = 3?

Pass Fail

An error could mean that the card cannot travel down the path (motor or belt issues) or the
head is not able to read the data on the card (head, MAG PCBA, or cable issues).

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Test 14: MAG Write Test HiCo

Note • This test verifies that the printer can encode and read data on a card, but it does not
verify that the encoding meets ISO Standard. Only the use of a MAG 3x can do that.

This test encodes three HiCo MAG cards with Read Verify turned on. The printer reads back
data encoded on the card and verifies it against the data written to the card.

For this test, you will need five PVC HiCo MAG cards.

Start

MAG installed? Y

Load Media

Set Mag Coercivity

to High

Set Mag Write

Verification = On

N=0

Send MAG Only

Job to printer

Get Job Status

Job Error? Y

N N = 3?

Pass Fail

Failures could be the result of a bad MAG motor, MAG head, and/or accompanying MAG
circuits and cables.

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Test 15: MAG Write Test LoCo

Note • This test verifies that the printer can encode and read data on a card, but it does not
verify that the encoding meets ISO Standard. Only the use of a MAG 3x can do that.

This test encodes three LoCo MAG cards with Read Verify turned on. The printer reads back
data encoded on the card and verifies it against the data written to the card.

For this test, you will need five PVC LoCo MAG cards.

Start

MAG installed? Y

Load Media

Set Mag Coercivity

to Low

Set Mag Write

Verification = On

N=0

Send MAG Only

Job to printer

Get Job Status

Job Error? Y

N N = 3?

Pass Fail

Failures could be the result of a bad MAG motor, MAG head, and/or accompanying MAG
circuits and cables.

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Test 16: Smart Card Enable

Three options are available:

• No Smart card.
• Contact Station (contact external) enable.
• MIFARE (contact internal, contactless MIFARE) enable.

Start

Select Smart Card

Option

No Smart Card Contact Station

Option?

MIFARE

Contact = Disabled Contact = Internal Contact = External

Contactless = Contactless = Contactless =

node MIFARE none

Save Backup

Start

Note that the printer will not power the USB connection for the smart card reader unless the
option is enabled; i.e., if the PC does not see a smart card reader connected when the printer is
connected, it is possible that the option is not enabled.

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Test 17: Smart Card Calibration

This procedure is used for contact smart card calibration. It will find the range of offsets for
positioning the contact smart card. Once the range is found, the center point is chosen as the
contact offset point.

Note that this test only works with SLE4442 or similar contact smart cards.

Start

Reader
N Fail
detected?

Offset = -150

Load Smart Card

Offset = Offset + Verify Smart

N
10 Card Pin?

Min Offset = Offset

Offset = Offset +
10

Load Smart Card

Offset = Offset + Verify Smart

Y
10 Card Pin?

Max Offset =
Offset

Smart Card Offset

= ((MinOffset –
MaxOffset) / 2) +
MaxOffset

Save Backup

Pass

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Test 18: Smart Card Contact Read/Write Test

This procedure encodes random data on five contact smart cards and then reads and verifies
the data from the cards. This procedure is also used to ensure that the smart card calibration
(Test 15) was successful.

For this test, you will need five SLE4442 or similar contact smart cards.

Start

Reader
N Fail
detected?

Offset = -150

Load Smart Card

Offset = Offset + Verify Smart

N
10 Card Pin?

Min Offset = Offset

Offset = Offset +
10

Load Smart Card

Offset = Offset + Verify Smart

Y
10 Card Pin?

Max Offset =
Offset

Smart Card Offset

= ((MinOffset –
MaxOffset) / 2) +
MaxOffset

Save Backup

Pass

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Test 19: Smart Card Contactless Read/Write Test

This procedure encodes random data on five contactless smart cards and then reads and
verifies the data from the cards.

For this test, you will need five MIFARE Classic 1k or similar contactless smart cards. Note
that his test only supports MIFARE Classic 1K cards. MIFARE Classic 4K cards may also
work, but MIFARE Ultralight and MIFARE DESFire cards will not.

Start

Reader
N Fail
detected?

Offset = -150

Load Smart Card

Offset = Offset + Verify Smart

N
10 Card Pin?

Min Offset = Offset

Offset = Offset +
10

Load Smart Card

Offset = Offset + Verify Smart

Y
10 Card Pin?

Max Offset =
Offset

Smart Card Offset

= ((MinOffset –
MaxOffset) / 2) +
MaxOffset

Save Backup

Pass

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Test 20: Wired Ethernet Test

Note • The test setup requires a connection to a Router with a DHCP server to get a network
address. The test software will not assign an IP address to the printer.

This test uses the USB connection to get the printer’s IP address from the printer itself. It then
tries to PING the IP Address and wait for a response. If successful, it will then try to connect
to that IP Address and verify that it is indeed the same printer it was testing by checking the
serial number.

Start

Enable DHCP

Get IP Address

IP = 0.0.0.0 Y

Ping IP Address

Success? N

Open connection
to IP Address

Serial Number
N
matches?

Pass Fail

There is a known problem in this test where sometimes the first PING sent is unsuccessful.
This is not a problem with the code but the system device library that is used. A retest should
come back as passed. If it fails on the retest, then there is something wrong.

Most failures are caused by bad cable connections. Sometimes the printer will report an
IP Address of 0.0.0.0. This can be caused by a bad network card, bad cable, or a problem
with the router; e.g., no DHCP.

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Test 21: Wireless Ethernet Test

This procedure updates the firmware over a wireless network.

Before testing, you will have to configure the wireless network that will be used to test the
option; see next page.

Start

Has wireless
N
MAC address?

Y
Set SSID, Channel
and Security
setings

Set Wireless
Radio State = On

Connected?
N

Y
Enable DHCP

Get IP Address

IP = 0.0.0.0 Y

Ping IP Address

Success? N

Open connection
to IP Address

Serial Number
N
matches?

Pass Fail

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Wireless Ethernet Test Setup

Before testing, you will have to configure the wireless network that will be used to test the
option. This is done thru the Setup -- Configuration menu as follows:

a. Go to File > Login.

b. Enter the Engineering mode password (default is “spikespike” and can be changed).

The Setup menu will now be unlocked. Go to the Configuration form, select Wireless
Settings, and fill in the blanks.

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Test 22: Overlay Density Adjustment

This procedure is a simple density adjustment test. A slider bar is presented that allows the
operator to increase or decrease the heat (EWB) applied of the Overlay panel. The overlay is
adjusted by visually inspecting the test card to see if there is a lack of transfer onto the surface
of the card. If so, increase the value.

