ZXP 1 Series PDF

ZEBRA ZXP Series 1™
Service Manual
P1061942-001
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 1 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 our web site at:
http://www.zebra.com/environment
P1061942-001 Rev. B
Contents
1 • General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Features, Controls, and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.4 ISO Standard Card Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.5 Compliance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.1 Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.2 Zebra Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2 • Installation and Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.2 Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.3 Setting up the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.4 Connecting Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.5 Connecting the Printer to your Computer . . . . . . . . . . . . . . . . . . . . . . . .19
2.6 Viewing Printer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
2.7 Installing the Windows Printer Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.7.1 USB Driver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.7.2 Ethernet Driver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.7.3 Setting Up a Network Printer . . . . . . . . . . . . . . . . . . . . . . . . . . .31
2.7.4 Printer Pooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
2.8 Changing the Printer Driver Options . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.8.1 Printer Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.8.2 Printing Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
2.1 Installing the Ribbon Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
2.2 Loading Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
2.3 Print a Test Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
2.4 Printer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
2.5 Packing the Printer for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
P1061942-001 ZXP Series 1 Card Printer Service Manual iii

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3 • Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
3.2 Card Printing Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
3.3 Card Path Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
3.4 Card Movement During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
3.5 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
3.6 CPU PCBA Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
4 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
4.2 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
4.2.1 LCD Panel Warnings and Error Messages . . . . . . . . . . . . . . . .90
4.2.2 Print Quality Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
5 • Replacement Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
5.2 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
5.3 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
5.4 Procedure List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
5.5 Spare Kit List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
5.6 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
5.6.1 Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
5.6.2 Ribbon Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
5.6.3 Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
5.6.4 Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
5.6.5 Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
5.6.6 Feed Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
5.6.7 LCDisplay PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
5.6.8 Printhead Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
5.6.9 Feed Cover Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
5.6.10 Feeder Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
5.6.11 Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
5.6.12 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
5.6.13 Ethernet PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
5.6.14 Main PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
5.6.15 Ground Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
5.6.16 PCBA Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
5.6.17 Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
5.6.18 Card Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
5.6.19 Flipper Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
5.6.20 Front Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
5.6.21 Ribbon Flag Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .140
5.6.22 Encoder Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
5.6.23 Linkage - Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
5.6.24 Rocker - Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
5.6.25 Printhead Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
5.6.26 Ribbon Take-Up Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
5.6.27 Ribbon ID PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
5.6.28 Lid Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
5.6.29 Linkage - Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
iv ZXP Series 1 Card Printer Service Manual P1061942-001

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5.6.30 Rocker - Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

5.6.31 Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
5.6.32 Printhead Lift Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
5.6.33 Pressure Rollers - Front and Back . . . . . . . . . . . . . . . . . . . . . .169
5.6.34 Mag Encoder Assembly - Head and Sensor . . . . . . . . . . . . . .173
5.6.35 Mag Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
5.6.36 Card Sync Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
5.6.37 Cleaning Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
5.6.38 Platen Roller and Exit Roller . . . . . . . . . . . . . . . . . . . . . . . . . .178
5.6.39 ATM Card Feed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
5.6.40 Drive Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
6 • Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.1 Cleaning the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.1.1 When to Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
6.1.2 How to Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
6.2 Cleaning the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
A • Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

B • Advanced Sharing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
C • Accessing a Network Printer via a Web Browser . . . . . . . . . . . . 201
D • CardSense Single Card Feed Option . . . . . . . . . . . . . . . . . . . . . . 213
E • Magnetic Encoder Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
F • Half-Panel Ribbon Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
G • Upgrade Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
H • Spares List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
I • Worldwide Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
P1061942-001 ZXP Series 1 Card Printer Service Manual v

vi ZXP Series 1 Card Printer Service Manual P1061942-001
1
General Description
1.1 Description
This manual contains installation, operation, and maintenance information for the Zebra ZXP
Series 1 Card Printer, manufactured by Zebra Technologies Corporation.
The printer provides full color dye sublimation or monochrome thermal transfer printing on
standard CR-80, ISO 7810 format, 2.12 inch by 3.38 inch (54 mm by 86 mm) PVC or
PVC Composite plastic 10-mil to 40-mil cards.
Zebra ZXP Series 1 Load-N-Go™ ribbon cartridges are used with an integrated card cleaning
roller for easy ribbon changing or replacement.
Several options are available, making the printers configurable for varied application
environments:
• Magnetic Encoder
• USB only or USB and 10/100 Ethernet
• CardSense™ Single Card Feed Roller Kit
Its auto-switching external power supply uses inter-changeable power cords for
maximum flexibility.
P1061942-001 Zebra ZXP Series 1 Card Printer Service Manual 1

1: General Description
Features, Controls, and Indicators
1.2 Features, Controls, and Indicators

The picture below points out some of the printer’s external features.
Card Feeder
Cover Quick Help
QR Code
Lid Release
Button
Multi-Function LCD
Display Panel
Multi-Function
Control Button
Card Output Zebra Print

Hopper Touch Tag
• Card Feeder Cover - Opening the Card Feeder Cover gives access to the automatic card
feeder. The translucent cover allows you to see when the card supply is running low. The
feeder has a 100-card capacity (30-mil cards).
• Lid Release Button - Pressing the Lid Release Button allows the printer’s lid to swing
open. This gives internal access for changing the Ribbon Cartridge, changing Cleaning
Rollers, and cleaning the printer.
• Multi-Function LCD Display Panel - The Multi-Function LCD Display Panel displays
printer status information. Messages also alert the user of the need for action and indicate
certain fault conditions.
• Multi-Function Control Button - The Multi-Function Control Button initiates several

functions; these are described in the appropriate sections of this document.
• Card Output Hopper - Front-side Card Output Hopper has a 50-card capacity.
• Quick Help QR Code - The QR code launches web-based help pages to find user videos
for simple set-up and maintenance instructions; see http://www.zebra.com/zxp1-info
for details.
• Zebra Print Touch Tag - This touch point uses NFC technology to provide key
information about the printer; see http:\\zebra.com/nfc for details.
2 Zebra ZXP Series 1 Card Printer Service Manual P1061942-001

Rear Panel Connectors, Controls, and Indicators
Standard USB Connection

The figure below shows the rear of the Printer with the standard USB connection.
USB Power
Connector Socket
Security Power
Cable Slot Switch
Ethernet Connection
The figure below shows the rear of the printer with the standard USB interface with the
Ethernet connection.
USB Power
Connector Socket
Security Power
Cable Slot Switch
Link LED Power LED
Ethernet Connector
The Ethernet Connector has two LED status indicators:
• Power LED (amber): When illuminated, indicates power is on.

• Link LED (green): When illuminated, indicates valid Printer-Ethernet connectivity.

Multi-Function LCD Panel
Your printer is equipped with a Multi-Function LCD Panel to provide printer status
information. The readout is controlled by the Multi-Function Control Button directly below
the viewing window.
Multi-Function LCD Panel messages fall into three categories: Operational, Warning,
and Error.
Operational Messages
Operational Messages are displayed during the Printer’s normal operation.
OPERATIONAL
CARD READY
CLEANING PRINTER
CLOSE FEEDER DOOR
DOWNLOADING DATA
DOWNLOADING FIRMWARE
EMPTY FEEDER THEN CLOSE COVER
FEED LONG CLEANING CARD IN EXIT
INITIALIZING
INSERT CARD
INSERT FEEDER CLEANING CARD
MAG ENCODING
PRINTING BLACK
PRINTING CYAN
PRINTING MAGENTA
PRINTING MONO
PRINTING OVERLAY
PRINTING YELLOW
PUSH BUTTON TO CONTINUE
READY
REMOVE FEEDER CLEANING CARD
REMOVE LONG CLEANING CARD
REMOVE RIBBON THEN CLOSE LID
SINGLE CARD READY-PRINT OR EJECT

Warning Messages
Warning messages alert the operator to action that should be taken; the printer will generally
continue operation.
WARNINGS (Printer will still operate)

CHECKING RIBBON
CLEAN PRINTER
CLOSE LID
ENCODING ERROR
INVALID MAGNETIC DATA
Error Messages
Error messages are displayed when a situation causes the printer to stop operating. Depending
on the cause of the error message, restarting the printer or curing the displayed Error may
return the printer to operational status, or the printer may require troubleshooting and repair.
ERRORS (Printer will not operate)

CHECK RIBBON
COMMAND ERROR
COVER OPEN
LID OPEN
MECHANICAL ERROR
OUT OF CARDS
OUT OF RIBBON

Specifications
1.3 Specifications
Specifications are provided for reference and are based on printer tests using Zebra brand
consumables. Results may vary in actual application settings or when using other than
recommended Zebra supplies. Zebra recommends always qualifying any application with
thorough testing.
Standard Features
• Eco-Friendly Load-N-Go™ drop-in ribbon ZXP Series 1 cartridges

• ZRaster™ host-based image processing
• Auto calibration of ribbon
• USB connectivity
• Microsoft Certified Windows drivers
• Print Touch NFC tag for online Printer documentation access
• 100 card covered feeder (30 mil)
• 50-card capacity integrated flip-out card output hopper (30 mil)
• 16-character LCD operator control display
• 300 dpi (11.8 dots/mm) print resolution
• Two-year warranty on printer
• Two-year (unlimited passes) original printhead
• One-year hot swap (U.S. only)
Printing Specifications
• Dye-sublimation thermal transfer direct to card

• Full color or monochrome printing
• Single-sided printing
• Edge-to-edge printing on standard CR-80 media
Printing Throughput
Printing throughput (cards per hour) based on click-to-drop printing, average print
coverage, with USB connectivity. Times may vary depending on the computer and
other configurations.
• 500 cph monochrome single-sided
• 120 cph single-sided YMCKO

Specifications
Encoding Options and Specifications
• Magnetic stripe encoder – ISO 7811 (new and re-encoded; tracks 1, 2, and 3; high
and low coercivity; stripe down; 30 mil card only; factory install only)
Optional Features
• CardSense™ Single-Card Feed Roller Kit - optional, field upgradable

• ZebraCare™ extended product warranty programs
Communications Interfaces
• USB V2.0 (cable included) - standard

• Built-in 10/100 Ethernet - optional, field upgradable
Card Compatibility
NOTE: For optimum print quality and printer performance, use of Zebra genuine
supplies is recommended.
• Card Thickness: 10-40 mil
• Card Size: CR-80, ISO 7810 format, Type ID-1, 2.12" (54 mm) x 3.38" (86 mm)
• Card Material: PVC and PVC composite
• Spot Color or monochrome print only on less than 20 mil or greater than 35 mil
card thickness
Physical Specifications (standard model)
Printer
Height 9.3" (236 mm)
Width 7.9" (200 mm)
Depth 13.0" (330 mm)
Weight 11.6 lbs (5.3 kg)
Electrical Specifications
• Auto-switching single-phase AC power

• Operating range: 90-132VAC and 190-264VAC RMS
• Frequency range: 47-63 Hz
• Power requirement is 100W max continuous and 607W peak (for 450 µsec)
output power
• FCC Class A

Specifications
Supplies Specifications
NOTE: The ZXP Series 1 printer is designed to work only with Zebra True Colours
ix Series, ZXP Series 1 ribbons.
• Zebra ix Series intelligent technology automatically detects and authenticates ribbon
• Integrated cleaning roller included on each ribbon
• Media Starter Kit – 1 YMCKO ribbon, 100 30-mil PVC cards
• Cleaning Kit: 4 print engine cleaning cards and 4 feeder cleaning cards,
1000 images/card
True Colours ix Series ZXP Series 1 Ribbon Options
Eco Cartridge
Ribbon Description
Image Count
YMCKO 100
1/2 YMCKO 400
Black Monochrome 1000
White Monochrome 500
Preventative Maintenance
Zebra recommends cleaning the printer on a regular basis using standard Zebra cleaning
supplies and parts. Go to www.zebra.com/supplies for details.
Environmental Specifications
• Operating Temperature: 60º F to 86º F (15º C to/30º C)

• Storage Temperature: 23º F to 131º F (-5º C to 55º C)
• Operating Humidity: 20% to 65% non-condensing
• Storage Humidity: 20% to 70% non-condensing
• Media Storage:
- Temperature: 41º F to 77º F (5º C to 30º C)
- Humidity: 35% to 65% non-condensing
- Store in dark location

Specifications
Agency Approvals
Zebra ZXP Series 1 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, cfr47, Part 15 Subpart J
- FCC 15.257 2008, Part 15 Subpart C
- Canadian STD RSS-210
- NOM-ETL (Mexico)
- IEC 60950-1:2005+A1:2009 Safety Standard (TUV & NRTL)
- C-Tick (Australia) Electromagnetic Radiation Standard
• For Europe:
- 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+A11:2009+A1:2010+A12:2011, CB Scheme
- RFID Enabled
Applicable Directives and Supporting Standards:
99/5/EC R&TTE Directive, EN 301 489-3 V1.4.1,

EN 300 330 V1.5.1

ISO Standard Card Dimensions
1.4 ISO Standard Card Dimensions

Dimensions for Plain Card ISO Standard 7810
2.125 ± 0.002 in
(53.98 ± 0.050 mm)
3.375 ± 0.010 in
(85.72 ± 0.25 mm)
Radius
0.125 in
(3.18 mm)
0.009 ~ 0.034 in
(0.23 ~ 0.84 mm)
Dimensions for Magnetic Stripe Card ISO Standard 7811
0.623 in (15.82 mm) min
0.218 in (5.54 mm) max
MAGNETIC STRIPE
0~0.115 in (2.92 mm) 0~0.115 in (2.92 mm)

Compliance Information
1.5 Compliance Information

FCC Compliance Statement
This device complies with Part 15 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.
This equipment has been tested and found to comply with the limits for Class A Digital
Devices, 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 product manuals, 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.
The user is cautioned that any changes or modifications not expressly approved by Zebra
Technologies could void the user’s authority to operate the equipment. To ensure compliance,
this printer must be used with Shielded Communication Cables.
FCC Radiation Exposure Statement (RLAN)

This equipment complies with FCC radiation exposure limits set forth for an uncontrolled
environment.
Important
1. The radio must be installed with a minimum 20cm separation between the user and
the antenna.
2. The radio must not be co-located or used in simultaneous transmitting condition with
another radio.
3. The host system shall have a label to indicate that the system contains a certified
module. An example is “Contains FCC ID : XXXXX , IC ID: YYYYY”.
Canadian DOC Compliance Statement

Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.
This Class A digital apparatus complies with Canadian ICES-003.

Compliance Information
European Union and EFTA

The Class 2 RLAN may be operated in the following countries with the restrictions and
limitations indicated below.
AT BE BG CY CZ DK EE
FI FR DE GR HU IE IT
LV LT LU MT NL PL PT
RO SK SI ES SE GB
IS LI NO CH
Important Notice:
Operation in band 5150 – 5350 MHz shall be

restricted to indoor use.
Japanese Notification
NCC Warning Message
Brasil - Aviso da Anatel

Este equipamento opera em caráter secundário, isto é, não tem direito a proteção contra
interferência prejudicial, mesmo de estações do mesmo tipo, e não pode causar interferência a sistemas operando em
caráter primário.
“Este produto está homologado pela ANATEL, de acordo com os procedimentos regulamentados pela Resolução 242/
2000, e atende aos requisitos técnicos aplicados”
Para maiores informações, consulte o site da ANATEL www.anatel.gov.br

Icons
1.1 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 Caution • Warns you of the potential for electrostatic

discharge.
Electric Shock Caution • 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.
1.2 Zebra Supplies

Genuine Zebra supplies meet stringent quality standards and are recommended for optimal
printing quality and proper printer performance; see http://www.zebra.com/supplies
for details.
ZXP Series 1 printers are designed to work only with Zebra ZXP Series 1 True Colours®
ix Series Ribbons.

2
Installation and Setup
2.1 General Information

This section will guide you through the installation and setup of your printer. This consists of
the following procedures, which should be performed in the order presented.
Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Setting up the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connecting Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connecting the Printer to your Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Viewing Printer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installing the Windows Printer Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Changing the Printer Driver Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installing the Ribbon Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Loading Cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Print a Test Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Printer Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
The procedure to be followed for Packing the Printer for Shipment is given at the end of
this section.