For this test, you will need thirty 30-mil PVC cards and a color ribbon.

Start

Load Color
Ribbon

Reset Overlay Set Overlay EWB

Y
Panel? to 100

Print Black
Extraction Card

Adjust Overlay
value via Slider

Print Black
N Extraction Card

Acceptable?

Save Backup

Print Black
Extraction Card

End

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Test 23: Offset Adjustment

This procedure prints a MAX Gray card and then prompts the operator to adjust the X and Y
offset values to position the image onto the card. This is done for the leading edge and top
margin.

For this test, you will need thirty 30-mil PVC cards.

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Test 24: Print Speed Calibration

This procedure calibrates the print speed factor which is used to compute the end-of -card
position by the printer. This calibration adjusts only the trailing edge offset of the image
printed on the card. The calibration also takes a reading of the platen temperature and stores it
on the printer as it is used to compensate for platen diameter changes when heated.

The operator is asked to measure the trailing edge white space and enter the distance. The
software will then compute a print speed factor to adjust for a trailing edge white space no
more than 0.350mm and no less than 0.250mm. The process is repeated until a test card
measures in the allowable range.

For this test, you will need 30-mil PVC cards.

Start

Load Color
Ribbon

Set Platen
Temperature
Offset = 0

Get Platen
Temperature

Print Test Card

Program new
PrintSpeedAdj
value Enter White Space
measurement

Calculate new
reading > 0.250 &
PrintSpeedAdj N
reading < 0.350
value

Set Platen
Temperature
Offset = Platen
Temperature

Save Backup

End

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Test 25: Monochrome Quality Test

This test is used to validate the image quality for a monochrome only print job. This requires
the use of a black monochrome ribbon. The software will not use the K panel on a YMCK
ribbon and will prompt the operator to remove any YMC ribbons. Quality is subjective and
requires comparison to limit samples; see Appendix G, Print Quality, for details.

For this test, you will need 30-mil PVC cards and a black monochrome ribbon.

Front Back

None

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Test 26: Print Test (Thin Cards)

This test performs single-sided printing on 10-mil media in color. Operator will be prompted
to insert the correct media prior to start. Field of 5 images printed.

Front Back

None

None

None

None

None

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Test 27: Print Test (Flat Field)

This test performs dual-sided printing (single-sided on Z71 printers) in color with standard
30-mil PVC media. Field of 3 images printed. One image is printed twice.

Front Back

None

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Test 28: Image Quality Test

This test uses standard 30 mil PVC media and prints about 10-15 images in color. Dual-sided
if dual-sided printer. Single-sided for single-sided printers. Front is always in color, back is
always in black.

Front Back

None

None

None

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Front Back

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Test 29: Laminate Sensor Calibration

This test is sed to calibrate laminate sensors.

This test requires that the laminates be reset in the cartridges prior to start. That means that the
laminate should be removed and then reinstalled into the laminator unit. The laminate should
not be pre-feed into the laminator at the start of the test. The software attempts to check for
laminate and prompts the operator to reinstall cartridges. Once that is done, the calibration will
feed laminate into the laminator and calibrate. When completed, the operator will be prompted
to reset the cartridges again.

Start

Load
Laminate(s)

Reset Laminate under

Y
Cartridges sensor?

Calibrate Laminate

Pass

A fail here indicates a problem with either the laminate feed or a bad sensor.

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Test 30: Laminate Offset Adjustment

This procedure is used to adjust the Top and Bottom X offsets for laminate patch placement.
There are 4 offsets to adjust: 1) Top Fine X Offset Adjustment, 2) Bottom Fine X Offset
Adjustment, 3) Course X Offset Adjustment, and 4) Patch Length. Course adjustment affects
both top and bottom offsets. The fine adjustments are used to tune in the top and/or bottom
laminates individually.

Patch length sets the total length of the laminate patch. The X adjustments affect the leading
edge of the patch, and the patch length controls the trailing edge. It should be noted that
these offsets can only adjust the laminate positions in the X direction. It is not possible to
adjust Y offset.

Start

Load Color
Ribbon &
Laminate

Get Original
Offsets

Print Test card

Display Offsets /
Get new offsets

Program New
Test Next Action?
Offsets

Done

Print Test card

Save Backup

Pass

Test 31: Lamination Print Test

This test uses standard 30 mil PVC media and prints about 10-15 images in color. Dual-sided
if dual-sided printer. Single-sided for single-sided printers. Front is always in color, back is
always in black. After printing, the card is then laminated.

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Test 32: Print Stats Card

This procedure prints stats cards for the ZXP 7. Note that the Laminator card is printed only if
a laminator is present.

Front Back

Standard Test Card

Parameters Card

Encoders Card

Laminator Card

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Debug
The Debug tab lists various screens to assist Zebra-trained and certified service personnel in
diagnosing and/or evaluating printer operation. These screens include: Information, Printer
Status, Print Card, Laminator, Density Adjustment, and Sensors.

To enable the Debug tab:

Step 1. Select the printer type (USB, Network, or All) by clicking on the appropriate
radio button.

Step 2. Click the Discover button.

Step 3. From the Connection dropdown menu, select the desired printer.

Step 4. Click on the Connect button.

Step 5. The Debug tab is now functional.

Step 6. When finished with the Debug tab, click on the Disconnect button.

Step 7. When finished with the Service Tool, select File > Exit from the Menu Bar.

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Debug Options
, Information, on page 489
, Printer Status, on page 490
, Print Card, on page 491
, Laminator, on page 492
, Density Adjustment, on page 493
, Sensors, on page 494

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Information
The Information screen provides limited administrative control over the printer.

• Device Identification

• Reset

• XML

• Firmware

• Backup/Recovery: Saves and restores system Non-Volatile Memory (NVM) to and from
Flash Memory. Can be user to restore factory defaults if not overwritten.

• Click on the Save Backup button to save NVM to Flash.

• Click on the Restore Backup button to restore Flash to NVM.
• Click on the Get Backup button to retrieve Flash (XML file) to be saved, opened,
and read.

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Printer Status
Printer Status cannot be edited or changed by the user; however, this information may be
useful for Zebra-trained and certified personnel in diagnosing or evaluating printer status.

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Print Card
The Print Card screen allows you to print a sample card with either a built-in test image or a
custom image of your choice.

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Laminator
The Laminator screen is used for checking status and making temperature and laminate offset
adjustments and saving the changed settings to laminator memory.