2: Installation and Setup
Unpacking the Printer
2.2 Unpacking the Printer

Your ZXP Series 1 Card Printer ships in a cardboard carton, protected by foam inserts and a
protective anti-static bag. Keep all packaging material in case you need to move or re-ship
the printer.
Step 1. Before opening and unpacking the printer, inspect the carton to ensure that no
damage occurred during shipment.
Step 2. Ensure that you have a clean and nearly dust free environment for proper operation
and storage of the printer.
Step 3. Open the carton, and remove the box containing the printer accessories.
Step 4. Lift the printer out of the carton.
Step 5. Remove the protective foam inserts.
Step 6. Make sure the following accessories are included with your printer:
a. Software CD-ROM
b. Quick Start Guide
c. Cleaning Kit
d. Power Cords (one or two depending on the configuration)
e. Power Supply
f. USB Printer Cable
If any items are missing, please contact your dealer. To reorder, refer to Appendix I.

Setting up the Printer
2.3 Setting up the Printer

Step 1. Place the printer in a location that allows easy access to all sides. The printer should
never be operated while resting on its side or upside down.
Step 2. Remove the yellow CAUTION label from the back of the printer.
Step 3. Ensure that the printer’s power switch is in the OFF (O) position.

Connecting Power
2.4 Connecting Power
Caution • Limit electrical power supplied to the printer to 24 VDC. Limit excess current
draw to 16 amps or less, using an associated circuit breaker or other such device. Never
operate the printer in a location where operator, computer, or printer can get wet.
Personal injury could result. The printer must be connected to an earthed electrical
power supply and properly protected against electrical surges and grounding faults. The
power supply pack can only be replaced by the same product from the manufacturer.
Caution • Do not power the printer with USB attached to your computer at this time.
THE DRIVER WILL PROMPT YOU WHEN IT IS TIME TO PLUG IN AND POWER UP
YOUR PRINTER.
Step 1. Insert the power supply plug into the power socket, attach the power cord (120VAC
or 230VAC) to the power supply, then plug the power cord in to a grounded electrical
socket of the proper voltage and type.
120 VAC
230 VAC
Step 2. Ensure that the printer’s power switch is in the OFF (O) position.

Connecting the Printer to your Computer
2.5 Connecting the Printer to your Computer

Step 1. If your printer has only the USB interface, attach the included USB cable to your
computer and the printer.
Step 2. If your printer has the optional Ethernet interface (as well as the USB interface),
connect either the USB cable to printer and computer or the Ethernet cable to the
printer and the Ethernet network.
Important • Do not connect both the USB and the Ethernet interfaces at the same time!
Ethernet USB

Viewing Printer Information
2.6 Viewing Printer Information

Step 3. Turn printer power ON, wait until the LCD Display Panel shows READY, turn
printer power OFF, and then wait a minimum of 20 seconds.
Step 4. While holding down the Control Button, turn printer power ON. The LCD Display
Panel will glow blue.
LCD Display
Panel
Control
Button
Step 5. Keep pressing the Control Button, and observe the LCD Display Panel show
Initializing and CHECKING RIBBON.
Step 6. When the PRINTER INFO message appears in the display panel, momentarily release
and press the Control Button to display the first parameter: Model Name.
Step 7. Continue to tap the Control Button to advance through the parameters and cycle back
to the beginning:
a. Model Name (including the printer configuration)

b. Serial Number
c. Firmware Version
d. Head Resistance
e. X & Y Offset (front)
f. X & Y Offset (back)
g. EC Offset (front and back)
h. Ribbon Type
i. Smart Offset
j. IP Address (note this address for Ethernet installation; see Page 26)
k. Mask
l. Gateway
m. DHCP (enabled or disabled)
Step 8. A long press of the Control Button (about 1 second) will escape the sequence. Idle
time of 15 seconds will also escape the sequence.

Installing the Windows Printer Driver
2.7 Installing the Windows Printer Driver

2.7.1 USB Driver Installation
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 an older Printer Driver is installed on your computer, the Select Features window
will be displayed; otherwise go to Step 8.
Step 7. In the Select Features window, choose the maintenance operation to be performed:
Important • Windows requires you to reboot your computer anytime after a driver is
updated or un-installed. Failure do to reboot may cause Windows to not recognize your
newly installed or updated driver correctly.
a. Select to upgrade the older printer driver, click the Next button, and
follow the screen prompts. At the end of the process, you will be asked to
re-boot your computer. Re-boot your computer. The upgrade is complete.
b. Select to remove the older printer driver, click the Next button, and
follow the screen prompts. At the end of the uninstall process, you will be
asked to re-boot your computer. Re-boot your computer, and start over
with Step 1.
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 in the OFF (O) position; and then click the
OK button.
Step 11. This will bring up the License Agreement window. To proceed with the installation,
click the Yes button.

Step 12. This will bring up the Setup Type window. Select Complete to install all program
features, and click the Next button.
Step 13. This will bring up the Select Program Folder window. Type in a new folder name or
select one from the existing folders list, and click the Next button.

Step 14. Observe the Setup Status window.
Step 15. The Congratulations window will appear.

Step 16. At this point, turn on your printer; and then click the Next button. The Windows
New Hardware Found wizard will find the printer.
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 orientation, ribbon type, etc.), encoding,
overlay, and/or black panel settings via the Printer Driver; see Printing Preferences
on page 51.
Note • You may also need to set the card thickness adjustment to the thickness of the cards
being used; see Loading Cards on page 71.

2.7.2 Ethernet Driver Installation

Important • The Ethernet Network must be configured correctly, with the Printer and the
host computer on the same subnet mask. If you are not sure how to verify this or change the
configuration, consult someone knowledgeable on Ethernet Networks.
Step 1. 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 an older Printer Driver is installed on your computer, the Select Features window
will be displayed; otherwise go to Step 8.
Step 7. In the Select Features window, choose the maintenance operation to be performed:
Important • Windows requires you to reboot your computer anytime after a driver is
updated or un-installed. Failure do to reboot may cause Windows to not recognize your
newly installed or updated driver correctly.
a. Select to upgrade the older printer driver, click the Next button, and
follow the screen prompts. At the end of the process, you will be asked to
re-boot your computer. Re-boot your computer. The upgrade is complete.
b. Select to remove the older printer driver, click the Next button, and
follow the screen prompts. At the end of the uninstall process, you will be
asked to re-boot your computer. Re-boot your computer, and start over
with Step 1.

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. 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 11. This will bring up the Setup Type window. Select Complete to install all program
features, and click the Next button.

Important • To get the printer’s IP Address, see Viewing Printer Information on page 20.
Step 12. Setup will find and list all Zebra ZXP Series 1 Printers on the network. Select the
printer from the list (if listed), or enter the IP Address (example, arrow below);
and click the Next button.
Step 13. This will bring up the Select Program Folder window. Type in a new folder name,
or select one from the existing folders list; and click the Next button.
Step 14. Observe the Setup Status window.
Step 15. When the Congratulations window will appears, click the Next button.

Step 16. When the InstallShield Wizard Complete window appears, click the Finish button.
Step 17. This completes Ethernet driver installation.
Note • You may need to change the card setup (card orientation, ribbon type, etc.), encoding,
overlay, and/or black panel settings via the Printer Driver; see Printing Preferences
on page 51.
Note • You may also need to set the card thickness adjustment to the thickness of the cards
being used; see Loading Cards on page 71.

2.7.3 Setting Up a Network Printer

Use this procedure if you have already installed an Ethernet printer on your system (refer
to Section 2.7.2), 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.

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 Standard TCP/IP Port (2nd arrow above).
Step 9. Click on the Next button.
Step 10. Observe the Type a printer hostname or IP address window.
Step 11. Enter the IP address of your printer in the Hostname or IP address text box (circled
above). Note that the Port name will automatically be filled in when you enter the
IP Address. Do not change the Port Name.
Step 12. Ensure that the Query the printer ... checkbox is selected (arrow above).

Step 14. Observe the Install the printer driver window.
Step 15. Select the Manufacturer and the Printer (arrows above).
Step 17. Observe the Which version of the driver do you want to use window.
Step 18. Select the Use the driver that is currently installed radio button (arrow above).
Step 19. Click the Next button.
Step 20. Observe the Type a printer name window.

Step 21. 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 22. Click the Next button.
Step 23. Observe the You’ve successfully added ... window.
Step 24. If appropriate, select the Set as the default printer checkbox (arrow above).
Step 25. Click on the Finish button to complete the Add Printer Wizard.
You have successfully installed the network printer.

2.7.4 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 1 USB Card Printer listing. Select Printer properties > Ports.
Step 3. Select the three network printers by selecting the associated checkbox (circle above).
Step 4. Select the Enable printer pooling checkbox (arrow above).
Step 5. Click the Apply button, then click the OK button.

Using Printer Pooling
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.

Changing the Printer Driver Options
2.8 Changing the Printer Driver Options

Note • The screen shots shown in this section are for the printer using the USB interface. If
you are using the Ethernet interface, the screens will refer to the “Network Printer.”
2.8.1 Printer Properties

To access the Card Printer Properties, select Start > Devices and Printers. Right click on the
Zebra ZXP Card Printer listing, then select Printer properties.
General Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Sharing Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ports Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Advanced Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Color Management Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Security Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Device Settings Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
The OK button saves the settings and closes the printer properties pages.
The Cancel button exits Printer Properties. Changes made are abandoned.
The Apply button saves the settings but does not close the printer properties pages.
The Help button enables you to view a corresponding page of help information.

General Tab
The General tab shows the selected printer and lists the features of the printer.
To access the General tab, select Start > Devices and Printers. Right click on the Zebra ZXP
Card Printer listing. Select Printer properties > General.
• Location - Lets you specify where the printer is 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 - Specifies the name of the printer driver installed.
- Features - Specifies whether various options are available on the printer.
The Preferences button takes you to Printing Preferences used to set selected configuration
parameters; see Printing Preferences on page 51.
The Print Test Page button sends the standard Windows test page to the printer.

Sharing Tab
On the Sharing tab, you can choose to share the printer over the network and install additional
drivers to accommodate different operating systems. See Appendix B for the various printer
sharing options allowed and the configurations required.
To access the Sharing tab, select Start > Devices and Printers. Right click on the Zebra ZXP
Card Printer listing. Select Printer properties > Sharing. Click on the Change Sharing
Options button to enable this tab.
Printer sharing tasks that you can perform include:
• To share a printer, select the Share this printer checkbox; and specify a name for the
shared resource. Click OK when you are finished.
• To change the shared name, simply enter a new name in the Share name field; and
click OK.
• To quit sharing a printer, deselect the Share this printer radio button. Click OK
when you are finished.
Drivers: If this printer is shared with users running different versions of Windows, you may
want to install additional drivers, so that the users do not have to find the print driver when
they connect to the shared printer. Click on the Additional Drivers button.
For Printer Sharing Configurations and Advanced Sharing Settings, refer to Appendix B
for details.

Ports Tab
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
Card Printer listing. Select Printer properties > Ports.
An exception to this is if you wish to use printer pooling, the ability to distribute print jobs to
multiple printers.
To enable printer pooling, select the Enable printer pooling checkbox, then check the
additional ports boxes. Each port should have a single Zebra printer installed on it. All the
pooled printers must be identical models with the same configuration (e.g., all with YMC
front, K back); and each must have its own printer driver installed.
Now, when you print to the “main printer” (that is, whichever printer you right-clicked in
Printers and Faxes to get to this screen), this printer will get print jobs until it has buffered as
many jobs as it can take. The remaining jobs will then “spill over” to other printers until all
printers in the pool are busy.

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
Card Printer listing. Select Printer properties > Advanced.
You can make the printer always available by selecting the Always available radio button, or
you can limit availability by selecting the Available from radio button and specifying the
“Available from” and “To” times. Click the Apply button, and then the OK button.
To enable spooling: Select the radio button labeled Spool print documents so program
finishes printing faster.
• Select Start printing after last page is spooled if you want the entire document to be
spooled before printing begins. This option ensures that the entire document is sent to the
print queue before printing. If for some reason printing is canceled or not completed, the
job will not be printed.
• Select Start printing immediately if you want printing to begin immediately when the print
device is not already in use. This option is preferable when you want print jobs to be
completed faster or when you want to ensure that the application returns control to users
as soon as possible.
To disable spooling: Select the radio button labeled Print directly to the printer radio button.

Color Management Tab

You should not have to change your color management settings. Usually, the default settings
will be fine. Change these settings only if you have specific color management requirements
that are not being met by your current color settings.
To access the Color Management tab, select Start > Devices and Printers. Right click on the
Zebra ZXP Card Printer listing. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
All Profiles Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Advanced Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
For details on color management, click on the Understanding color management settings link
on the Color Management Devices tab.

Devices Tab
Use the Devices tab to set your display and printing devices.
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.

All Profiles Tab

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).

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).

Security Tab
This is the standard Windows security screen, showing user access to various printer control
options. Both Print and Manage Printers must be checked for full functionality of the printer.
To access the Security tab, select Start > Devices and Printers. Right click on the Zebra ZXP
Card Printer listing. Select Printer properties > Security.
The Security tab allows you to assign the actual permissions that apply to the print queue.
You can apply permissions to both users and to groups. It is usually considered a better
practice to only apply security to groups.
Both “Print” and “Manage this printer” Allow checkboxes must be selected to ensure full
functionality of the printer.
The Advanced Security Settings properties sheet allows you to assign a more comprehensive
set of permissions than the basic Security tab found on the printer’s properties sheet does.
For details on security settings, click on the Learn about access control and permissions link
(arrow above).

Device Settings Tab

The Device Settings tab provides device information, security status, and printer usage.
To access the Device Settings tab, select Start > Devices and Printers. Right click on the
Zebra ZXP Card Printer listing. Select Printer properties > Device Settings.
Device Information
• Model: Specifies the printer model number.
• Fw Version: Specifies the installed firmware version.
• Serial Number: Specifies the printer serial number.
• Ribbon Type: Specifies the ribbon installed in the printer.
• Head resistance: Specifies the printhead resistance value.
• Mag Encoder: Specifies if this option is present.
• Panels: Shows the total number of panels printed for the lifetime of the printer.
• Remaining Count: Shows the remaining card count for the ribbon installed. For
monochrome ribbons, this will display Unknown.
Click on the Save/Restore button to save your printer and/or driver settings. You can later
restore those saved settings; see Page 48 for details.
Click on the Tools button to access a dialog box that allows you to test and communicate with
the printer; see Page 49 for details.

Save/Restore
Dialog box for saving printer and driver settings or restoring previously saved settings.
To save settings:
Step 1. Click on the appropriate Save button (Printer Settings or Driver Settings).
Step 2. Observe a browse window showing the default location where the configuration files
are saved.
Step 3. Enter an appropriate file name, and click the Save button. Note: A prefix, P_ or D_,
will be added to the file name for printer settings and driver settings respectively.
Step 4. Your selected settings will be saved.
To restore settings:
Step 1. Click on the appropriate Restore button (Printer Settings or Driver Settings).
Step 2. Observe a browse window showing the default location where the configuration files
are saved.
Step 3. Select the desired file, and click the Open button. Note that prefixes P_ and D_
indicate printer settings and driver settings respectively.
Step 4. Your selected settings will be restored.

Tools
Dialog box for testing and communicating with the printer.
• Command to send to printer - Enter a printer command (all capitals without the leading
escape character) in the top edit box; e.g., MI MO, which will pick and eject one card.
Then click on the Execute button. Printer Status will show the status of the command.
Contact Zebra Technical Support for a complete list of the printer commands.
• Print test card - Select the desired test card type from the dropdown menu: Standard,
Printer Parameters, and Encoder Parameters. Click on the Print button to print the
selected test card.
• Cleaning - Select the desired cleaning to be performed from the dropdown menu: Printer
only or Magnetic encoder. Click on the Clean button to run the cleaning process.
• Offset setting - Enter the Front X and Y direction offsets, and click on the Set Offsets
button to set the offsets for printing the card.
• Firmware Download: See Page 50 for details.
• Send File - This command will allow a .prn or .txt file to print.
- The .prn file must be created with a Zebra printer driver using the same ribbon as
present in the printer.
- The .txt file must contain firmware commands only with only one command per line.
The first line must only contain MASTER; the last line must only contain SLAVE.

Firmware Download
This option is used to install the firmware downloaded from the Zebra web site at
http://www.zebra.com under Drivers & Downloads.
Important • Do not turn off the power to the printer until the process is done and the OCP
displays READY. If the download process is interrupted, the printer will not operate.
Step 1. Download the firmware from Zebra web site ( http://www.zebra.com ), and save it to
a location you can easily find.
Step 2. In the Tools window, click on the Select File button.
Step 3. From the Browse window, “find” and select the downloaded firmware (BIN file
type); and click on the Open button.
Step 4. Click on the Start Firmware Download button to install the firmware.
Step 5. Wait while the firmware downloads and installs, and then wait while the printer
resets and initializes.
Step 6. When the installation is complete, the Status field will display Firmware
Downloaded Successfully.

2.8.2 Printing Preferences
Note • The screen shots shown in this section are for the printer using the USB interface. If
you are using the Ethernet interface, the screens will refer to the “Network Printer.”
To access the Card Printer Preferences, select Start > Devices and Printers. Right click on the
Zebra ZXP Card Printer listing, then select Printing preferences.
Card Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Encoding Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
About Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Click on the Job Log button to create and manage a database of card transactions; refer to
Job Log on page 62 for details.
Click on the Image Control button to adjust the image colors; see Image Control on
page 64 for details.
The OK button saves the settings and closes the printing preferences pages.
The Cancel button exits Printing Preferences. Changes made are abandoned.
The Apply button saves the settings but does not close the printing preferences pages.
The Help button enables you to view a corresponding page of help information.

Card Setup Tab

Card Setup tab allows the user to adjust selected card and print job parameters.
To access the Card Setup tab, select Start > Devices and Printers. Right click on the Zebra
ZXP Card Printer listing, then select Printing preferences > Card Setup.
• Printing options
- Orientation: Selection for portrait or landscape printing.
- Rotate 180o: Selection for rotating the image 180o. The options are No and Yes.

- Monochrome Conversion: Specifies the method of monochrome conversion used in

printing. Different selections have different effects on the way the image is printed.
The options are Diffusion, Halftone, Barcode, Text Mode, and Auto.
• Diffusion: Error diffusion is used primarily where you

have a full color (RGB image with 8 bits per pixel) or
full gray (single color but still 8 bits per pixel) that
you need to print with binary printing (can only print
full-on or full-off; i.e., 1 bit per pixel). Typically
preferred over halftoning (see below) for most images.
• Halftone: To simulate gray in graphics, halftones are

printed. Halftones are arrays of dots arranged in a grid
(e.g., 6x6 or 8x8) to represent each image pixel as a
shade of gray. For dark gray, more grid dots are black.
For light gray, more grid dots are white As the grid
size goes up so does the number of possible output
levels, 6x6 cell has 36 possible output levels while
8x8 has 64. But as cell size increases, there is a
corresponding decrease in resolution.
• Barcode: This is the simplest method for converting from 8 bits per pixel to 1 bit
per pixel. For example, the input pixel can be a value from 0 to 255. If the
threshold is 128, any pixel over 128 becomes full on (1); and any pixel that is less
than 128 becomes full off (0). This does not work for continuous-tone pictures.
• Text Mode: This mode can be used when you have text, particularly black anti-
aliased text, as well as small text and text with thin lines. Black anti-aliased text is
typically black in the center; but on the edges, it has shades of gray that get lighter
as you move out form the center of the text. This anti-aliased text will have a
softer looking edge that is less sharp than non anti-aliased text. This does not
work for continuous-tone pictures.
• Auto (default): This mode analyzes the image and optimizes the conversion
mode for each element automatically, not one mode for the entire card.
SUMMARY
Element Diffusion Text Halftone Barcode Auto

Barcode Yes No No Yes Yes
* **
Text Yes Yes Yes Yes Yes
Pictures Yes No Yes No Yes
Graphics/Logos Yes Yes Yes Yes Yes
Lines Yes Yes Yes Yes ** Yes
* Do not use on anti-aliased text.
** Does not work well with small text or text with fine lines.

- Copies - Sets the number of copies of cards printed.

- Printing Mode - Sets the type of printing required:
• Print.
• Encode Only is used when magnetic encoding is the only function desired,
printing will not occur.
• Print and Encode on same side prints on the magnetic stripe side of the card.
• Single Feed options (refer to Appendix D for details on the single-card feed mode)
- Card feeder: The printer will attempt to a pull a card from the Card Feeder. If the
Card Feeder is empty, the printer will generate an OUT OF CARDS error message.
- Single feeder slot: For each print job, the printer will generate an INSERT CARD
message. Any cards in the Card Feeder will not be used.
- Auto feed: If a card s inserted in the single feed slot, the printer will use that card;
otherwise it will pull a card from the Card Feeder. If the Card Feeder is empty, the
printer will generate an OUT OF CARDS error message.
• Ribbon info and options
- Ribbon type displays type of ribbon installed in printer.
Eco Cartridge
Ribbon Description
Image Count
YMCKO 100
1/2 YMCKO 400
Black Monochrome 1000
White Monochrome 500
Depending on the printer model and ribbon combination selected, the Black Panel
Options and Overlay Varnish Options buttons are enabled for color ribbons and
disabled for monochrome ribbons; see Page 55 and Page 61 respectively.

Black (K) Panel Options

The Black Panel Options window is available when using K panel ribbons; e.g., YMCKO. The
figure below shows settings for the front side of the card.
To set how the printer prints the black areas of color images, several selections must 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 YMC printed under
the K), not the sharp edges typically desired for a barcode.
- Print all black data uses only the K panel to print the portions of the image that are
identified as being black. Note that the areas that are identified as black are based on
the threshold selections made in the black level area in the black extraction from color
images area; see Page 57.

• Apply black extraction on:
Option 1. Black text applies black extraction to areas of the image identified as text; e.g.,
company name, address.
Zebra
Technologies
Option 2. Black graphics applies black extraction to areas of the image identified
as graphics primitives; e.g., lines, circles, rectangles, area fills, etc.
Option 3. Black color bitmaps applies black extraction to areas of the image identified
as monochrome bitmap data contained in a color bitmap image.
Option 4. Black monochrome bitmaps applies black extraction to areas of the image
identified as monochrome data in a bitmap; e.g., logos.

• Black extraction from color images:
- Print black with K panel:
• Defined areas applies black extraction to areas of the image inside of the zones
specified in the Area manager.
• Undefined 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.
- 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 dot to be treated as black.
The maximum setting is R25, G25, B25.

• Area manager: This option is enabled when either the Defined areas (extract inside the
zone) or the Undefined areas (extract outside the zone) radio button is selected.
• 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.
In practice, determine the size of the area the question (e.g., the exclusion zone for the ID
card portrait); then click one of the six radio buttons to activate the dimensioning boxes
(probably button #1 in the first instance). Then set the area size and offsets to match the
portrait; then, if no other exclusion zones are required, check the “confirm settings” box.
This would gray-out everything in the Area Manager box.
If another area is required (e.g., a ghosted smaller portrait), before confirming the settings,
select the next button; then size the area in the same way. To add another area, or to null an
existing area, simply uncheck the “confirm” box. There is no means of zeroing a box
automatically; simply null the settings manually.

Black Panel Print Overview

This section covers special handling of black data specified on the “Black Panel (K)” tab
and applies only to surfaces of the card on which both YMC (color) and K (black) are to
be printed.
Reasons and Behavior for Black Panel Extraction

To print black during the print process, equal amounts of process colors Y, M, and C (printer
ribbon panels) are delivered, with maximum intensity, to create a near-black image.
• However, this “composite” image appears as a dark shade of gray and not machine
readable. For example, a visually-black barcode printed with Y, M and C will not be
detectable by most barcode readers and is not a true Visible Black color.
• The remedy for this is to “extract the black.” In other words, print the same text, graphics,
or barcode, using the K (black) panel, on top of the YMC barcode. (You can also choose
to print only in K, omitting YMC from that region.)
Depending on the application used to design the card layout, different elements of the card
image may be identified in different ways to the printer driver. The printer driver needs to
recognize four types of basic elements:
1. Black text
2. Black (monochrome) graphics -- lines, circles, rectangles, and area fills
3. Black color bitmap images
4. Black monochrome bitmap images
These elements may not always be sent to the driver as expected. For example, a barcode may
be sent as black text, a series of black area fills, or a black monochrome bitmap. Results will
depend on the application used to create the card design. Another variable, again controlled by
the card design application, is the precedence (stacking order) of the various element types in
the event that one or more of them overlap.

If the printer is set up to print both YMC and K on the same side, text, lines and pixels, area
fills and monochrome bitmaps, if (and only if) designated black by the application, can be
directed to the K panel. For this to happen, the graphic type in question has to be selected on
the “Black Panel (K)” tab. For text, lines and pixels, area fills and monochrome bitmaps the
designation “black” is set at RGB values of 0,0,0. This threshold can be adjusted up to
25,25.25, with the Black level slider adjustment. Near-black doesn’t qualify.
In the Black Panel (K) tab, the “element selection” portion is straightforward – simply
designate any or all of the four graphic types to be printed in K, either K alone, or over process
black (YMC).
Black extraction is quite different. It applies only to the fourth graphic type – the color bitmap
image.To perform black extraction, the driver generates a K image by looking for black
features (pixels) in the color bitmap, that is, instances where all three YMC values are at, or
close to, the maximum (full intensity). Each such true-black or near-black instance generates a
corresponding cluster of black pixels in the extracted image, which will be printed with the
K (black) panel either on top of the YMC image, or replacing it entirely – your choice.
A problem that can arise when K is extracted from an entire card image is over-emphasis of
every black cluster; e.g., dark hair in a portrait photo or scenic background. K overprinting in
such areas can be displeasing. To deal with this, set up exclusion zones within which no
extraction is performed. Six such areas are provided for on each side of the card,
independently. In the default state, all areas are null (0,0 offsets, and zero size).
There is a choice of black extraction within the defined areas or outside the defined areas.; see
Print black with K panel: on page 57 for details.

Overlay Varnish Options

The Overlay Varnish Options window allows you to manage and configure the use of the
Overlay when the selected ribbon shows the O panel (e.g. YMCKO).
Select the overlay varnish type - Option selection for applying overlay varnish ribbon to a
card. Default setting is full edge-to-edge varnish.
There are various varnish options. A preview pane is shown for each selection.
• Full overlay varnish - Applies an edge-to-edge overlay.

• No overlay - Does not apply any overlay.
• Selected area overlay varnish - Applies the overlay inside the area specified by the
user. When this option is selected, position the Left, Right, Top, and Bottom overlay
edges via the buttons (circled above).
• Selected area blank - Applies the overlay outside the area specified by the user. When
this option is selected, position the Left, Right, Top, and Bottom overlay edges via the
buttons (circled above).
• Bitmap-based overlay varnish - Applies a user-defined bitmap in the overlay panel.
When selected, click the Browse button; in the browse window, find the desired
monochrome bitmap (1 bpp); and click the Open button.
• Smartcard ISO - Does not apply overlay in the area of the ISO standard Smart
Card contacts.
• Smartcard AFNOR - Does not apply overlay in the area of the AFNOR standard
Smart Card contacts. AFNOR stands for Agence Française de Normalisation, a
standardization organization based in France.
• Magnetic Stripe - Does not apply overlay in the area of the ISO standard
Magnetic Stripe.

Job Log
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 unchecked, the data is saved to a log file
of your choice (Filename).
- If the box is checked, the data is saved to log file with the day’s date; e.g.,
ZXPLog_6/25/13.
- In addition to the Filename, you may wish to enter a special field Separator Character.
The default field Separator Character is “|”.

• 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 MM/DD/YYYY format.
- Printer serial number: Logs the serial number of the printer that printed the card.
- IP address: Logs the IP address of the PC that sent the card to the printer.
- User name: Logs the username of the person submitting the card print job.
- Spooler job number: Logs the number which the card print job was assigned in the
Windows print spooler.
- Magnetic Track 1, 2, 3 Data: Logs the data sent to the printer to be encoded on the
card’s magnetic stripe.
- Static text: Adds the text in the text box (16 characters maximum) to the record.
The Delete log files button deletes the log files.
The Save Job Log Settings button saves the Job Log settings.

Image Control
Note • Printed colors can appear different than displayed colors; the following controls
allow you to optimize the printed results.
Allows you to adjust the image colors; these adjustments apply to the entire card, not just
photographic image.
- Intensity - increase or decrease the image intensity by moving the Black, Yellow,
Magenta, and Cyan slider bars left or right. This will change the overall lightness or
darkness of the image. Move the slider to the right (0 to 100) to increase the intensity
and to the left (0 to -100) to decrease the intensity. Note that color ribbon wrinkling
can be eliminated by reducing the intensity.
Use the Restore Defaults button to reset the settings to the driver defaults.

Encoding Tab
The Encoding tab dialog box is for setting Magnetic Encoder parameters. This feature is not
enabled if the printer does not have the magnetic encoder option.
To access the Encoding tab, select Start > Devices and Printers. Right click on the Zebra ZXP
Card Printer listing, then select Printing preferences > Encoding.
• Enable macro processing - This option is used to set the encoding preamble and other
magnetic encoder parameters.
- Start of Data - Beginning of the data string for the encoder. Note that Start of Data
characters must be immediately followed by a one-digit number representing desired
track where the data will be written. Use the normal Windows default fonts.
- End of Data - Ending of the data string for the encoder.
• Advanced Settings - Click on the Advanced Settings button for additional encoding
options; for details, see Advanced Settings on page 67.
• HiCo/LoCo - Select the type of coercivity of magnetic stripe cards to be used. Note that
radio button No Change is not implemented.
• Encoder Position - Select the printer encoder position: Normal.
• Encoder Type - Select the type of encoder: ISO/JIS. Note that JIS is not implemented.

• Direct Encoding - For writing data and reading encoded data.
Track selection:
- To read encoded data: Click on the checkboxes to select Track 1, Track 2, and/or
Track 3; click on the Read button, and validate the data read.
- To write data: Click on the checkboxes to select Track 1, Track 2, and/or Track 3;
enter the data to be written; and click on the Encode button.
- To eject the card: Click on the Eject Card button to eject the card.
The Restore Defaults button to reset the settings to the original values.

Advanced Settings
Advanced Settings provides advanced configuration capabilities and tools to manage magnetic
encoder operation. This option is primarily used for Non-ISO encoding.
• Track: Select the track you want to configure.
• Track Settings: Select the Mode (ISO1, ISO2, ISO3, 3 bit, 4 bit, 5 bit, 6 bit, or 7 bit) and
Density (75 bpi or 210 bpi) for the tracks.
• Start/Stop Character (For Non-ISO encoding only): Enter an ASCII value for the Start
and Stop characters.
• Encoding Start Position (For Non-ISO encoding only): Enter the encoding start position
in millimeters (mm).
• Character Parity (For Non-ISO encoding only): Choose the Character Parity you want to
work with -- No parity, Even parity, or Odd parity.
• LRC Parity (For Non-ISO encoding only): Choose the LRC Parity you want to work
with -- No parity, Even parity, or Odd parity.
Click the Restore Defaults button to reset the settings to the original values.

About Tab
This tab specifies the Printer Model, the Driver Version, and the Zebra Technologies
Corporation Copyright.
To access the About tab, select Start > Devices and Printers. Right click on the Zebra ZXP
Card Printer listing, then select Printing preferences > About.

Installing the Ribbon Cartridge
2.1 Installing the Ribbon Cartridge

The ZXP Series 1 Printer requires genuine Zebra ZXP Series 1 True Colours® ix Series
Ribbons. These high-performance Resin Thermal Transfer and Dye Sublimation ribbons are
specifically designed for the ZXP Series 1 Printer.
• Each ribbon cartridge includes an integrated adhesive cleaning roller assembly that is
used to clean the cards entering the printer. Improper cleaning will reduce printer life
and degrade print quality
• When the ribbon is completely used, change the cartridge assembly.
Electrostatic Discharge Caution • DO NOT TOUCH the printhead or the electronic

components on the printhead. Discharge of electrostatic charge from the human body or other
surfaces can damage the printhead or other electronic components
Step 1. Open printer lid by pressing the Cover Release button on the top of your printer.
Step 2. Peel protective wrapper from the adhesive cleaning roller by gently pulling on the
tape. Discard the protective wrapper.

Installing the Ribbon Cartridge
Step 3. Insert the ribbon cartridge with the cleaning roller facing down, so the gears on the
ends of the rollers fit into the appropriate slots.
Step 4. Close the printer lid, and push down until you hear an audible click.
Note • After the lid is closed, the ribbon automatically synchronizes when the printer
power is on.