• Temperature Offsets:
- Top Temp adjustment ranges from -5 to 5.
- Bottom Temp adjustment ranges from -5 to 5.

• For Laminate Offsets:

- Top Offset adjustment ranges from -30 to 30.
- Bottom Offset adjustment ranges from -30 to 30.
- Patch Length adjustment ranges from -50 to 50.
- Coarse Offset adjustment ranges from -50 to 50.

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Density Adjustment
The Density Adjustment screen is used for modifying Density Adjustments made at the
factory and/or changing Density Adjustments made by the user via the driver.

• Manufacturing density adjustments range from 50 to 150.

• User density adjustments range from 80 to 120.

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Sensors
The Sensors screen cannot be edited or changed by the user; however, this information may
be useful for Zebra-trained and certified service personnel in diagnosing or evaluating printer
sensor status.

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Service

• Printer Logs: This control lets you select, view, and save Printer Logs (Errors, Clean
Events, Service, and Events).

• NVMEM (Non-Volatile Memory): This control is used to back up NVMEM to XML

for importing back into a printer. This does a full restore of all printer settings and
calibration data. Use the control when replacing the Main PCBA (MCB); i.e., backup the
settings, replace the board, and restore the settings.

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 APPENDIX G
Print Quality

Introduction
This section gives the criteria for evaluating print quality.

Image Quality
Image Viewing Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
Density Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
Varnish (Bleeding) Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Monochrome Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Vertical Banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Horizontal Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Mis-Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Uniformity – Both Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Image Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Wavy Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Ribbon wrinkle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
Laminate Quality
Laminate Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
Laminate Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
Laminate Patch Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
Laminate Dirt/Debris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
Laminate Air Bubble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Laminate Scratch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Card Warp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Laminate Patch Adhesion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Laminate Wrinkle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Laminate Overhang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518

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 G: Print Quality

Printing
Image Viewing Conditions
The following viewing conditions required for evaluation of limit sample images:

Limit Sample Quality Inspection Viewing Criteria:

Viewing Distance: 8-12”

Viewing Angle: Any
View Time: 10 seconds maximum, if determination cannot be made
within 10 seconds, operator escalates to 2nd party (image
quality champion) for agreement and disposition
Lighting Conditions: Fluorescent desk lamp, Cool White bulb, 4200K Color
Temperature, CRI rating of 55-65, or equivalent

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 G: Print Quality

Density Adjustment
Criteria
Measure all 5 squares. Add the 5 readings and divide the total by 5. Average reading should be
in the range below. Use a densitometer.

• Tester: .97 – 1.03

• QA: .94 – 1.06

SAMPLE:

Corrective Action
Adjust the Yellow, Magenta, and/or Cyan power to increase or decrease the relative
temperature that is applied to the each color panel, which determines the amount of color that
is applied to the card; see Mechanical and Power Adjustment Tab on page 383 for details.

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 G: Print Quality

Varnish (Bleeding) Defects

Criteria
None allowed in the area indicated below.

Example of Defective Card:

None allowed in the area between black line and barcode (arrow below).

Corrective Action
Adjust the Overlay power to increase or decrease the relative temperature that is applied to the
overlay panel, which determines the amount of overlay that is applied to the card; see
Mechanical and Power Adjustment Tab on page 383 for details.

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Monochrome Printing
Criteria
Measure inside square only on card using a densitometer. Aim for center of the square. (The
cross-hair intersect ___location in the image below).

• Tester: .25 to .31. Optimal target of .28

• QA: .23 to .33. Optimal target of .28

For monochrome images, the following criteria must be met to pass:

• Text to be legible
• No barcode bleeding
• Border to be uniform

SAMPLE:

Corrective Action
Adjust the K-resin power to increase or decrease the relative temperature that is applied to the
K panel, which determines the amount of K that is applied to the card. There is a separate
control for front-side and back-side printing; see Mechanical and Power Adjustment Tab
on page 383 for details.

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 G: Print Quality

Vertical Banding
Criteria
See mid-magenta limit sample for minimum requirement.

Minimum Level for PASS

Corrective Action
Replace the printhead; see Printhead Assembly on page 167 for details.

If the problem persists, send the printer to Zebra Repair Services for evaluation.

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Horizontal Lines
Criteria
For horizontal lines that show up across the GREY card, print the 2nd GREY card in the suite
as a referee:

• If the horizontal line(s) DOES NOT show up in the same ___location on the 2nd GREY
CARD card, then PASS printer.
• If the horizontal line(s) can be seen in the same ___location on both cards, print 2nd set of
cards, if seen in both sets of cards, then FAIL printer; see Corrective Action below.

Example of a Defective Cards:

Corrective Action
Ensure that the density is set properly; see Density Adjustment on page 499.If you are using
PVC cards, try printing with composite cards.

Ensure that the card path clean; see Cleaning the Printer on page 351 for details.

A dirty printhead or left over debris form a ribbon jam/break can cause horizontal lines; see
Cleaning the Printer on page 351 for details.

Replace the printhead; see Printhead Assembly on page 167 for details.

If the problem persists, send the printer to Zebra Repair Services for evaluation.

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 G: Print Quality

Mis-Registration
Criteria
Criteria applies to ALL printed areas on ALL images printed during test.

If mis-registration is seen visually then use an eye loop for below specification.

• Tester and QA: 0.10mm or less PASS

Corrective Action
If the mis-registration is less at the lead edge of printing and gets worse at the trail edge, then
this is what we call progressive mis-registration. This is affected by the image content. If there
is lot of any one color (Y, M, or C) but very little of another, this imbalance causes the
resulting print for each panel to be slightly different lengths. Adjusting the YMC preheat
level might improve this for particular images; see Color (YMC) Optimization Tab on page 91
for details.

Another type of mis-registration is when the ribbon panel is not staged properly before
printing. For example, at start of a yellow print pass, the yellow ribbon panel is staged too late;
so the beginning of the yellow pass actually starts in the cyan panel. If this is happening, make
sure that the tricolor sensor is securely mounted; and calibrate the tricolor sensor; see Tricolor
Sensor Calibration on page 453.

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Scratches
Criteria
The following criteria applies to ALL ZXP Series 7 printers:

• Full length Scratch – FAIL

• Multiple Lines Scratch – FAIL (Scratches that reappear on multiple cards in the
same ___location)
• Deep Scratch - FAIL

Example of Defective Card

Corrective Action
Make sure that anything that comes in contact with the card (i.e., card path, rollers, guides,
printhead, etc.) are all clean and free of debris and not nicked or scratched. Use the ___location of
the scratches on the card as a guide as to where to look. Clean the card path as required; see
Cleaning the Printer on page 351 for details.