Loading Cards
2.2 Loading Cards

Card Feeder
The card feeder is used for loading cards, it can hold up to 100 cards of 30-mil thickness. The
card feeder is located under the card feeder cover of the printer.Check with your card vendor
or packaging label to identify the thickness of your cards. A typical card thickness is 30 mil.
Step 1. Set the card thickness adjustment (circled below) to the number corresponding to the
thickness of the cards being loaded. Note that the thickness adjustment ranges from
10 mils to 40 mils.
Failure to make the proper thickness adjustment (particularly for 10-mil cards)
may result in a multiple-card jam. To clear a card jam, refer to MECHANICAL
ERROR on page 91.

Loading Cards
Step 2. Open the card feeder cover.
Step 3. Slide the card guide all the way to the right until it locks in place with an
audible click.
Caution • Hold the cards by the edges only. DO NOT touch print surfaces as this can
reduce print quality.
Step 4. Remove the wrapper from the card stack.
Step 5. Examine the cards, and discard any cards with damaged edges.
Step 6. Holding the card stack by its sides, fan the cards (like flexing a deck of playing
cards) at least once from each end, so as to separate all the cards.
Step 7. Restore the card stack to its original squared-off condition.
Step 8. Place the stack of cards into the card feeder.
Step 9. Close the card feeder cover. When card feeder cover is closed, the card guide locking
mechanism will be released automatically.

Loading Cards
Card Output Hopper

Step 1. Raise the printer lid.
Step 2. Pull the card output hopper down to place it in its functional position.
Step 3. When not using the printer, place the card output hopper back in its closed position to
protect the printer from dust.

Print a Test Card
2.3 Print a Test Card

With ribbon cartridge and cards loaded, your printer is ready to print. To check the operation
of the printer, you should print a test card.
Step 1. Select Start > Devices and Printers. Right click on the Zebra ZXP Series 1 Card
Printer listing. Select Printer properties > Device Settings; and click on the
Tools button.
Step 2. Observe the Tools window.
Step 3. From the Print Test Card menu, select the desired test card (circled above).
Step 4. Click on the Print button (arrow above) to print the selected test card; see sample
test cards below.
Standard: Printer Parameters: Encoder Parameters:

Printer Operation
2.4 Printer Operation

The ZXP Series 1 Card Printer can be used with your software application program, using the
Drivers on the CD provided with your Printer; refer to Installing the Windows Printer Driver
on page 21.
Creating a Sample Card

Before you begin a new printing session, print a sample card to ensure that the cards will be
printed correctly. Follow the steps below to print your first card.
Step 1. Open a new Microsoft Word document.
Step 2. If the Zebra Printer was not set as the default printer, select the ZXP Series 1 Card
Printer as the default.
Step 3. From the Microsoft Word document., set the Page Layout:
a. Size: CR-80, ISO 7810 format, 2.12 inch by 3.38 inch (54 mm by 86 mm) Card
b. Orientation: Portrait or Landscape
c. Margins: Top, Bottom, Left, and Right = 0 (zero).
Step 4. The card appears as a Microsoft Word document.
Step 5. Design a card with both black and colored text and with colored images similar to the
sample card shown below.
SAMPLE CARD
M. CHRIS JONES
SALES DIRECTOR
http://www.zebra.com
Printing the Sample Card

Once you complete creating your sample card, you are ready to print. Ensure that your printer
has a True ColoursTM Card Printer Ribbon Cartridge installed and that there are cards in the
card feeder.
Step 1. Print your sample card to the ZXP Series 1 Card Printer.
Step 2. Once the printing is completed, remove the sample card from the card output hopper;
and check for any discrepancies. For quality issues, see Troubleshooting on page 89.
Step 3. If the sample card is correct, your printer is ready to produce more cards.

Packing the Printer for Shipment
2.5 Packing the Printer for Shipment

If the printer is to be shipped, use the original printer packing and shipping material for
shipping the printer only. It is important to use the original packing and shipping material to
prevent damage to the printer.
Important • Do not ship the printer with either the ribbon or the cards in the printer.
If the original material is lost or damaged, a replacement Shipping Kit can be ordered from
Zebra; see Worldwide Support locations listed in Appendix I.

3
Theory of Operation
3.1 Introduction
This section includes five major topics:
Card Printing Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Card Path Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Card Movement During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
CPU PCBA Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3: Theory of Operation
Card Printing Basics
3.2 Card Printing Basics

This section provides an overview description of how images are printed on plastic cards.
Printhead
The Printhead Assembly mounts in the Printhead Bracket, which holds the Printhead at a right
angle to the card’s long surface.
The Printhead is a thin-film device that consists of a row of individually addressable heating
elements. Each heating element is approximately 0.0033 inch (0.08 mm) wide, giving a print
resolution of 300 dots per inch.
There are a total of 672 heating elements. Since the width of the plastic card is 2.125 inches
(54 mm), 638 elements provide full-width coverage.
The “extra” 34 elements (17 on either side of the card’s nominal width) are present to support
programmable image centering and full bleed imaging even if a card is slightly oversize.

Printing Technologies and Ribbons
There are two types of printing technology used in the ZXP Series 1 Card 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. Zebra ZXP Series 1
True Colours® ix Series Ribbons have a smart chip built into the supply spool; the smart chip
identifies the ribbon type and panel count. (Note that the lack of a smart chip 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.
Smart Chip
Contact
Ribbon ID
Contact

A YMCKO ribbon has successive panels as follows:
Dye Sublimation Printing Process Thermal Transfer Printing Process
Yellow Magenta Cyan Black Overlay (YMCKO

(“Y”) (“M”) (“C”) (“K”) (“O”) Pattern
Dye Dye Dye Resin Varnish Repeats)
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 your printer, or go to the Zebra Card Printer Solutions
website at http://www.zebra.com.
Additionally, the driver software allows the user to specify which ribbon panels are printed on
either side of the card.
The ribbon synchronizes to its “starting” position whenever the Lid is opened and then closed.
For a YMCKOK ribbon, the starting position is with the leading edge of a Yellow Panel at the
Printhead location.

The following figure shows how the ribbon and card move relative to each other during the
printing process.
Printhead at
1. Ribbon Moves
Fixed Position
Yellow Panel into
Position at Printhead
2. Card is Fed to Printing

Position Under the
Printhead
3. Card and Ribbon Move Together

as Yellow Panel is Printed
4. Card and Ribbon Stop at

End of Yellow Panel
5. Ribbon is Stationary; Card is

Moved Back to Printing Position
6. Card and Ribbon Move Together

as Magenta Panel is Printed

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.
Printhead
Ribbon
Carrier
Layer
Ribbon
Card Dye
Layer
Gaseous Dye
is Absorbed by
Platen Roller Card
Thermal Transfer Printing
In Thermal Transfer, 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 transferred to the card) or not; there are no
intermediate levels.
Thermal Transfer printing with a resin ribbon is used for printing bar codes, since contrast
between the light and dark areas is the highest and the edges are the sharpest.
Printhead
Ribbon
Carrier
Layer
Ribbon
Ink Layer
Card
Ink Transferred
to Surface of
Card
Platen Roller

Card Path Elements
3.3 Card Path Elements

The figure below shows the rollers that transport cards as they make their way through the
Printer. The rollers keep the card on a horizontal path, reducing the chance of a card edge
catching on anything.
Exit Rollers Main Drive Feeder Roller Card Transport

Rollers Rollers
Platen Roller Cleaning Rollers
The figure below shows the relative locations of the sensors that track card and ribbon position
and movement.
Lid Sensor J7 Color Ribbon Feed Cover Ribbon Flag Position

(on left side) Sensor J5 Sensor J8 Sensor J6
ATM Card Feed

Sensor J12
Mag Encoder Card Sync Transport Position Sensor J11 Card Load Sensor J10
Sensor J23 Sensor J9 (on Card Transport) (on Card Transport)

Card Movement During Printing
3.4 Card Movement During Printing

Step 1. The card is fed from the Card Input Hopper and loaded into the Card Transport
where it is rotated into the print position.
Magnetic Stripe Card Transport Card Printhead

Encoder (optional) (under Hopper) Guide
Lid
Card Output
Hopper
Platen Cleaning Card Input

Roller Roller Hopper
Ribbon
Cartridge
Step 2. The card is moved into the Print Engine, passing the Cleaning Roller, which cleans
dust or dirt particles from the upper card surface.
Step 3. If the Printer includes an optional Magnetic Stripe Encoder, the card is moved to the
Magnetic Stripe Encoder, and the stripe is encoded.
After the card is encoded, it is checked to verify that the magnetic stripe was
properly encoded.
If encoding fails, the card is ejected into the Card Output Hopper. 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.

Card Movement During Printing
Step 4. The card is printed.
Dye-Sublimation Printing
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.
The last time the Lid was opened and closed, the ribbon was automatically
synchronized, bringing the leading edge of the yellow ribbon panel (for a YMCKO
ribbon) under the Printhead.
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 pass is completed, the Printhead is raised, the card is moved back
pre-print position, and printing continues with the Magenta panel, the Cyan panel,
the Black panel, and finally the Overlay panel.
Thermal-Transfer Printing
If using a monochrome ribbon (used when printing a bar code on a card), 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.
Step 5. When printing is completed, the card is moved to the Card Exit, where it falls into the
Card Output Hopper.

Block Diagram
3.5 Block Diagram

Most of the circuitry in the ZXP Series 1 Card Printer is on the Main PCBA. Since the Main
Controller PCBA is not a serviceable unit, circuit analysis to the component level is pointless.
Below is a block diagram of the functional circuits of the Printer; the block diagram also
shows how signals are passed to and from the Main Controller PCBA to the rest of
the Printer.

CPU PCBA Connections
3.6 CPU PCBA Connections
TOP SIDE J23

J29 J6 J26
J13
J12
J8
J11
J10
J27 J16
J19 J21
J7
J22
J25 J28 J24 J5 J9 J18
J1 SCM CTRL (Note 1) J16 RIBBON MTR

J2 None J17 SCM PLT MTR (Note 1)
J3 None J18 CRYPTO PORT
J4 BDM PORT (Note 1) J19 PWR JACK
J5 COLOR RIBBON J20 RS232 (Note 1)
J6 RIBBON ENCODER INTERUPTOR J21 AIR FAN
J7 MAIN DRIVE LOCK J22 PLATEN STEPPER MTR
J8 FEED COVER SENSOR J23 MAG HEAD / MAG SYNC
J9 CARD SYNC INTERUPTOR J24 LCD
J10 CARD LOAD INTERUPTOR J25 HEAD FAN
J11 TRANSPORT POSITION INTERUPTOR J26 CAM MTR
J12 ATM CARD INTRPTR J27 FEEDER MOTOR
J13 USB J28 PRNT HEAD
J14 SCM CAM MTR (Note 1) J29 TRANSPORT MTR
J15 JTAG (Note 1) J30 ETHERNET TO USB MODULE (Note 1)
Note 1: Bottom side of PCBA
BOTTOM SIDE J30
J14
J17
J1
J20 J15 J4

4
Troubleshooting
4.1 Introduction
The objective of troubleshooting is to relate a problem to an associated assembly or system
function, in order to most efficiently isolate and repair the problem. Typically this involves
determining the failure symptom and then checking one or more possible causes of the failure.
Only a symptom-related list of possibilities appears. In general, for a given failure symptom
one or more possible causes are listed, with suggested corrective action to take. These causes
should be checked and corrective actions taken in the order given; they are listed in order of
likelihood and complexity.
When the suggestions presented fail to lead to a repair, a CPU Board replacement, if not
prescribed, should nevertheless be tried. A check for broken or disconnected cables and any
loss of power should also take place along with checks for obvious mechanical damage.
Zebra Card Printer solutions offers Technical Support and factory repair as options.

4: Troubleshooting
Troubleshooting Procedures
4.2 Troubleshooting Procedures

4.2.1 LCD Panel Warnings and Error Messages
The following tables show causes and solutions to symptoms related to improper operation.
Check the table when experiencing any loss of operation or print quality.
PANEL WARNINGS (printer will still operate)

Problem / Symptom Description or Cause Possible SolutionNote
CHECKING RIBBON Printer is determining type of ribbon No action required -- status message
installed. only.
CLEAN PRINTER Printer cleaning required. Refer to Section 6.1: Cleaning the
System.
CLOSE LID The lid is open. Make sure that the lid is completely
and securely closed.
ENCODING ERROR May be incorrect card type. Check that you are using the correct
magnetic card type (for low or high
coercivity encoding).
INVALID MAGNETIC DATA The magnetic data may be invalid. Check data format.
Note: If the problem persists, contact Technical Support; see Appendix I.

4: Troubleshooting
ERROR MESSAGES (printer will not operate)

CHECK RIBBON Wrong type of ribbon may be Install proper ribbon.

installed. Ribbon for P1XX will
not work.
Ribbon may be improperly installed. Reload ribbon cartridge. Refer to

Section 2.1: Installing the Ribbon
Cartridge.
COMMAND ERROR A command error occurred. Reset the Printer, and try printing the
card again.
COVER OPEN The cover is open. Make sure that the cover is
completely and securely closed.
LID OPEN The lid is open. Make sure that the lid is completely
and securely closed.
MECHANICAL ERROR Check that you are using the correct See Section 1.3: Specifications.
card type.
Check that ribbon is loaded Refer to Section 2.1: Installing the

correctly. Ribbon Cartridge.
Check for a card jam in the card Power off the printer, open the lid,
feed module. release the card feeder by pressing
the finger tab lever to the left of the
card thickness adjustment (arrow
below), lift up the card feeder, and
remove any jammed cards from the
card transport module. Note that you
may need to rotate the card transport
module by hand to access the
jammed cards.

4: Troubleshooting
ERROR MESSAGES (printer will not operate)

MECHANICAL ERROR The card feeder feeds two cards Calibrate the Card Load Sensor via
(continued) completely onto the card feed the !SAP 1 command. For command
module. implementation, refer to Tools on
page 49.
The card feeder partially feeds the The card thickness adjustment (arrow
second card, thereby blocking card below) should be closed one or two
feed module operation. clicks, one click at a time.
The card feeder does not feed a card. Remove the card, fan the card stack,
This may be because two cards are and return the cards to the
stuck together or a leading edge card feeder.
is damaged.
The card feeder does not feed a card; The card thickness adjustment
and it is not due to stuck-together (circled below) should be opened one
cards, damaged cards, or cards that or two clicks, one click at a time.
were not fanned.
OUT OF CARDS Check for cards in the card feeder. If no cards present, load cards; then
press the Panel Button for 1 second.
The printing job will restart.
Card did not feed. 1. Verify that the card thickness

adjustment is set to the thickness of
the cards being used.
2. Fan the card stack to ensure that

cards are not stuck together.
3. Remove the first card in the stack,

and check if the edge is damaged;
discard if it is.
4. Open the card thickness adjustment

one or two detent clicks.
OUT OF RIBBON Check ribbon. May be defective or Load a new ribbon cartridge. Refer to
entirely used. Section 2.1: Installing the Ribbon
Cartridge.

4: Troubleshooting
4.2.2 Print Quality Issues
Important • The use of Zebra cards and True Colours ribbons will give the best print quality.
This section will help you resolve print quality problems.
The print quality is dependent on several factors. The two most important factors that will
increase your print quality are cleanliness and card stock.
To diagnose and fix print quality problems, follow the troubleshooting procedures below:
Small spots - - - - - - - - - - - - - - - - - - - - - - - - - 94
Non-printing horizontal lines (white) - - - - - - - - - - - - - 95
Pale or inconsistent results - - - - - - - - - - - - - - - - - - 96
Blurry printed image - - - - - - - - - - - - - - - - - - - - - 97
No printing - - - - - - - - - - - - - - - - - - - - - - - - - 98

4: Troubleshooting
Example • Small spots
Small spots appear on the printed card with a non-printed area or a different color.
Possible Cause:
• Contamination on the card surface.
Solutions:
• Check that cards are stored in a dust free environment.
• Use a different supply of cards.
Possible Cause:
• Dust inside the printer and/or dirty Cleaning Roller.
Solutions:
• Clean the printer. Refer to Section 6.1: Cleaning the System.
• Check that the protective cover was removed from the ribbon cartridge cleaning
roller. Refer to Section 2.1: Installing the Ribbon Cartridge.

4: Troubleshooting
Example • Non-printing horizontal lines (white)
There are non-printing horizontal lines (white) on the card surfaces.
Possible Cause:
• Ribbon cartridge is not correctly positioned.
Solutions:
• Ensure that the ribbon is properly rolled onto the ribbon cores of the cartridge and that
there are no wrinkles in the ribbon.
• Replace ribbon cartridge. Refer to Section 2.1: Installing the Ribbon Cartridge.
Possible Cause:
• Printhead is dirty.
Solutions:
• Clean the Printhead. Refer to Section 6.2: Cleaning the Printhead.
Possible Cause:
• Printhead elements are damaged (e.g., scratched or burnt).
Solutions:
• Call Zebra Customer Service for Printhead replacement information; see Appendix I.

4: Troubleshooting
Example • Pale or inconsistent results
Printing shows very pale or inconsistent results.
Possible Cause:
• Ribbon cartridge have been stored improperly or is damaged.
Solution:
• Change ribbon cartridge, and print again. Refer to Section 2.1: Installing the Ribbon
Cartridge.
Possible Cause:
• Cards may not meet specifications. Refer to Section 1.3: Specifications.
Solution:
Possible Cause:
• Dust or embedded contamination on elements of the Printhead.
Solution:
• Clean the Printhead. Refer to Section 6.2: Cleaning the Printhead.
Possible Cause:
• Printing on wrong side of writable back cards.
Solution:
• Reverse direction of cards in feeder.
Possible Cause:
• Improperly adjusted print intensity/density.
Solution:
• Adjust the print intensity/density. Refer to Image Control on page 64.

4: Troubleshooting
Example • Blurry printed image
Printing shows blurry printed image.
Possible Cause:
• Dust or embedded contamination inside the printer.
Solution:
• Clean the Rollers and the Printhead. Refer to Section 6.1: Cleaning the System and
Section 6.2: Cleaning the Printhead respectively.
Possible Cause:
• Ribbon cartridge may not be correctly positioned.
Solution:
• Check that the ribbon is properly rolled onto the ribbon cores of the cartridge, with
no wrinkles.
• Replace ribbon cartridge, making sure it locks in place, and print again. Refer to
Section 2.1: Installing the Ribbon Cartridge.
Possible Cause:
• Ribbon may not be synchronized on the correct color panel position.
Solution:
• Open lid, then close lid to synchronize ribbon.
Possible Cause:
Solution:

4: Troubleshooting
Example • No printing
No printing on the card.
Possible Cause:
• Ribbon cartridge may not be installed in the printer.
Solution:
• Check for ribbon cartridge in the printer. Refer to Section 2.1: Installing the Ribbon
Cartridge.
Possible Cause:
Solution:
Possible Cause:
• Cable on Printhead may be disconnected.
• Printhead elements may be scratched or burnt.
Solution:
• Call Service for Printhead repair or replacement information; see Appendix I.

5
Replacement Procedures
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.
Spares Kits are listed in Appendix H.
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 • 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.

5: Replacement Procedures
Required Tools
5.2 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.
Important • When removing any of the nylon or plastic pulleys or gears, the use of a gear
puller is strongly recommended. If a gear puller is not available, use pliers and/or a flat-blade
screwdriver to pry the gear or pulley off its shaft. In either case, remove any Loctite residue
from the shaft and the gear/pulley.
Inspect the old gear/pulley very carefully. If any teeth have burrs, are missing, or are
damaged, or if the center hole is distorted or enlarged, the gear/pulley must be replaced rather
than the old one re-installed.
1. Flat-Blade Screwdrivers, from 1/16 inch (1.5 mm) to 1/4 inch (6.5 mm)
2. Phillips Screwdrivers, numbers 0, 1, and 2
3. TORX T6, TORX T7, and TORX T10 drivers
4. Fine-Point, Offset Fine-Point, and Needle-Nose pliers
5. Small Diagonal Cutters or other cutter for cutting cable ties
6. Hex Keys, 1.5 mm and 2.0 mm
7. Hex Driver, 0. 9 mm and 5.5 mm (this can also be used for securing push nuts)
8. Small and Medium Spring Hook Tools
9. 3-Jaw Gear Puller
10. LOCTITE® 420
11. Super Lube® Synthetic Multi-Purpose Grease, Zebra P/N 807048-001

12. Belt Tensioning Tool, Zebra P/N 900754-003

Removal Sequence
5.3 Removal Sequence

The figures on this page and the following page show the recommended sequence for
removing parts.
For each item, follow the diagram upward to see what must be removed for access. For
example, to remove the Front Bezel (Section 5.6.20), you would remove the Left Side Cover
(Section 5.6.3) and the Right Side Cover (Section 5.6.4); follow the red path below.
5.6.6 5.6.5
Feeder Cover 5.6.37
Top Cover Cleaning Roller
page 119 page 117 page 177
5.6.7 5.6.8 5.6.9 5.6.10

LCDisplay PCBA Printhead Fan Feed Cover Feeder Latch
Sensor
page 120 page 121 page 122 page 123
5.6.3 5.6.4 5.6.1

Left Side Cover Right Side Cover Printhead
Assembly
5.6.20 5.6.2
Front Bezel Ribbon
Sensor
page 139 page 114

Removal Sequence
5.3 Removal Sequence (continued)
5.6.3 5.6.12 5.6.11 5.6.4

Left Side Cover Rear Cover Bottom Cover Right Side Cover
5.6.14 5.6.13
Main PCBA Ethernet PCBA
page 127 page 126
5.6.15
Grpond Plate
page 132
5.6.27 5.6.17 5.6.21 5.6.16

Ribbon ID PCBA Lid Ribbon Flag PCBA Fan
Position Sensor
5.6.18 5.6.22
Card Feeder Encoder Wheel
Assembly
page 136 page 142
5.6.19
Flipper Module
page 137
PRINT ENGINE
(next page)

Removal Sequence
5.3 Removal Sequence (continued)
PRINT ENGINE
5.6.28 5.6.29 5.6.23
Lid Sensor Linkage (Left Linkage (Right
Side) Side)
5.6.31 5.6.26
Stepper Motror Ribbon Take-Up
Motor
page 161 page 148
5.6.38 5.6.40 5.6.30

Platen Roller and Drive Roller Rocker (Left Side)
Exit Roller Assembly
5.6.39 5.6.32 5.6.24

ATM Card Feed Printhead Lift Cam Rocker (Right Side)
Sensor
5.6.33 5.6.25
Pressure Rollers Printhead Lift
(Front and Back) Motor
page 169 page 147
5.6.34
Mag Encoder
Assembly
page 173
5.6.35 5.6.36
Mag Sensor Card Sync Sensor
page 175 page 176

Procedure List
5.4 Procedure List

5.6.1 Printhead Assembly - - - - - - - - - - - - - - - - - - - - - 106
5.6.2 Ribbon Sensor - - - - - - - - - - - - - - - - - - - - - - - - - 114
5.6.3 Left Side Cover - - - - - - - - - - - - - - - - - - - - - - - - - 115
5.6.4 Right Side Cover - - - - - - - - - - - - - - - - - - - - - - - - 116
5.6.5 Top Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - 117
5.6.6 Feed Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - 119
5.6.7 LCDisplay PCBA - - - - - - - - - - - - - - - - - - - - - - - 120
5.6.7 LCDisplay PCBA - - - - - - - - - - - - - - - - - - - - - - - 120
5.6.8 Printhead Fan - - - - - - - - - - - - - - - - - - - - - - - - 121
5.6.9 Feed Cover Sensor - - - - - - - - - - - - - - - - - - - - - - 122
5.6.10 Feeder Latch - - - - - - - - - - - - - - - - - - - - - - - - - 123
5.6.11 Bottom Cover - - - - - - - - - - - - - - - - - - - - - - - - - 124
5.6.12 Rear Cover - - - - - - - - - - - - - - - - - - - - - - - - - - 125
5.6.13 Ethernet PCBA - - - - - - - - - - - - - - - - - - - - - - - - 126
5.6.14 Main PCBA - - - - - - - - - - - - - - - - - - - - - - - - - - 127
5.6.15 Ground Plate - - - - - - - - - - - - - - - - - - - - - - - - - 132
5.6.16 PCBA Fan - - - - - - - - - - - - - - - - - - - - - - - - - - 133
5.6.17 Lid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 134
5.6.18 Card Feeder Assembly - - - - - - - - - - - - - - - - - - - - 136
5.6.19 Flipper Module - - - - - - - - - - - - - - - - - - - - - - - - 137
5.6.20 Front Bezel - - - - - - - - - - - - - - - - - - - - - - - - - - 139
5.6.21 Ribbon Flag Position Sensor - - - - - - - - - - - - - - - - - 140
5.6.22 Encoder Wheel - - - - - - - - - - - - - - - - - - - - - - - - 142
5.6.23 Linkage - Right Side - - - - - - - - - - - - - - - - - - - - - 143
5.6.24 Rocker - Right Side - - - - - - - - - - - - - - - - - - - - - - 144
5.6.25 Printhead Lift Motor - - - - - - - - - - - - - - - - - - - - - - 147
5.6.26 Ribbon Take-Up Motor - - - - - - - - - - - - - - - - - - - - 148
5.6.27 Ribbon ID PCBA - - - - - - - - - - - - - - - - - - - - - - - 151
5.6.28 Lid Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - 153
5.6.29 Linkage - Left Side - - - - - - - - - - - - - - - - - - - - - - 154
5.6.30 Rocker - Left Side - - - - - - - - - - - - - - - - - - - - - - 155
5.6.31 Stepper Motor - - - - - - - - - - - - - - - - - - - - - - - - 161
5.6.32 Printhead Lift Cam - - - - - - - - - - - - - - - - - - - - - - 163
5.6.33 Pressure Rollers - Front and Back - - - - - - - - - - - - - - - 169
5.6.34 Mag Encoder Assembly - Head and Sensor - - - - - - - - - - 173
5.6.35 Mag Sensor - - - - - - - - - - - - - - - - - - - - - - - - - 175
5.6.36 Card Sync Sensor - - - - - - - - - - - - - - - - - - - - - - 176
5.6.37 Cleaning Roller - - - - - - - - - - - - - - - - - - - - - - - - 177
5.6.38 Platen Roller and Exit Roller - - - - - - - - - - - - - - - - - 178
5.6.39 ATM Card Feed Sensor - - - - - - - - - - - - - - - - - - - - 181
5.6.40 Drive Roller Assembly - - - - - - - - - - - - - - - - - - - - 182

Spare Kit List
5.5 Spare Kit List

The following table lists all the spare kits and upgrade kits, by kit number, and their associated
replacement procedure section(s).
KIT, # Description Section

P1031925-001 KIT, Upgrade, Ethernet PCBA 5.6.13
P1031925-007 KIT, MLB Single-sided 5.6.14
P1031925-009 KIT, CRYPTOGRAPHIC PCBA 5.6.27
P1031925-010 KIT, LCDisplay PCBA 5.6.7
P1031925-011 KIT, Mag Head 5.6.34
P1031925-012 KIT, Ribbon Sensor 5.6.2
P1031925-014 KIT, ATM Sensor 5.6.39
P1031925-015 KIT, Lid & Ribbon Encoder Sensors 5.6.28, 5.6.21
P1031925-018 KIT, Motor, Head Lift 5.6.25
P1031925-019 KIT, Ribbon Motor 5.6.26
P1031925-021 KIT, Linkage Springs 5.6.23, 5.6.24, 5.6.29, 5.6.30
P1031925-023 KIT, Ribbon Drive System 5.6.26
P1031925-025 KIT, Belts & O-Rings for Print Engine -
P1031925-026 KIT, Encoder Disk 5.6.22
P1031925-029 KIT, Cleaning Roller Assembly 5.6.37
P1031925-038 KIT, Latch for Feeder 5.6.10
P1031925-040 KIT, Ground Plate 5.6.15
P1031925-042 KIT, Cover for Feeder 5.6.6
P1031925-046 KIT, Feet for Printer 5.6.11
P1031925-047 KIT, Covers for Frame 5.6.21, 5.6.27
P1031925-048 KIT, Cables Electronics -
P1031925-049 KIT, Power Supply -
P1031925-050 KIT, Packaging -
P1031925-052 KIT, Miscellaneous Hardware -
P1031925-053 KIT, Feed Cover Sensor 5.6.9
P1031925-054 KIT, Sync Sensor 5.6.36
P1031925-055 KIT, Flipper Sensor 5.6.19
P1031925-070 KIT, Printhead 5.6.1
P1031925-071 KIT, Cooling Fans 5.6.8, 5.6.16
P1031925-072 KIT, Drive Linkage 5.6.23, 5.6.24, 5.6.29, 5.6.30
P1031925-073 KIT, Drive Gears & Camshaft 5.6.32
P1031925-074 KIT, Pressure Rollers 5.6.33
P1031925-076 Kit Flipper Assembly 5.6.19
P1031925-100 Kit Upgrade Manual Front Feed 5.6.20
P1031925-137 KIT, Button For Door 5.6.5
P1031925-141 KIT, Top Cover And Badge 5.6.5
P1031925-143 KIT, Side Panels Bezels 5.6.3, 5.6.4, 5.6.12, 5.6.20
P1031925-217 KIT, Motor Card Drive 5.6.31
P1031925-224 KIT, Drive System 5.6.24
P1031925-228 Kit Platens For Print Engine 5.6.38, 5.6.40
P1031925-230 KIT, Feeder Assembly 5.6.18
P1031925-233 KIT, Carrier And Drive For Flipper 5.6.19
P1031925-235 KIT, Inner Top Assembly 5.6.17
P1031925-244 KIT, Output Hopper Non-Encode 5.6.20

Procedures
5.6 Procedures
5.6.1 Printhead Assembly
NOTE • This procedure uses Spare Kit # P1031925-070: KIT, PRINTHEAD.
Electrostatic Discharge Caution • The Printhead is extremely susceptible to

Electrostatic Discharge (ESD) damage. Do not touch the bottom surface of the Printhead.
The replacement 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.
Important • This procedure describes replacing the Printhead Assembly. The Printhead
Assembly is supplied with components in correct alignment with each other. These
alignments are critical to proper operation of the printer. Do not deviate from the procedure
given here, do not loosen or tighten any screws except those specifically noted in this
procedure, and do not attempt to adjust any part of the Printhead Assembly.
NOTE • The Printhead Assembly can be replaced without removing any other parts of
the printer.
Step 1. Turn the printer off, and disconnect the power cord.
Step 2. Press the access button in, and raise the Lid.
Step 3. Locate the Printhead Assembly (circled above).

Procedures
Step 4. Push the Printhead in and upward.
Step 5. Lift the Printhead out of the Frame.
Step 6. Gently tug on the 4-color wire set to pull the connector through the hole in the
frame (arrow below) to allow disconnection.
Step 7. With a small flat-blade screwdriver, loosen and remove the printhead data and
power cable (circled above).

Procedures
Step 8. Disconnect the 4-wire Color Ribbon Sensor (circled below). Do not let the 4-wire
connector go into the access hole -- it is difficult to retrieve. Note that this sensor
connects to J5 on the Main PCBA.
Step 9. Disconnect the green ground wire.
Step 10. Remove the Printhead Assembly.

Procedures
Replacement
Step 1. Record the resistance (e.g., 3161 Ω circled below) of the new Printhead.
Step 2. Connect the 4-wire Color Ribbon Sensor.
Step 3. Connect the printhead data and power cable. Note that the connector is keyed. Use a
small flat-blade screwdriver to guide the connector into place.
Step 4. Connect the green ground wire.
Step 5. Insert the 4-wire connector back through the hole in the frame. Failure to do so
may cause the printhead frame to be broken when the Lid is closed.
Step 6. Push the printhead alignment pin into the alignment hole (arrow below).
Step 7. Press in and downward, lowering the Printhead into place.
Step 8. The Printhead installation is complete.