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 G: Print Quality

Uniformity – Both Directions

Criteria
See min-magenta limit sample for minimum requirement.

Minimum Level for PASS

Corrective Action
Ensure that the density is set properly; see Density Adjustment on page 499.

A dirty printhead or left over debris form a ribbon jam/break can cause uniformity issues; see
Cleaning the Printer on page 351 for details.

Dark and light difference between inboard or outboard long edges might be caused by the
printhead not moving down properly. If so, look for anything that could cause binding or
restriction to the up/down motion of the printhead.

Replace the printhead; see Printhead Assembly on page 167 for details.

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 G: Print Quality

Image Placement
Criteria
No cards are allowed to have images outside of the below specification. Use an eye loop
to monitor.

0 - .1

.20 - .45 .20 - .45

0 - .1

Dimensions are in millimeters Allow skew of

± .05

Corrective Action
Run the Offset Adjustment on page 477. Visually inspect the test card, and adjust the X and Y
offset values as required. Then run the Print Speed Calibration on page 478. Measure the
trailing edge white space, and adjust the trailing edge offset of the image as required.

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 G: Print Quality

Wavy Lines
Criteria
Wavy lines allowed on 25 percent of card maximum.

Example of Defective Card

Corrective Action
Change the ribbon.

Change the cards.

Ensure that the density is set properly; see Density Adjustment on page 499.

A dirty printhead or left over debris form a ribbon jam/break can cause wavy lines; see
Cleaning the Printer on page 351 for details.

Replace the printhead; see Printhead Assembly on page 167 for details.

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Ribbon wrinkle
Criteria
No ribbon wrinkle allowed on any printed card.

Corrective Action
Reduce the print density. Adjust the Yellow, Magenta, and/or Cyan power to decrease the
relative temperature that is applied to the each color panel; see Mechanical and Power
Adjustment Tab on page 383 for details.

Ensure that the card path and the printhead are clean; see Cleaning the Printer on page 351
for details.

If the problem persists, try running the Ribbon Torque Calibration on page 462.

Replace the printhead; see Printhead Assembly on page 167 for details.

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Miscellaneous
Criteria
The following defects are NOT ALLOWED on ANY printed card.

• Missing Pixels

Corrective Action
If there is a line that is very thin and crisp that runs the full long length of the card, then it is
likely a defective pixel in the printhead. Replace the printhead; see Printhead Assembly
on page 167 for details.

If the line is not crisp, the problem might be caused by debris on the printhead, which can be
cleaned with an alcohol swab.

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 G: Print Quality

Miscellaneous (continued)
• Panel Sync

Corrective Action
Run Tricolor Sensor Calibration on page 453. This procedure calibrates the RGB values of the
Tricolor Sensor for proper ribbon panel color detection. Failure may indicate that the tricolor
sensor needs replacement.

If the problem persists, try running the Ribbon Torque Calibration on page 462.

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 G: Print Quality

Laminating
Laminate Placement
Criteria
The laminate placement spec is .063” ±.031” (1.6 ± 0.8mm) on all sides.
No cards are allowed to have laminate placement outside of the spec.

1.6 ± .80

PATCH LENGTH
82.5 ± .5

1.6 ± .80

1.6 ± .80

Dimensions are in millimeters

1.6 ± .80

Corrective Action
Run Laminate Offset Adjustment on page 485. Visually inspect the test card, and adjust the X
offset value as required.

If the placement is out in the Y direction, replace the laminate roll and reprint cards.

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 G: Print Quality

Laminate Skew
Criteria
Skew is allowed as long as the best and worst case dimensions fall within the laminate
specification of .063’’ ± .031” (1.6 ± 0.8mm).

Corrective Action
A dirty card path can cause skew issues; see Cleaning the Printer on page 351 and Cleaning
the Laminator on page 356 for details.

Laminate Patch Length

Criteria
There is a patch length specification of 82.5mm ± 0.5mm (nominally 3.250” ± .020”).

Corrective Action
Run Laminate Offset Adjustment on page 485. Visually inspect the test card, and adjust the
patch length as required.

Laminate Dirt/Debris
Criteria
No amount of dirt/debris trapped between the laminate and the card is acceptable.

Corrective Action
Ensure that the cards are clean. Then use the cleaning cards and clean the printer card path and
the laminator card path; see Clean the Card Path on page 353 and Clean the Laminator Card
Path on page 357 for details.

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 G: Print Quality

Laminate Air Bubble

Criteria
No amount of air bubbles are acceptable.

Corrective Action
Debris and/or moisture can cause laminate air bubble issues. Ensure the laminator is clean
and dry; see Cleaning the Laminator on page 356 for details.

Laminate Scratch
Fine lines caused by surface abrasions, usually very straight.

Criteria
No amount of scratches is acceptable.

Corrective Action
If this issue appears, make sure that the cards are clean and reprint cards.

If this issue persists, then use the cleaning cards and clean the printer card path and the
laminator card path; see Clean the Card Path on page 353 and Clean the Laminator Card Path
on page 357 for details.

Card Warp
Criteria
Card warpage of more than 1 card thickness is not acceptable.

Corrective Action
If you are using PVC cards, try printing with composite cards.

This problem may be caused by too much heat being applied to the laminate during the
lamination process. Try decreasing the roller temperature offset and increasing the lamination
speed offset.; see Laminator Adjustments Tab on page 385 for details.

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 G: Print Quality

Laminate Patch Adhesion

Criteria
The laminate patch shall be securely adhered to the card. If the laminate can be lifted from the
card without damaging the card, then perform the Corrective Action below.

Failing Example:

Corrective Action
This problem may be caused by insufficient heat being applied to the laminate during the
lamination process. Try increasing the roller temperature offset and decreasing the lamination
speed offset; see Laminator Adjustments Tab on page 385 for details.

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 G: Print Quality

Laminate Wrinkle
Criteria
Laminate wrinkle is laminate that does not lay flat on the card.

No amount of laminate wrinkle is acceptable.

Failing Example:

Corrective Action
If this issue appears, the laminate roll may be bad. Replace the laminate.

If this issue persists, then examine the heater rollers in the laminator oven for dirt or other
contamination. Clean as required; see Clean the Laminator Oven (Heater Rollers) on page 360
for details.

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 G: Print Quality

Laminate Overhang
Criteria
Laminate overhang is a laminate patch that exceeds the boundaries of the card.

No amount of laminate overhang is acceptable.

Failing Example:

Corrective Action
Run Laminate Offset Adjustment on page 485. Visually inspect the test card, and adjust the X
offset value and/or patch length as required.

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 G: Print Quality

Exceptions
The following are known and acceptable print images.

• Chattering

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Exceptions (continued)
The following is a known and acceptable print image.

• Scalloping (Printer + Laminator only)

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520 Zebra ZXP Series 7 Card Printer Service Manual P1036102-002
 APPENDIX H
Upgrade Kit Instructions

This section contains detailed instructions for the following upgrade kits:

MIFARE Contact Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .523

Contact Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .531
Mag Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543
Laminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .558

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 H: Upgrade Kit Instructions
MIFARE Contact Encoder

MIFARE Contact Encoder

Caution • This upgrade kit may only be installed by Zebra trained and certified
personnel. Any attempt to install it by other than Zebra trained and certified
personnel will void the product warranty and may cause damage to the equipment.

Introduction
These instructions describe installing MIFARE Contact Encoder Upgrade Kit P1037750-001
in a Zebra ZXP Series 7 Card Printer.

In general, only removal directions are presented; unless otherwise noted, replacement would
be performed by reversing the removal steps.

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 H: Upgrade Kit Instructions
MIFARE Contact Encoder

Parts List
P1037750-001: Kit, Upgrade, MIFARE Contact Encoder, ZXP7
QTY PART NUMBER DESCRIPTION
1 P1030522 KIT,ENCDR,MIFARE,ZXP7

Special Tools
• TORX T10 Driver
• ZXP Series 7 Service Tool with Driver

Procedure
Electric Shock Caution • Before performing any of the procedures in this section, set
the printer power to OFF (O) and disconnect the power cord.
Electrostatic Discharge Caution • This replacement procedure must be performed at a
static-free work station, an anti-static wrist strap must be worn and properly terminated,
or other appropriate protection must be used.
Caution • Before beginning any of the steps that follow, read completely through this
procedure. If you do not have the specified tools, or if any step(s) seem beyond your skill
or experience level, do not attempt the procedure. You may cause additional damage to
the printer.

Installation
Step 1. If not already done, remove the Feeder Cartridge.

Step 2. Open the Print Cover and the Options Cover.

Step 3. Remove the Manual Feed Cleaning Cassette.

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 H: Upgrade Kit Instructions
MIFARE Contact Encoder

Step 4. Remove the Back Cover.

a. With a TORX T10 driver, remove the three screws (SCR EJOT 30x10, 4 in-lb)
holding the Back Cover in place. Use an 8-inch tapered bit TORX T10 driver
for the screw on the left.

b. Remove the Back Cover, and set it aside.

Step 5. With a TORX T10 driver, install the MIFARE/Contact Encoder PCBA with four
screws (SCR EJOT 30x8, 5.5 in-lb) and washers. Note that the PCBA should be
able to move slightly.

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 H: Upgrade Kit Instructions
MIFARE Contact Encoder

Step 6. Install the module cables.

a. Connect J1 on the OPSC MODULE PCBA to J4 on the Flipper PCBA; see

arrows below.

J4
J1 J2

J50

b. Connect J2 (above) on the OPSC MODULE PCBA to J50 (below) on the

Main PCBA.

J2

J50

c. Ensure that the cables are routed through the cable brackets.

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 H: Upgrade Kit Instructions
MIFARE Contact Encoder

Step 7. Remove the Shroud.

a. Depress the two tabs (arrows below) to unlock the Shroud.

b. Lift the Shroud up and out of the Printer, and set it aside.

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 H: Upgrade Kit Instructions
MIFARE Contact Encoder

Step 8. Install the MIFARE/Contact Encoder Module. Note that the Options Module has
been removed from the Printer for clarity.

a. Rotate the locking key fully counter-clockwise, to the unlocked position

(circle below).

b. Set the Module into place, an then slide it to the rear (dashed arrows above).
Ensure the plug on the back of the Module is fully seated in the connector.

c. Press the spring-loaded key down, and rotate it fully clockwise (dashed arrows
below) to lock the Module in place.

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 H: Upgrade Kit Instructions
MIFARE Contact Encoder

Reassembly
Reassembly is performed by reversing the installation steps.

Step 1. Install the Shroud see Installation step 7.

Step 2. Install the Back Cover; see Installation step 4.

Step 3. Install the Manual Feed Cleaning Cassette.

Step 4. Close the Covers.

Step 5. Install the Feeder Cartridge.

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 H: Upgrade Kit Instructions
MIFARE Contact Encoder

MIFARE Contact Encoder Tests

Use the ZXP Series 7 Service Tool to check the operation of the MIFARE Contact Encoder.

You will need five SLE4442 cards and five MIFARE cards. Note that the cards can be reused
for the various tests.

Perform the four tests circled below: Smart Card Enable, Smart Card Calibration, Smart Card
Contact Read/Write Test, and Contactless Read/Write Test.

Step 1. Enter the Serial Number of the Printer.

Step 2. Select the desired test.

Step 3. Click the START button.

Step 4. Follow the on-screen instructions.

Step 5. When each test is completed, note the results: Test Passed or Test Failed.

The printer must pass all four tests to ensure that the MIFARE Contact Encoder
is functioning properly.

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 H: Upgrade Kit Instructions
Contact Station

Contact Station

Caution • This upgrade kit may only be installed by Zebra trained and certified
personnel. Any attempt to install it by other than Zebra trained and certified
personnel will void the product warranty and may cause damage to the equipment.

Introduction
These instructions describe installing Contact Station Upgrade Kit P1037750-002 in a Zebra
ZXP Series 7 Card Printer.

In general, only removal directions are presented; unless otherwise noted, replacement would
be performed by reversing the removal steps.

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 H: Upgrade Kit Instructions
Contact Station

Parts List
P1037750-002: Kit, Upgrade, Contact Station, ZXP7
QTY PART NUMBER DESCRIPTION
1 P1028143 ASSY,OPTION,CONTACT STATION

Special Tools
• TORX T10 Driver
• 5.5mm Nut Driver
• Adjustable Wrench
• ZXP Series 7 Service Tool with Driver
• Zebra External Contact Station Reader with Driver
• Contact Station Upgrade Tool (P1037750-403)

Procedure

Electric Shock Caution • Before performing any of the procedures in this section, set
the printer power to OFF (O) and disconnect the power cord.