Procedures
Tests and Adjustments
Important • To perform the tests and adjustments in this section, you will need a
YMCKO Ribbon and a Black Monochrome Ribbon.
Preliminary Setup - Printing preferences

Step 1. Ensure that a YMCKO Ribbon is installed in the printer.
Step 2. Go to Start > Devices and Printers. Right click on the Zebra ZXP Card Printer
listing, and select Printing preferences.
Step 3. The Printing Preferences window will open.
Step 4. Select the Card Setup tab.
Step 5
Step 6
Step 5. Set Monochrome Conversion to Barcode.
Step 6. Click the Image Control button.
Step 7. Observe the Image Control window.
Step 8. Ensure that the Black slider is set to 0.
Step 9. Click the Close button to close the Image Control window.
Step 10. Click on the OK button to save the settings and to close the Printing
Preferences window.

Procedures
Preliminary Setup - Printer properties

listing, then select Printer properties.
Step 2. Click on Device Settings > Tools.
Step 3. This brings up the Tools window.
Type the
command
here ... ... then
click the
Execute
button.
Step 4. From the Tools window, perform the following tests and adjustments:
Printhead Resistance Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Ribbon Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Monochrome Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Procedures
Printhead Resistance Update

Step 1. In the Command Line (left arrow above), type the Printhead Resistance
command (!R), a space, and the resistance (e.g., 1234) of the replacement
printhead. For this example, the complete command is !R 1234.
Step 2. Click the Execute button.
Step 3. <ACK> should appear in the Printer Status field indicating that the Printhead
Resistance command was successfully completed.
Ribbon Sensor Calibration

Step 1. Ensure that a YMCKO Ribbon is installed in the printer.
Step 2. In the Command Line, type the Calibration command (!SAP), a space, and 3 (for
the ribbon color detect sensor). The complete command is !SAP 3.
Step 3. Click the Execute button, and wait while the ribbon motor runs for approximately
25 seconds.
Step 4. A string of values followed by <ACK> should appear in the Printer Status field
indicating that the Calibration command was successfully completed.
Step 5. This completes the ribbon sensor calibration.

Procedures
Monochrome Adjustment
Step 1. Ensure that a Black Monochrome Ribbon is installed in the printer.
Step 2. In the Command Line, type +MONO to determine the current monochrome value.
Step 3. The current monochrome value will be displayed in the Printer Status field;
e.g., -20 0 <ACK> where -20 is the current monochrome value. Make a note of the
current monochrome value.
Step 4. Print a test card with an image similar to the sample below Note that the sample
image will be converted to monochrome via the driver and its settings (refer to
Preliminary Setup - Printing preferences).
Step 5. Examine the monochrome image on the printed test card.
• If the image is too dark, go to Step 6; and decrease the monochrome value.
• If the image is too light, go to Step 6; and increase the monochrome value.
• If you are satisfied with the image, go to Step 8.
Step 6. Adjust the image quality by increasing/decreasing the current monochrome value.
The monochrome values range from -127 to +128.
For example: In the Command Line, type +MONO, a space, and -25 (to lighten
the monochrome image). The complete command is +MONO -25.
Step 7. Continue printing and examining cards, and adjusting the monochrome value until
you are satisfied with the quality of the monochrome image; then go to Step 8.
Step 8. In the Command Line, type SDATA to save the values entered in the previous steps.
Step 10. Verify that <ACK> appears the Printer Status field to acknowledge that the data
was saved.
Step 11. Click the Close button to close the Tools window.
Step 12. Click the OK button to close Printer Properties window.
Step 13. This completes the monochrome adjustment.

Procedures
5.6.2 Ribbon Sensor
NOTE • This procedure uses Spare Kit # P1031925-012: KIT, RIBBON SENSOR.
Step 1. Remove the Printhead; see Section 5.6.1.
Step 2. With a TORX T6 driver, remove the screw (SCR M2x10MM, 4.0 in-lb) that
holds the sensor and housing in place; see arrow below.
Step 3. Slide the sensor out of the housing.
Step 4. Remove the Ribbon Sensor. Note that this sensor connects to J5 on the Main PCBA.

Procedures
5.6.3 Left Side Cover
NOTE • This procedure uses Spare Kit # P1031925-143: KIT, SIDE PANELS BEZELS.
Step 1. Locate the two screws (circled below) that hold the Left Side Cover in place.
Step 2. With a TORX T10 driver, loosen the two screws (9.0 in-lb).
Step 3. Remove the Left Side Cover.

Procedures
5.6.4 Right Side Cover
Step 1. Locate the two screws (circled below) that hold the Right Side Cover in place.
Step 2. With a TORX T10 driver, loosen the two screws (9.0 in-lb).
Step 3. Remove the Right Side Cover.

Procedures
5.6.5 Top Cover
NOTE • This procedure uses Spare Kit # P1031925-141: KIT, TOP COVER BADGE; and
P1031925-137, KIT, BUTTON FOR DOOR.
Step 1. Press the access button, and raise the Lid.
Step 2. With a TORX T10 driver, remove the four screws (SCR, PLAST, 4-.37L, 7.0 in-lb)
that hold the Top Cover to the Lid; see arrows below.

Procedures
Step 3. Lower and latch the Lid.
Step 4. With one hand, grasp the front lip of the Top Cover. With the other hand, press down
and to the rear with enough force to “pop” the Top Cover loose.
Step 5. Remove the Top Cover and Button.
Step 6. Set the Top Cover and Button aside.

Procedures
5.6.6 Feed Cover
NOTE • This procedure uses Spare Kit # P1031925-042: KIT, COVER FOR FEEDER.
Step 1. Locate the Feed Cover (arrow below).
Step 2. With a flat-blade screwdriver, free the pivot pin from the pivot tab (arrow below).
Step 3. Carefully remove the Feed Cover, and set it aside.

Procedures
5.6.7 LCDisplay PCBA
NOTE • This procedure uses Spare Kit # P1031925-010: KIT, LCDISPLAY PCBA.
Step 1. Locate the LCD Display PCBA (circled below).
Step 2. Carefully remove the 10-wire plug (circled below) from the connector on the LCD
Display PCBA.
Step 3. With a TORX T10 driver, remove the two screws (SCR, PLAST, 4-.25L, 4.0 in-lb)
that hold the LCD Display PCBA to the Frame; see arrows above.
Step 4. Remove the LCD Display PCBA.

Procedures
5.6.8 Printhead Fan
NOTE • This procedure uses Spare Kit # P1031925-071: KIT, COOLING FANS.
Step 1. Locate the Printhead Fan (circled below).
Step 2. With a TORX T10 driver, remove the two screws (SCR, PLAST, 4-1.0L, 5.5 in-lb)
that hold the Printhead Fan in place.
Step 3. Cut the cable ties holding the various wires and connectors going to the Main PCBA.
Step 4. Disconnect the 2-wire Printhead Fan plug from connector J25 on the Main PCBA.
Step 5. Remove the Printhead Fan.

Procedures
5.6.9 Feed Cover Sensor
NOTE • This procedure uses Spare Kit # P1031925-053: KIT, FEED COVER SENSOR.
Step 1. Locate the Feed Cover Sensor (circled below).
Step 2. With a TORX T7 driver, remove the screw (SCR, PLAST, 2-.25, 2.5 in-lb) that
holds the sensor in place.
Step 3. Cut the cable ties holding the various wires and connectors going to the Main PCBA.
Step 4. Disconnect the 4-wire sensor plug from connector J8 on the Main PCBA.
Step 5. Remove the Feed Cover Sensor.

Procedures
5.6.10 Feeder Latch
NOTE • This procedure uses Spare Kit # P1031925-038: KIT, LATCH FOR FEEDER.
Step 1. With the Top Cover removed, locate the Feeder Latch (circled below).
Caution • The pulling force of the torsion springs is very strong, therefore care must be
taken when removing and replacing them.
Step 2. Carefully press in on the spring arms (arrows below), and unhook the two torsion
springs. This will free the Feeder Latch. Note the orientation of the torsion springs.
Step 3. Set the Feeder Latch aside.

Procedures
5.6.11 Bottom Cover
NOTE • This procedure uses Spare Kit # P1031925-046: KIT, FEET FOR PRINTER.
Step 1. Turn the printer over, bottom-side up.
Step 2. With a flat-blade screwdriver, carefully pry off the four rubber feet (they are held
in place with adhesive).
Step 3. With a TORX T10 driver, remove the four screws (SCR, PLAST, 4-.37L,7.0 in-lb);
see arrows above.
Step 4. Remove the Bottom Cover.

Procedures
5.6.12 Rear Cover
from the bottom of the Rear Cover.
Step 2. With a TORX T10 driver, loosen the two screws (SCR, PLAST, 4-.37L, 9.0 in-lb)
from the top of the Rear Cover.
Step 3. Remove the Rear Cover.

Procedures
5.6.13 Ethernet PCBA
NOTE • This procedure uses Spare Kit # P1031925-001: KIT, ETHERNET PCBA.
Step 1. With a TORX T10 driver, Remove the four screws (SCR M3x6, 6.0 n-lb) holding
the Ethernet Plate to the Ground Plate; arrows below.
Step 2. Remove the Ethernet PCBA and Plate.

Procedures
5.6.14 Main PCBA
NOTE • This procedure uses Spare Kit # P1031925-007: KIT, MLB SINGLE SIDED.
Step 1. Print a Standard Test Card (see Section 2.3). This card will provide you with the
Head Resistance, the X and Y Offsets, and the End of Text value to update the
firmware on the replacement Main PCBA.
Step 2. With the Bottom Cover removed, the Main PCBA is visible and accessible.
Step 3. Remove the ground wires from the tabs (circled below) on the Ground Plate.

Procedures
Step 4. With a TORX T10 driver, remove the five screws (SCR, PLAST, 4-.25L, 5.5 in-lb)
holding the Main PCBA and Ground Plate in place; arrows below.
Step 5. If necessary, cut the cable ties to free the cables connected to the Main PCBA.
Step 6. Lift the Main PCBA (and Ground Plate) out of the Frame, and carefully disconnect
the various wires and connectors that attach to the Main PCBA. Be careful to avoid
damaging any of them.
Step 7. If present, remove the Ethernet PCBA; see Section 5.6.13.
Step 8. Remove the Ground Plate (and Fan); see Section 5.6.15.
Step 9. Set the Main PCBA aside. Note that the figure above shows the Main PCBA with
the Ground Plate and Fan attached.

Procedures
Step 10. The following layouts show the connections to the Main PCBA.
TOP SIDE J2
J29 J6 J2
J13
J12
J8
J11
J10
J27 J16
J19 J21
J7
J22
J25 J28 J24 J5 J9 J18
J1 SCM CTRL (Note 1) J16 RIBBON MTR

J2 None J17 SCM PLT MTR (Note 1)
J3 None J18 CRYPTO PORT
J4 BDM PORT (Note 1) J19 PWR JACK
J5 COLOR RIBBON J20 RS232 (Note 1)
J6 RIBBON ENCODER INTERUPTOR J21 AIR FAN
J7 MAIN DRIVE LOCK J22 PLATEN STEPPER MTR
J8 FEED COVER SENSOR J23 MAG HEAD / MAG SYNC
J9 CARD SYNC INTERUPTOR J24 LCD
J10 CARD LOAD INTERUPTOR J25 HEAD FAN
J11 FLIPPER POSITION INTERUPTOR J26 CAM MTR
J12 ATM CARD INTRPTR J27 FEEDER MOTOR
J13 USB J28 PRNT HEAD
J14 SCM CAM MTR (Note 1) J29 FLIPPER MTR
J15 JTAG (Note 1) J30 ETHERNET TO USB MODULE (Note 1)
Note 1: Bottom side of PCBA
BOTTOM SIDE J30
J14
J17
J1
J20 J15 J4

Procedures
Parameter Update
Important • Before starting the Firmware Update, refer to the Standard Test Card you
printed prior to removing and replacing the Main PCBA. You will need the Head Resistance,
the X and Y Offsets, and the End of Text value to update the firmware on the replacement
Main PCBA.
If for any reason you were unable to print the Test Card, contact Zebra Technical Support to
obtain the above values.
listing, then select Printer properties.
Step 2. Click on Device Settings > Tools.
Step 3. This brings up the Tools dialog box.
Type the
command
here ... ... then
click the
Execute
button.

Procedures
Step 4. From the information on the Standard Test Card, update the printer’s parameters.
a. In the Command to send to printer field, type the Print Head Resistance (!R)
command, a space, and the resistance of the Printhead. From the Standard Test
Card shown above, the complete command is !R 2840.
b. Click the Execute button.
c. In the Command to send to printer field, type the End of Print (+EC) command,
a space, and the end-of-print value. From the Test Card shown above, the
complete command is +EC 13.
d. Click the Execute button.
e. In the Offset setting section of the Tools display, enter the X and Y offsets for the
card front in the Front X and Front Y fields respectively. From the Standard Test
Card shown above, set Front X = 5 and Front Y = 16.
f. In the Offset setting section of the Tools display, enter the X and Y offsets for the
card back in the Back X and Back Y fields respectively. From the Standard Test
Card shown above, set Back X = 5 and Back Y = 16.
g. Click the Set Offsets button.
Step 5. The Parameter Update is complete.

Procedures
5.6.15 Ground Plate
NOTE • This procedure uses Spare Kit # P1031925-040: KIT, GROUND PLATE.
Step 1. With a TORX T10 driver, remove the two screws (SCR M2x6, 3.5 in-lb) holding the
Main PCBA to the Ground Plate.
Step 2. Disconnect the fan plug from connector J21 (arrow below) on the Main PCBA.
Step 3. Remove the Ground Plate (and Fan).

Procedures
5.6.16 PCBA Fan
NOTE • This procedure uses Spare Kit # P1031925-071: KIT, COOLING FANS.
Step 1. With the Ground Plate removed, you can remove the PCBA Fan.
Step 2. With a TORX T10 driver, remove the two screws (SCR M3x25, 5.5 in-lb)
holding the Fan in place. Note the orientation of the Fan.
Step 3. Set the Fan aside

Procedures
5.6.17 Lid
NOTE • This procedure uses Spare Kit # P1031925-235: KIT, INNER TOP ASSEMBLY.
Step 1. Locate the Lid.
Step 2. If not already done, remove the Printhead; see Section 5.6.1.
Step 3. Remove a retaining clip (arrow below) from one end of the shaft.

Procedures
Step 4. Push the shaft through the mounting holes thereby freeing the Top Cover and Card
Feeder. Note that the cable and ground wires are attached.
Step 5. Remove the ground wire from the Feeder.
Step 6. If necessary, cut any cable ties preventing Lid removal.
Step 7. Remove the Lid.
Step 8. Set the Lid to the side.

Procedures
5.6.18 Card Feeder Assembly
NOTE • This procedure uses Spare Kit # P1031925-230: KIT, FEEDER ASSEMBLY.
Step 1. With the shaft removed (Section 5.6.17) and the plugs disconnected from the Main
PCBA, lift the Card Feeder out of the Frame.
Step 2. Unwrap the spiral cable tie, cut the cable tie, and then pull the ground wire and
card-feeder cable out of the access hole.
Step 3. Remove the Card Feeder Assembly.

Procedures
5.6.19 Flipper Module
NOTE • This procedure uses Spare Kit # P1031925-076: KIT, FLIPPER ASSEMBLY; and
P1031925-233, KIT CARRIER AND DRIVE FOR FLIPPER.
Step 1. If the Mag Encoder option is installed, remove the Inertia Wheel.
a. Remove the retaining clip; circled above.

b. With a 0.9 mm Hex driver, remove the set screw (7.0 in-lb); arrow above.
c. Slide the Inertia Wheel off the shaft.
Step 2. Slip the belt (circled below) off the pulleys.

Procedures
Step 3. With a TORX T10 driver, remove the four screws (SCR, PLAST, 4-.37L, 9.0 lb),
two on each side, holding the Flipper Module to the Frame; circled below.
Step 4. Cut the cable ties holding the various cables and connectors.
Step 5. Remove the Flipper Module.

Procedures
5.6.20 Front Bezel
Step 1. With a TORX T10 driver, remove the four screws (SCR 4-.25L, 4.0 in-lb), two
per side, holding the Left and Right Bezels to the Frame; the two left-side screws
are circled below.
Step 2. Remove the Front Bezels.

Procedures
5.6.21 Ribbon Flag Position Sensor
NOTE • This procedure uses Spare Kit # P1031925-015: KIT, LID & RIBBON ENCODER
SENSORS or Spare Kit # P1031925-047: KIT, COVERS FOR FRAME.
Step 1. Locate the Ribbon Flag Position Sensor. The sensor is mounted behind the cover
(arrow below).
Step 2. With a TORX T7 driver, remove the two screws (SCR, PLAST, 2-.25, 2.5 in-lb)
holding the sensor Cover to the Frame.; circled below.
Step 3. Remove the cover.