Electrostatic Discharge Caution • This replacement procedure must be performed at a

static-free work station, an anti-static wrist strap must be worn and properly terminated,
or other appropriate protection must be used.

Caution • Before beginning any of the steps that follow, read completely through this
procedure. If you do not have the specified tools, or if any step(s) seem beyond your skill
or experience level, do not attempt the procedure. You may cause additional damage to
the printer.

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 H: Upgrade Kit Instructions
Contact Station

Installation
Step 1. If not already done, remove the Feeder Cartridge.

Step 2. Open the Print Cover and the Options Cover.

Step 3. Remove the Manual Feed Cleaning Cassette.

Step 4. Remove the Back Cover.

a. With a TORX T10 driver, remove the three screws (SCR EJOT 30x10, 4 in-lb)
holding the Back Cover in place. Use an 8-inch tapered bit TORX T10 driver
for the screw on the left.

b. Remove the Back Cover, and set it aside.

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 H: Upgrade Kit Instructions
Contact Station

Step 5. Remove the Shroud.

a. Depress the two tabs (arrows below) to unlock the Shroud.

b. Lift the Shroud up and out of the Printer, and set it aside.

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 H: Upgrade Kit Instructions
Contact Station

Step 6. Slide the module cable through the access hole in the Frame.

Step 7. Set the Smartcard Module into position, but do not lock it in place.

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 H: Upgrade Kit Instructions
Contact Station

Step 8. With a TORX T10 driver, install the Contact Station PCBA with four screws
(SCR EJOT 30x8, 5.5 in-lb) and washers. Note that the PCBA should be able to
move slightly.

Step 9. Locate the DB9 connector bracket (arrow below).

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 H: Upgrade Kit Instructions
Contact Station

Step 10. Install the DB9 connector assembly.

a. With a 5.5mm Nut Driver, attach the DB9 connector (circle below) to the
connector bracket.

b. DB9 hardware details.

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 H: Upgrade Kit Instructions
Contact Station

c. Connect the module cable and the DB9 cable.

d. Route the cable through the cable brackets.

e. Remove the DB9 plug in the Back Cover.

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 H: Upgrade Kit Instructions
Contact Station

Step 11. Install the module cables.

a. Connect J1 on the OPSC MODULE PCBA to J4 on the Flipper PCBA; see

arrows below.

J4
J1 J2

J50

b. Connect J2 (above) on the OPSC MODULE PCBA to J50 (below) on the

Main PCBA.

J2

J50

c. Ensure that the cables are routed through the cable brackets.

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 H: Upgrade Kit Instructions
Contact Station

Step 12. Install the Contact Station Module.

a. Slide the module to the rear and into position.

b. Press the key down, and rotate it clockwise to lock the module in place.

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 H: Upgrade Kit Instructions
Contact Station

Reassembly
Reassembly is performed by reversing the installation steps.

Step 1. Install the Shroud see Installation step 5.

Step 2. Install the Back Cover; see Installation step 4.

Step 3. Install the Manual Feed Cleaning Cassette.

Step 4. Close the Covers.

Step 5. Install the Feeder Cartridge.

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 H: Upgrade Kit Instructions
Contact Station

Contact Station Tests

Use the ZXP Series 7 Service Tool to check the operation of the Contact Station.

Connect the External Contact Station Reader to the Printer and Computer.

You will need five SLE4442 cards. Note that the cards can be reused for the various tests.

Perform the three tests circled below: Smart Card Enable, Smart Card Calibration, and
Smart Card Contact Read/Write Test.

Step 1. Enter the Serial Number of the Printer.

Step 2. Select the desired test.

Step 3. Click the START button.

Step 4. Follow the on-screen instructions.

Step 5. When each test is completed, note the results: Test Passed or Test Failed.

The printer must pass all four tests to ensure that the Contact Station is functioning properly.

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Mag Encoder

Mag Encoder

Caution • This upgrade kit may only be installed by Zebra trained and certified
personnel. Any attempt to install it by other than Zebra trained and certified
personnel will void the product warranty and may cause damage to the equipment.

Introduction
These instructions describe installing Mag Encoder Upgrade Kit P1037750-003 in a Zebra
ZXP Series 7 Card Printer.

In general, only removal directions are presented; unless otherwise noted, replacement would
be performed by reversing the removal steps.

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Parts List
P1037750-003: Kit, Upgrade, Mag Encoder, ZXP7
QTY PART NUMBER DESCRIPTION
1 P1020981 KIT,MAG,ISO,ZXP7
1 P1051857 TOOL,MAG,TENSIONING SPRING,ZXP7

Special Tools
• TORX T10 Driver
• Belt Tensioning Tool, P1051857
• ZXP Series 7 Service Tool with Driver

Procedure

Electric Shock Caution • Before performing any of the procedures in this section, set
the printer power to OFF (O) and disconnect the power cord.

Electrostatic Discharge Caution • This replacement procedure must be performed at a

static-free work station, an anti-static wrist strap must be worn and properly terminated,
or other appropriate protection must be used.

Caution • Before beginning any of the steps that follow, read completely through this
procedure. If you do not have the specified tools, or if any step(s) seem beyond your skill
or experience level, do not attempt the procedure. You may cause additional damage to
the printer.

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Installation
Step 1. If not already done, remove the Feeder Cartridge.

Step 2. Open the Print Cover and the Options Cover.

Step 3. Remove the Manual Feed Cleaning Cassette.

Step 4. Remove the Shroud.

a. Depress the two tabs (arrows below) to unlock the Shroud.

b. Lift the Shroud up and out of the Printer, and set it aside.

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Step 5. Remove the Options Cover.

a. If not already done, remove the Cleaning Cartridge and Cleaning Cassette.

b. With a TORX T10 driver, remove the two screws (SCR EJOT 30x10, 4 in-lb)
holding the Options Cover in place.

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c. Disconnect the OCP cable-to-cable connection.

d. Remove the Options Cover, and set it aside.

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Step 6. Remove the Non-Mag Pressure Roller Assembly and Belt.

a. Locate the Pressure Roller Assembly; circle below.

b. With a TORX T10 driver, remove the screw (SCR EJOT 30x8, 5.5 in-lb)
holding the Pressure Roller Assembly in place; arrow below.

c. Remove the Belt; circle above.

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d. Pull the Pressure Roller Assembly forward, up, and out of the Frame.

e. Set the Pressure Roller Assembly and belt aside.

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Step 7. Remove the Back Cover.

a. With a TORX T10 driver, remove the three screws (SCR EJOT 30x10, 4 in-lb)
holding the Back Cover in place. Use an 8-inch tapered-bit TORX T10 driver
for the screw on the left.

b. Remove the Back Cover, and set it aside.

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Step 8. Install the Mag Head.

a. Connect the Mag Head Cable to the Mag Head PCBA (circle below), and pass
the cable through the access hole in the Frame (dashed arrow below).

b. With a TORX T10 driver, install the two screws (SCR EJOT 30x8, 5.5 in-lb)
holding the Mag Head in place; arrows below.

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Step 9. Install the Mag Control PCBA.

a. Pull the Mag Head Cable (installed in step 8) out of the Frame, and connect the
plug to the Mag Control PCBA.

b. With a TORX T10 driver, install the five screws (SCR EJOT 30x8, 5.5 in-lb)
that hold the Mag Control PCBA in place.

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c. Connect J1 on the OPMAG MODULE PCBA to J3 on the Flipper PCBA; see

arrows below.

J1 J3

J2

J51

d. Connect J2 (above) on the OPSC MODULE PCBA to J51 (below) on the

Main PCBA.

J51

J2

e. Ensure that the cables are routed through the cable brackets.

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Step 10. Install the Mag Pressure Roller Assembly and Belt. Note that the Options Module
has been removed from the Printer for clarity.

a. Push the Pressure Roller Assembly down and forward, into the Frame.

b. With a TORX T10 driver, install the screw (SCR EJOT 30x8, 5.5 in-lb) that
holds the Pressure Roller Assembly in place; arrow below.

c. Install the Belt; circled above.

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Step 11. Adjust the belt tension. For this adjustment, you will need the Mag Tensioning
Spring Tool (P1051857).

a. Loosen the two motor mounting screws (arrows below).

b. With the Belt Tensioning Tool, hook the spring around the motor shaft (right
arrow below).

c. With the Belt Tensioning Tool, hook the ring in the notch (left arrow above).

d. Tighten the two motor mounting screws; see step a.

e. Remove the Belt Tensioning Tool.

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Reassembly
Reassembly is performed by reversing the installation steps.

Step 1. Install the Back Cover see Installation step 7.

Step 2. Install the Options Cover; see Installation step 5.

Step 3. Install the Shroud see Installation step 4.

Step 4. Install the Manual Feed Cleaning Cassette.

Step 5. Close the Covers.

Step 6. Install the Feeder Cartridge.

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Mag Encoder Tests

Use the ZXP Series 7 Service Tool to check the operation of the Mag Encoder.

For these tests, you will need five PVC HiCo MAG cards and five PVC LoCo MAG cards.
Note that the cards can be reused for the various tests.

Perform the three tests circled below: MAG Calibration, MAG Write Test HiCo, and
MAG Write Test LoCo.

Step 1. Enter the Serial Number of the Printer.

Step 2. Select the desired test.

Step 3. Click the START button.

Step 4. Follow the on-screen instructions.

Step 5. When each test is completed, note the results: Test Passed or Test Failed.

The printer must pass all three tests to ensure that the Mag Encoder is functioning properly.

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 H: Upgrade Kit Instructions
Laminator

Laminator

Caution • This upgrade kit may only be installed by Zebra trained and certified
personnel. Any attempt to install it by other than Zebra trained and certified
personnel will void the product warranty and may cause damage to the equipment.

Introduction
These instructions describe installing Single-Sided Laminator Upgrade Kit P1037750-011 or
Dual-Sided Laminator Upgrade Kit P1037750-012 in a Zebra ZXP Series 7 Card Printer.

In general, only removal directions are presented; unless otherwise noted, replacement would
be performed by reversing the removal steps.

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Laminator

Parts List
P1037750-011: Kit, Lam SS, ZXP7
QTY PART NUMBER DESCRIPTION
1 P1052874 ASSY,AMK,ZXP7 LAMINATOR,SS

P1037750-012: Kit, Lam DS, ZXP7

QTY PART NUMBER DESCRIPTION
1 P10528746 ASSY,AMK,ZXP7 LAMINATOR,DS

Special Tools
• TORX T10 Driver
• Phillips screwdriver
• ZXP Series 7 Service Tool with Driver

Procedure

Electric Shock Caution • Before performing any of the procedures in this section, set
the printer power to OFF (O) and disconnect the power cord.

Electrostatic Discharge Caution • This replacement procedure must be performed at a

static-free work station, an anti-static wrist strap must be worn and properly terminated,
or other appropriate protection must be used.

Caution • Before beginning any of the steps that follow, read completely through this
procedure. If you do not have the specified tools, or if any step(s) seem beyond your skill
or experience level, do not attempt the procedure. You may cause additional damage to
the printer.

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Laminator

Preparation
Step 1. Open the Print Cover.

Step 2. Remove the Ribbon Drawer.

a. If a ribbon is installed, remove the ribbon.

b. Slide the Ribbon Drawer out of the Printer until it stops.

c. Depress the two locking tabs (one on each side) to free the Ribbon Drawer.

d. Slide the Ribbon Drawer out of the Printer, and set it aside.

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Step 3. Remove the Back Cover.

a. With a TORX T10 driver, remove the three screws (SCR EJOT 30x10, 4 in-lb)
holding the Back Cover in place. Use an 8-inch tapered bit TORX T10 driver
for the screw on the left.

b. Remove the Back Cover, and set it aside.

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Step 4. Remove the Left Side Cover.

a. From the front of the Printer: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 4 in-lb) holding the Left Cover in place.

b. From the back of the Printer: With a TORX T10 driver, remove the two screws
(SCR EJOT 30x10, 4 in-lb) holding the Left Cover in place.

c. Remove the Left Cover, and set the cover and screws aside.

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Step 5. Remove the Belt and Gear Panel

a. With a TORX T10 driver, remove the four front screws (SCR EJOT 30x10, 4
in-lb) holding the Belt and Gear Panel in place.

b. Remove the Belt and Gear Panel, and set the panel and screws aside.

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Installation
Step 1. Remove the Laminator Rear Cover.

a. Open the Laminator Doors (Upper and Lower).

b. With a TORX T10 driver, remove the two screws (SCR EJOT 30x10, 5.5 in-lb)
holding the Rear Cover in place.

c. Set the Rear Cover aside.

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Step 2. Disconnect the AC Power cable at J8 (circled below).