Procedures
Step 4. With a TORX T7 driver, remove the screw (SCR, PLAST, 2-.25, 2.5 in-lb) holding
the sensor in place.; circled below.
Step 5. If not already done, disconnect the Ribbon Flag Position Sensor plug from
connector J6 on the Main PCBA.
Step 6. If necessary, cut any cable ties preventing sensor removal.
Step 7. Remove the Ribbon Flag Position Sensor.

Procedures
5.6.22 Encoder Wheel
NOTE • This procedure uses Spare Kit # P1031925-026: KIT, ENCODER DISK.
Step 1. Locate the Encoder Wheel (arrow below).
Step 2. Compress the clutch spring by pressing the washer inward (circle above), then use
fine-point pliers, a small flat-blade screwdriver, or retaining-ring pliers to remove
the retainer clip, then slip the washer and the clutch spring off the clutch shaft.
Step 3. Slip the gear wheel, felt washer, Encoder Wheel, and second felt washer off the
clutch shaft.

Procedures
5.6.23 Linkage - Right Side
NOTE • This procedure uses Spare Kit # P1031925-072: KIT, DRIVE LINKAGE or
Spare Kit # P1031925-021: KIT, LINKAGE SPRINGS.
Step 1. Remove the Linkage Spring (circled below).
and washers holding the Linkage to the Frame.; arrows above.
Step 3. Remove the Linkage (3 pieces).

Procedures
5.6.24 Rocker - Right Side
NOTE • This procedure uses Spare Kit # P1031925-023: KIT, RIBBON DRIVE SYSTEM.
Step 1. Remove the O-ring belt (dashed circle below).
Step 2. With a TORX T10 driver, remove the screw (SCR 4-.25L, 7.0 in-lb) and washer
holding the Rocker in place; circled above.
Step 3. Remove the retaining clips from the first and second Gears (arrows below), and
remove the two Gears.
Step 4. With a TORX T10 driver, remove the screw (SCR, PLAST, 4-.37L, 5.5 in-lb) from
the third Gear, circled above; and remove the Gear.

Procedures
Step 5. Release the two Rocker Springs (arrows below).
Step 6. Remove the Rocker Assembly (circled above).
Step 7. Set the Rocker Assembly aside.

Procedures
Replacement
Replacement is performed by reversing the removal steps. Note the following when
re-installing the gears.
Step 1. Slide the gears on their respective shafts in the order indicated below.
#1
#2
#3
Important • When installing the Gear #1, ensure that the grooves (outlined in orange below)
are aligned as indicated.
Step 2. Then lock the gears in place (screw for Gear #1 and clips for Gear #2 and Gear #3)
in the same order.

Procedures
5.6.25 Printhead Lift Motor
NOTE • This procedure uses Spare Kit # P1031925-018: KIT, MOTOR, HEAD LIFT.
Step 1. Locate the Printhead Lift Motor. (circled below)
Step 2. Using a TORX T10 driver, remove the four screws (SCR M3x6, 5.5 in-lb) holding
the Printhead Lift Motor to the Frame; arrows below. Note the orientation of the
connector on the motor (facing the front of printer).
Step 3. If not already done, disconnect the Printhead Lift Motor plug from connector J26
on the Main PCBA.
Step 4. Disconnect the ground wire, and remove the Printhead Lift Motor.

Procedures
5.6.26 Ribbon Take-Up Motor
NOTE • This procedure uses Spare Kit # P1031925-019: KIT, MOTOR FOR RIBBON.
Step 1. Locate the Ribbon Take-Up Motor (circled below).
the Gear in place; circled below. Remove the Gear.
Step 3. Remove the clip (arrow above) holding the lower pulley in place, then remove
the pulley and associated O-ring belt.

Procedures
Step 4. With a TORX T10 driver, remove the three “inside” screws (SCR M3x10, 7.0 in-lb)
holding the motor to the Bracket; arrows below.
Step 5. Remove the Ribbon Take-Up Motor.

Procedures
Replacement
Install the Gear and Lower Pulley (arrows below).
Important • When installing the Gear, ensure that the grooves (outlined in orange below) are
aligned as indicated.

Procedures
5.6.27 Ribbon ID PCBA
NOTE • This procedure uses Spare Kit # P1031925-009: KIT, CRYPTOGRAPHIC PCBA
or Spare Kit # P1031925-047: KIT, COVERS FOR FRAME.
Step 1. Locate the PCBA. The PCBA is mounted behind the cover (arrow below).
Step 2. With a flat-blade screwdriver, free the cable (arrow below) from the cable clamp.
Step 3. With a TORX T7 driver, remove the four screws (SCR, PLAST, 2-.25, 2.5 in-lb)
holding the cover in place; circled above.
Step 4. Remove the Cover.
Step 5. Slide the two springs off their respective standoffs.

Procedures
Step 6. Slide the PCBA of the standoffs.
Step 7. If not already done, disconnect the Ribbon ID PCBA plug from connector J18 on the
Main PCBA.
Step 8. Remove the Ribbon ID PCBA.

Procedures
5.6.28 Lid Sensor
NOTE • This procedure uses Spare Kit # P1031925-015: KIT, LID RIBBON ENCODER
SENSOR.
Step 1. Locate the Lid Sensor (circled below).
the Lid Sensor in place.
Step 3. If not already done, disconnect the Lid Sensor plug from connector J7 on the
Main PCBA.
Step 4. Remove the Lid Sensor.

Procedures
5.6.29 Linkage - Left Side
Spare Kit # P1031925-021: KIT, SPRINGS FOR LINKAGE.
Step 1. Remove the Linkage Spring (circled below).
and washers holding the Linkage to the Frame; arrows above.
Step 3. Remove the Linkage (3 pieces).

Procedures
5.6.30 Rocker - Left Side
Spare Kit # P1031925-021: KIT, SPRINGS FOR LINKAGE.
Step 1. Locate the Rocker (circled below).
Step 2. With a TORX T10 driver, loosen the three screws (circled below), holding the
Motor Collar and Tensioner in place. This will free the belt and allow you to remove
the Main Inertia Wheel.
Step 3. Remove the retaining clip (arrow above) from the Main Inertia Wheel.

Procedures
Step 4. With a 3-Jaw Gear Puller, remove the Main Inertia Wheel.
Step 5. Remove the associated Belt.
Step 6. Release the two Rocker Springs (arrows below).
Step 7. With a TORX T10 driver, remove the screw (SCR 4-.25L, 7.0 in-lb) and washer
holding the Rocker in place; circled above.
Step 8. Remove the Rocker Assembly.
Step 9. Set the Rocker aside.

Procedures
Belt Installation and Tensioning Tool

Step 1. The two scales on the Belt Tensioning Tool have been preset at the factory. DO NOT
CHANGE THESE PRESETS.
Scale 1
Scale 2
Step 2. With a TORX T10 driver, loosen the two motor collar screws (4-40x5/16), 7.0 in-lb),
two left arrows; and the tensioner screw (4-40x5/16), 5.5 in-lb), right arrow.

Procedures
Step 3. Install the belts and associated gears and pulleys. The following two figures show
the belt “path” for the two belts removed in this section.
a. Install Belt 1 (orange path below).
b. Install the Platen Roller Pulley.
c. Install Belt 2 (orange path below).

Procedures
Step 4. Set the Belt Tensioning Tool in place. Note that the arrows indicate the alignment
guide posts.
Step 5. Ensure that the tension arm is positioned under the belt (circled above).
Step 6. With a TORX T10 driver, tighten the two motor collar screws (7.0.in-lb).
Step 7. Rotate the Belt Tensioning Tool 180 degrees.

Procedures
Step 8. Set the Belt Tensioning Tool in place. Note that the arrows indicate the alignment
guide posts.
Step 9. Ensure that the tension arm guide post is positioned over the tensioner pulley
(circled above).
Step 10. With a TORX T10 driver, tighten the tensioner screw (7.0 in-lb); arrow below.
Step 11. Remove the Belt Tensioning Tool.
Step 12. Ensure that the Stepper Motor and associated gears and pulleys rotate freely as the
large pulley is turned.

Procedures
5.6.31 Stepper Motor
NOTE • This procedure uses Spare Kit # P1031925-217: KIT, MOTOR CARD DRIVE.
Step 1. Locate the Stepper Motor.
Step 2. If not already done, remove the left-side Linkage; see Section 5.6.29.
Step 3. With a TORX T10 driver, loosen the two screws (7.0 in-lb) holding the motor collar
in place; circled below.
Step 4. Remove the associated belt (arrow above).

Procedures
Step 5. With a TORX T10 driver, remove the four screws (SCR 4-40, 5/16; 7.0 in-lb)
holding the Stepper Motor in place; circled below. Note the orientation of the motor;
-- the connector is facing toward the back of the printer.
Step 6. If not already done, disconnect the Stepper Motor plug from connector J22 on the
Main PCBA.
Step 7. Disconnect the ground wire.
Step 8. Remove the Stepper Motor.

Procedures
5.6.32 Printhead Lift Cam
NOTE • This procedure uses Spare Kit # P1031925-073: KIT, DRIVE GEARS &
CAMSHAFT.
Step 1. Locate the Printhead Lift Cam (dashed circle below).
Step 2. From the right side: remove Gears #1 and #2:
a. Remove the retaining clip from Gear #1, and remove the Gear.
#2
#1
b. With a TORX T10 driver, remove the screw (SCR, PLAST, 4-.37L, 5.5 in-lb)
from Gear #2; and remove the Gear.

Procedures
Step 3. From the left side: remove the Printhead Lift Cam.
a. If not already done, remove the left-side Linkage; see Section 5.6.29.
b. Slide the Printhead Lift Cam out of the print engine.
Step 4. Set the Printhead Lift Cam aside.

Procedures
Replacement
Replacement is performed by reversing the removal steps. Note the special instructions on the
following pages when reinstalling the gears and belts.
Note the following when re-installing the Printhead Lift Cam

Step 1. Apply Super Lube Synthetic Multi-Purpose Grease, Zebra P/N 807048-001, to the
two surfaces (arrows below) all the way around.
.
Step 2. Apply Super Lube Synthetic Multi-Purpose Grease to the surface (arrow below) all
the way around.
.

Procedures
Step 3. Apply Super Lube Synthetic Multi-Purpose Grease to the inside surface (arrow
below) all the way around.
.
Step 4. Slide the Printhead Lift Cam into the Frame.

Procedures
Note the following when re-installing the Gears

a. Before installing Gear #3, apply Super Lube Synthetic Multi-Purpose Grease to
the surface (arrow below) all the way around.
Step 1. Slide the gears on their respective shafts in the order indicated below.
NOTE: Check the part number on the bottom of your printer. If your printer has a
“0” in the sixth position, example Z3x-xxxxx0xxxxxx, the washer (P1047187)
goes behind Gear #3 (P1038244). If your printer has a “2” in the sixth position,
example Z3x-xxxxx2xxxxxx, the washer is not used.
#1
#2
#3

Procedures
Important • When installing the Gear #1, ensure that the grooves (dashed circle below) are
aligned as indicated.
Step 2. Then lock the gears in place (screw for Gear #1, clips for Gears #2 and #3) in
that order.
#1
#2
#3

Procedures
5.6.33 Pressure Rollers - Front and Back
NOTE • This procedure uses Spare Kit # P1031925-074: KIT, PRESSURE ROLLERS.
Step 1. Locate the two Pressure Roller assemblies.
Step 2. With needle-nose pliers, remove the retaining springs (circled below) from both
sides of the Print Engine.
Step 3. Turn the Print Engine over (for access from bottom).

Procedures
Step 4. With a TORX T10 driver, remove the screw (SCR, PLAST, 2-.25, 2.5 in-lb), left
arrow; remove the screw (SCR, PLAST, 4-.25L, 7.0 in-lb), right arrow; then
disconnect the ground wires.
Step 5. Turn the Print Engine over (for access from top).

Procedures
Step 6. With a flat-blade screwdriver, free the locking pins that hold the Front Pressure
Roller assembly in place.
Step 7. Remove the Front Pressure Roller assembly.

Procedures
Step 8. With a flat-blade screwdriver, free the locking pins that hold the Back Pressure
Roller assembly in place.
Step 9. Remove the Back Pressure Roller assembly.

Procedures
5.6.34 Mag Encoder Assembly - Head and Sensor
NOTE • This procedure uses Spare Kit # P1031925-011: KIT, MAG HEAD.
Step 1. Locate the Mag Encoder Assembly (circled below).
holding the Mag Encoder Assembly in place.

Procedures
Step 3. If not already done, disconnect the Mag Encoder Head and Sensor plug from
connector J23 on the Main PCBA.
Step 4. Remove the Mag Encoder Assembly.
Replacement
Important • The orientation of the Head is critical. When installing the Head, ensure that the
heavy line (arrow below) is facing toward the Mag Sensor (circled below).

Procedures
5.6.35 Mag Sensor

Step 1. With the Mag Encoder Assembly removed (Section 5.6.34):
a. With a TORX 7 driver, remove the screw (SCR, PLAST, 2-.25, 2.5 in-lb)
holding the Mag Sensor in place.
b. Disconnect the three sensor wires (arrows below) from the Mag
Encoder connector.
Step 2. Remove the Mag Sensor.

Procedures
5.6.36 Card Sync Sensor
NOTE • This procedure uses Spare Kit # P1031925-054: KIT, SYNC SENSOR.
Step 1. Locate the Card Sync Sensor.
Step 2. With a TORX T7 driver, remove the screw (SCR, PLAST, 4-.37, 4.0 in-lb) and
retainer that hold the sensor in place.; arrow above.
Step 3. If not already done, disconnect the Card Sync Sensor plug from connector J9 on the
Main PCBA.
Step 4. Remove the Card Sync Sensor.

Procedures
5.6.37 Cleaning Roller
NOTE • This procedure uses Spare Kit # P1031925-029: KIT, CLEANING ROLLER
ASSEMBLY.
Step 1. Locate the Cleaning Roller.
Step 2. Note that the Cleaning Roller snaps in and out of place. Carefully grasp the roller,
and lift it up and out of the printer.
Step 3. Set the Cleaning Roller aside.

Procedures
5.6.38 Platen Roller and Exit Roller
NOTE • This procedure uses Spare Kit # P1031925-228: KIT, PLATENS FOR PRINT
ENGINE.
Step 1. Locate the Platen Roller (circled below) and the Exit Roller (arrow below).
Step 2. If not already done, remove the left-side Linkage; see Section 5.6.29.
Step 3. With a TORX T10 driver, loosen the screw (7.0 in-lb) that holds the Tensioner
in place; circled below.
Step 4. Remove the belt.

Procedures
Step 5. With a TORX T10 driver, remove the screw loosened in Step 3; and set the
Tensioner aside.
Step 6. Remove the retaining clip and associated gear pulley (arrow below).
Step 7. With a TORX T10 driver, remove the mounting screw (SCR 4-25L, 4.0 in-lb)
holding the Retaining Plate in place; see arrow above.
Step 8. In addition to the mounting screw removed in the previous step, two clips hold the
plastic Retaining Plate to the frame; see clip slots below. Use a flat-blade
screwdriver to loosen the clips from the inside of the printer; then remove the
Retaining Plate.

Procedures
Step 9. Turn the Print Engine up-side down, and remove the Platen Roller.
Step 10. Remove the Exit Roller.
Step 11. Set the Rollers aside.

Procedures
5.6.39 ATM Card Feed Sensor
NOTE • This procedure uses Spare Kit # P1031925-014: KIT, ATM SENSOR.
Step 1. Locate the ATM Card Feed Sensor (circled below).
Step 2. With a TORX T7 driver, remove the screw (SCR, PLAST, 2-.25, 2.5 in-lb) that
holds the retaining bracket and ATM Card Feed Sensor in place.
Step 3. If not already done, disconnect the ATM Card Feed Sensor plug from connector J12
on the Main PCBA.
Step 4. Remove the ATM Card Feed Sensor (and retaining bracket).