Step 3. Remove the Printer Power Supply.

a. With a TORX T10 driver, remove the upper screw; and free the cable
clamp and cables (arrow below).

b. With a Phillips screwdriver, remove the lower screw (arrow above).

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c. Disconnect the printer power supply connector (circled below).

d. With a TORX T10 driver, remove the four screws holding the Power Supply
in place.

e. Remove the Power Supply, and set it aside.

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Laminator

Step 4. Connect the Laminator Power Supply Cable to the Printer. This cable was
disconnected from the laminator in step 2.

a. Remove the two plastic spade-lug covers (circled below).

b. Slip the blue wire connector and the brown wire connector on the power switch
spade lugs (circled above). Blue goes on the bottom, and brown goes on the top.

c. With a 5.5mm Nut Driver, remove the two nuts (circled below) holding the
printer ground wire in place. Do not remove the ground wire.

d. With a 5.5mm Nut Driver and the nuts removed in step c, attach the ground
wire from the Laminator Power Supply Cable and the reattach the ground wire
from the Printer (circled above).

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Laminator

Step 5. With a TORX T10 driver and the four screws removed in step 3, re-install the Power
Supply. Tighten the four screws to 4 in-lb.

Step 6. Attach the Laminator to the Printer.

a. Slide the Laminator and Printer together.

b. Ensure the mounting holes are aligned, one in the back and three in the front.

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c. With a TORX T10 driver, insert a side cover mounting screw into the rear
mounting hole and tighten securely (5.5 in-lb).

d. With a TORX T10 driver, insert the three side cover mounting screw into the
front mounting holes and tighten securely (5.5 in-lb).

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Laminator

Step 7. Connect the printer/laminator cables.

a. With a Phillips screwdriver, attach the ground wire (arrow below).

b. With a TORX T10 driver, reattach the cable clamp and cables removed
in step 3.

c. Reconnect J8 (disconnected in step 2) on the Laminator (circled below).

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d. Reconnect the printer power supply connector (circled below).

e. Connect the DC Power cable (twisted red and black wires) to CN3 on the
Printer Power Supply (arrow below).

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Laminator

f. Remove the Printer Bottom Cover.

g. Feed the Laminator Control Cable through the access hole in the Frame and
connect it to J10 on the Main PCBA.

h. Reinstall the Printer Bottom Cover and Reject Bin.

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Reassembly
Reassembly is performed by reversing the installation steps.

Step 1. Install the Belt and Gear Panel; see Preparation page 563.

Step 2. Install the Left Side Cover; see Preparation page 562.

Step 3. Install the Back Cover; see Preparation page 561.

Step 4. Install the Ribbon Drawer.

Step 5. Close the Covers.

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Laminator Tests
Use the ZXP Series 7 Service Tool to check the operation of the Laminator.

For these tests, you will need 30 mil PVC cards.

Perform the three tests circled below: Laminate Sensor Calibration, Laminate Offset
Adjustment, and Lamination Print Test.

Step 1. Enter the Serial Number of the Printer.

Step 2. Select the desired test.

Step 3. Click the START button.

Step 4. Follow the on-screen instructions.

Step 5. When each test is completed, note the results: Test Passed or Test Failed.

The printer must pass all three tests to ensure that the Laminator is functioning properly.

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 APPENDIX I
Worldwide Support

For Technical Support or Repair Services, contact the appropriate facility listed below.

North America and Latin America - Technical Support

T: +1 877 ASK ZEBRA (877 275 9327)
+1 847 913 2259
E: [email protected]

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 Repair Order (RO) number. Mark the RO number
clearly on the outside of the box. Ship the equipment, freight prepaid, to the address listed below:

Zebra Technologies Repair Services

333 Corporate Woods Parkway
Vernon Hills, IL 60061

webform:www.zebra.com/repair
T: +1 877 ASK ZEBRA (877 275 9327)
E: [email protected]

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 I: Worldwide Support

Europe, Middle East, and Africa - Technical Support

Language Phone Email

Arabic +971 (0)46058220 [email protected]
Dutch +31 (0)33 450 50 48 [email protected]
English (UK) +44 (0)1628 556 225 [email protected]
(Sweden) +46 (0)8 594 709 88 [email protected]
+27 (0)11 201 7712 /
(South Africa) [email protected]
0860 393272
French +33 (0) 1 53 48 12 74 [email protected]
German +49 (0) 2159 676 870 [email protected]
Hebrew +97 236 498 140 [email protected]
Italian +39 0 2 575 06388 [email protected]
Polish +48 223 801 980 [email protected]
Russian +7 495 739 5993 [email protected]
Spanish +34 (0) 917 992 896 [email protected]
Turkish +90 212 314 1010 [email protected]

For further assistance, contact:

Zebra Technologies Card Printer Solutions
Dukes Meadow
Millboard Road, Bourne End
Buckinghamshire SL8 5XF, UK

T: +44 (0) 1628 556 025

F: +44 (0) 1628 556 001
E: [email protected]

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 I: Worldwide Support

Europe, Middle East, and Africa - Repair Services

Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-of-
warranty repair, contact your supplier for a Return Materials Authorization (RMA) number, or
contact one ot the following repair centers for support and instructions:

Type of repair and ___location Phone Email

Depot Repair in Germany,
+49 (0) 2159 676 870 [email protected]
Austria, Switzerland

Depot Repair in France +33 (0) 1 53 48 12 74 [email protected]

Depot and On-Site Repair in

+44 (0) 1628 556 225 [email protected]
UK and Ireland

Depot Repair in South Africa +27 (0) 11 201 7777 -

Depot Repair in Middle East +971 (0) 46058220 [email protected]

For further assistance, contact:

For assistance anywhere in the EMEA, contact After Sales Customer Services at:

T: + 44 (0) 177 2 69 3069

E: [email protected]

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 I: Worldwide Support

Asia Pacific - Technical Support

Zebra Technologies Asia Pacific Pte. Ltd.
120 Robinson Road
#06-01 Parakou Building
Singapore 068913

T: +65 6858 0722

F: +65 6885 0838
E: [email protected]

Asia Pacific - 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 either address listed below:

Zebra Technologies Asia Pacific Pte. Ltd.

No.5 Changi North Way Level 3
Singapore 498771
Agility Building

T: +65 6546 2670 ext 3203 and 3204

F: +65 6546 5328
E: [email protected]

Zebra Website
http://www.zebra.com

km.zebra.com (Knowledge Base)\

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