Procedures
5.6.40 Drive Roller Assembly
NOTE • This procedure uses Spare Kit # P1031925-228: KIT, PLATENS FOR PRINT
ENGINE.
Step 1. Locate the Main Drive Roller (circled below).
Step 2. Remove the retaining clip (arrow below) and associated gear pulley.
Step 3. With a TORX T10 driver, remove the two screws (SCR 4-25L, 4.0 in-lb) holding the
side of the support collar to the frame.; circled above.

Procedures
Step 4. Turn the Print Engine up-side down.
Step 5. With a TORX T10 driver, remove the two screws (SCR 4-.25L, 4.0 in-lb)
holding the support collar in place.
Step 6. Slide the support collar over the roller.

Procedures
Step 7. Lift the assembly up and out of the Print Engine.
Step 8. Slide the support collar off the roller.

6
Preventive Maintenance
6.1 Cleaning the System
Caution • PROTECT YOUR FACTORY WARRANTY!

The recommended maintenance procedures must be performed to maintain your 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.
Your Printer includes a simple cleaning system using pre-saturated cleaning cards. The regular
use of these cards will clean and maintain important parts of your printer that cannot be
reached: including the Printhead, the Transport Rollers, and the Magnetic Encoder Station
(optional feature).
To order ZXP Series 1 cleaning supplies, go to www.zebra.com/supplies for details.
6.1.1 When to Clean

Clean the Printer when:
• Print quality has been degraded.

• The LCD panel displays the message CLEAN PRINTER.
• You experience mag encoding failures.

6: Preventive Maintenance
Cleaning the System
6.1.2 How to Clean
Note • Cleaning can also be performed via the Tools dialog box; see Tools on page 49.
Step 1. Place the printer power switch in the ON ( | ) position.

Step 1. When the printer LCD shows READY, hold down the Multi-Function Control Button
for five seconds.
Step 2. When the cleaning cycle is initiated, the LCD message REMOVE RIBBON THEN
CLOSE LID will display. Open the lid, remove the ribbon, and close the lid.
Feeder Cleaning Card

Card Feeder
Cover
Multi-Function
LCD Panel
Multi-Function
Control Button
Long Cleaning
Card
Step 3. Once the ribbon is removed and the lid is closed, the firmware will eject any card
inside the printer; then the message EMPTY FEEDER THEN CLOSE COVER
will display. Open the cover, remove the cards, and close the cover.
Step 4. Once the cards are removed and the cover is closed, the LCD will display INSERT
LONG CLEANING CARD. Insert the long cleaning card.

Cleaning the System
Step 5. When the presence of the cleaning card is sensed, the rollers will take the card into
the printer; and the cleaning process will begin.
Step 6. When the cleaning process is completed, the printer will eject the cleaning card.
Step 7. The message INSERT FEEDER CLEANING CARD will display. Open the feeder
cover, and insert the feeder cleaning card.
Step 8. When the feeder cleaning card has been sensed by the feeder card sensor, the
message CLOSE COVER will display. Close the feeder cover.
Step 9. When feeder cleaning is complete, the message REMOVE FEEDER CLEANING
CARD will display. Open the feeder cover, remove the cleaning card, and
close the feeder cover.
Step 10. After the cleaning card is removed and the feeder cover is closed, the LCD will
display CLEANING DONE.
Step 11. You may now reload the ribbon and cards and continue printing.

Cleaning the Printhead
6.2 Cleaning the Printhead

Use of the cleaning cards will normally do an adequate job of cleaning the printer. However,
a separate Printhead cleaning, using swabs, can remove more stubborn deposits when print
anomalies persist. To avoid deposits, only use foam-tipped swabs.
Caution • Never use a sharp object to scrape deposits from the printhead. Permanent
damage to the printhead will result.
Step 1. Place the printer power switch in the OFF (O) position.
Step 2. Open the printer lid to fully to reveal the printhead mounted on the inside the cover.
Step 3. Clean the printhead by moving an alcohol-moistened swab tip side-to-side across the
printhead elements. Only use moderate force.
Step 4. Allow two to three minutes for the printhead to dry before closing the lid and placing
the printer power switch in the ON ( | ) position.

APPENDIX A
Model Numbers
The Zebra Product Number tells a story. Here is a quick summary of the ZXP Series 1 Card
Printer numbering and lettering system to help you; see next page.

A: Model Numbers
The Part Number of a particular Zebra ZXP Series 1 Card Printer is shown on a label affixed to
the bottom of the printer; that Part Number identifies the specific configuration for that printer.
This chart shows the configurations that are available:
PART NUMBER DESCRIPTION

Z 1 _ - _ _ 0 0 _ _ _ _ _ _ _ _ BASE UNIT
_ _ 1 - _ _ _ _ _ _ _ _ _ _ _ Single-Sided
SMART CARD OPTIONS
_ _ _ - 0 _ _ _ _ _ _ _ _ _ _ _ None
MAG ENCODER OPTIONS
_ _ _ - _ 0 _ _ _ _ _ _ _ _ _ _ None
_ _ _ - _M_ _ _ _ _ _ _ _ _ _ ISO HiCo/LoCo Mag S/W-selectable
Interface
_ _ _ - _ _ _ 0 _ _ _ _ _ _ _ _ USB only
_ _ _ - _ _ _ C _ _ _ _ _ _ _ _ USB and 10/100 Ethernet
SOFTWARE / KIT
_ _ _ - _ _ _ _ 0 _ _ _ _ _ _ _ None
Starter Kit: Monochrome ( Incl: 1 Monochrome Ribbon,
_ _ _ - _ _ _ _ G _ _ _ _ _ _ _ 100 PVC Cards )
_ _ _ - _ _ _ _ H _ _ _ _ _ _ _ Starter Kit: Color ( Incl: 1 YMCKO Ribbon, 100 PVC Cards )
MISCELLANEOUS
_ _ _ - _ _ _ _ _ 0 0 0 _ _ _ _ None
_ _ _ - _ _ _ _ _ _ _ G _ _ _ _ Buy America Act
COUNTRY CODE (power cord option)
_ _ _ - _ _ _ _ _ _ _ _ 0 0 _ _ No power cords
_ _ _ - _ _ _ _ _ _ _ _ A P _ _ Britain
_ _ _ - _ _ _ _ _ _ _ _ US _ _ Americas
_ _ _ - _ _ _ _ _ _ _ _ BR _ _ Brazil
_ _ _ - _ _ _ _ _ _ _ _ EM_ _ EMEA (Europe, the Middle East, and Africa)
_ _ _ - _ _ _ _ _ _ _ _ AU _ _ Australia
_ _ _ - _ _ _ _ _ _ _ _ CN _ _ China
_ _ _ - _ _ _ _ _ _ _ _ I N _ _ India
_ _ _ - _ _ _ _ _ _ _ _ TW_ _ Taiwan
_ _ _ - _ _ _ _ _ _ _ _ J P _ _ Japan
CUSTOM CODE
_ _ _ - _ _ _ _ _ _ _ _ _ _ 0 0 State / Province / Project / Other
ACCESSORIES
P1031925-100 CardSense single-card feed kit, field-upgradable option
105999-302 Cleaning Kit: 4 printer-path and 4 feeder cleaning cards

APPENDIX B
Advanced Sharing
Printer Sharing Configurations

This section covers:
Microsoft Driver Support Matrix - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 192

Client / Server Printer sharing support Matrix - - - - - - - - - - - - - - - - - - - - - - 192

B: Advanced Sharing
Microsoft Driver Support Matrix
Supported Windows One-to-One One-to-Many Many-to-One Many-to-Many Printer

2
Drivers Microsoft Pooling
1
OS
1 Printer - 1 Host - Many Multiple Hosts Multiple Hosts
1 Host Printers (Drivers) - (Drivers) -
One Printer Many Printers
Windows 8 (32bit)
3
Yes Yes Yes Yes Yes
Windows 8 (64bit) Yes Yes Yes Yes Yes
Server 2008 (64Bit) Yes Yes Yes Yes Yes
Server 2008 (32Bit) Yes Yes Yes Yes Yes
Server 2003 Yes Yes Yes Yes Yes
Windows 7 (64Bit) Yes Yes Yes Yes Yes
Windows 7 (32Bit) Yes Yes Yes Yes Yes
Vista (64Bit)
4
Yes
Vista (32Bit)
2
Yes
Windows XP Yes Yes Yes Yes Yes
Client / Server Printer sharing support Matrix

The following Matrix shows the tested configurations between various Microsoft OS in a shared
Client / Server print environment.
Sharing Matrix Windows OS Driver Clients
Windows OS Server Win 8 (32Bit) Win 8 (64Bit) Win 7 (32Bit) Win 7 (64Bit) Win XP
(Driver Host)
Server 2008 64 Bit) Yes Yes Yes
Server 2008 32 Bit) Yes Yes Yes
Server 2003 Yes Yes
Windows 7 64 Bit) Yes Yes Yes
Windows 7 (32 Bit) Yes Yes
Windows XP Yes
(All Editions)
SP 2 and above
1 Driver installed on individual Client PC’s
2 Printer Pooling Sharing not suppored.

B: Advanced Sharing
Advanced Sharing Settings

This section covers the following Advanced Sharing Settings:
Installing and setting up a Windows 2008 Server- - - - - - - - - - - - - - - - - - - - 193

Advanced Sharing Settings for Server R2 2008 - - - - - - - - - - - - - - - - - - - - - 194
Home or Work Network Settings: - - - - - - - - - - - - - - - - - - - - - - - - - - - 194
Public Network Settings: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 195
Advanced Sharing Settings for Server 2008 - - - - - - - - - - - - - - - - - - - - 196
Advanced Sharing Settings for Windows 7 - - - - - - - - - - - - - - - - - - - - - - - - 197

Home or Work Network settings: - - - - - - - - - - - - - - - - - - - - - - - - - - - 197
Public Network Settings: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 198
Installing and setting up a Windows 2008 Server

1. Install a new server OS, Windows 2008 Server 64 bit.
2. Log in as Admin user with password.
3. Check the following services by running the command “Services.msc” from the
Start->Run menu, and make sure the following services are started/running:
a. SSDP Discovery –
b. Function discovery resource publication.
c. UPnP device host-
d. DNS Client.
4. The services mentioned above should be running to ensure that the following network
settings are saved and take effect.

B: Advanced Sharing
Advanced Sharing Settings for Server R2 2008

Home or Work Network Settings:

B: Advanced Sharing
Public Network Settings:

B: Advanced Sharing
Advanced Sharing Settings for Server 2008

B: Advanced Sharing
Advanced Sharing Settings for Windows 7

Home or Work Network settings:

B: Advanced Sharing
Public Network Settings:

B: Advanced Sharing

Appendix C
Accessing a Network Printer
via a Web Browser
Introduction
If the ZXP Series 1 Card Printer is connected to a local Ethernet network, it can be accessed
via a Web Browser. This section describes how to access the printer’s web page using a
computer connected to the network.

C: Accessing a Network Printer via a Web Browser
Procedure
Step 1. Start your Web Browser.
Step 2. In the browser address bar, enter the IP address of the ZXP Series 1 Card Printer
connected to the local Ethernet network. You can get the IP address by checking the
printer configuration; see Viewing Printer Information on page 20 for details.
Step 3. When the Device Status screen appears, click on the Network Settings tab
(arrow below).
Important • For the next step, the User name = admin; and the Password = 1234.
Step 4. When the Windows Security dialog box appears, type the User name (admin) and
Password (1234); and click on the OK button.

Step 5. Select the desired option tab in the left-land column:
Status:
Device Status
Device Status Tab shows the network-connected USB Device Information and Printer
Network Configuration Information.
• USB Device: Displays the internal USB device name of the printer detected. When an
internal USB device name cannot be detected, it will be displayed as ProductID
(PID[0xXXXX]).
• Manufacturer Name: Displays the internal manufacturer name of the printer detected
when connected from the USB device. When printer name cannot be detected, it will be
displayed as VendorID (VID[0xXXXX]).

System Status
• Host Name Displays the HostName of the printer.

• IP Address Displays the printer IP address.
• Subnet Mask Displays the printer subnet mask.
• Default Gateway Displays the printer default gateway.
• DHCP/BOOTP Server Displays the IP address of a DHCP/BOOTP server when
an IP address of the printer is assigned by the DHCP/
BOOTP server.
• Lease Time (sec.) Displays the lease time when an IP address of the printer
assigned by the DHCP BOOTP server.
• mDNS Service Name Displays the current mDNS Service Name of the printer.
• mDNS Domain Name Displays the current mDNS Domain Name of the printer.
• LAN Interface Displays the Link status of the printer.
• Primary WINS Server Displays the IP address of a WINS Primary Server of
the printer.
• Secondary WINS Server Displays the IP address of a WINS Secondary Server of
the printer.
• NetBIOS Scope ID Displays the Scope ID of the printer.

Network Settings:
Network Settings
• Host Name Configure the Host Name of the printer. The name set here
is used with WINS and Utility, etc. The name must be
different from those of other network devices.
• DHCP/BOOTP Enable/Disable the function to get the IP address from the
DHCP/BOOTP server when the printer is turned on. To
get the IP address of this printer from the DHCP/BOOTP
server, the DHCP/BOOTP service must be turned on.
• IP Address Configure the IP address on this printer. The value must
be configured in the format of a four-part series of
numbers separated by decimal points, such as
xxx.xxx.xxx.xxx.
• Subnet Mask Configure the subnet mask on the printer. The value must
xxx.xxx.xxx.xxx.
• Default Gateway Configure the gateway IP address on this printer. The
value must be configured in the format of a four-part
series of numbers separated by decimal points, such as
xxx.xxx.xxx.xxx. The gateway must be in the network
where this printer exists.

• Network PnP Enable/Disable the Network PnP function.

• mDNS Enable/Disable the mDNS function (Apple Bonjour
function).
• mDNS Service Name Configure the mDNS Service Name of this printer. This
name is displayed when the printer is searched in the
network using the Apple Bonjour function. The name
must be unique within the network.
• LAN Interface Configure the physical network type. AUTO is
recommended. If the Link LED on the hub is not turned
on when you turn on this printer, change the network type
to the network type of the hub.
• Primary WINS Server Assign the WINS server's address (primary). The WINS
server will resolve the IP address from the host name.
Therefore you can use a hostname instead of the IP
address when communicating via TCP/IP.
• Secondary WINS Server Assign the WINS server's address (secondary). The WINS
server will resolve the IP address from the host name.
Therefore you can use a hostname instead of the IP
address when communicating via TCP/IP.
• NetBIOS Scope ID The NetBIOS Scope ID defines the computer group that
recognized the registered host name. All computers which
have the same Scope ID can recognize each other.

Security
• IP Filter Mode Configure the IP filter operations. Available options are

ALLOW and DENY. If you select ALLOW, only the data
from the configured IP address range can be accepted. If
you select DENY, the data from the configured IP address
range cannot be accepted.
• Start Address (Filter#0-#3) Configure the start address of the IP filter. The value must
xxx.xxx.xxx.xxx.
• End Address (Filter#0-#3) Configure the end address of the IP filter. The value must
xxx.xxx.xxx.xxx.

System Information:
System Information
• MAC Address Displays the MAC address of this printer.

• Firmware Version Displays the firmware version of this printer.
• URL Jumps to the Global Site of Zebra Technologies. You can
view FAQ and get latest software from Zebra
Technologies' Web site at http://www.zebra.com.

System Information (continued):

Password
• New Password Configure the administrator password in ASCII characters

(up to 7 characters). This is used as the authentication
password for configuration changes via the Web page.
• Re-enter New Password Re-enter the new password.


Reset
• Reboot Reboot this printer by clicking Start.

• Reset to Factory Default Reset this printer to factory default settings, and reboot by
clicking Start.


Log
• Time Displays the time when a PC is connected to or

disconnected from a networked USB device. The time
displayed will be the elapsed time since this printer is
turned on.
• Event Displays the PC event history. (Connect/Disconnect)
• USB Device Displays the USB device that is used.
• Connected PC Displays the IP address of a PC that is connected to a USB
device.


Update
• Firmware File Update the firmware. Specify the file path for the
firmware to be updated. Note that this update is the
ZBR-PS300 firmware, not the Printer firmware.
Step 6. When done, close the browser by clicking on the red X-button in the upper-right
corner of the browser screen.

Appendix D
CardSense Single Card
Feed Option
Introduction
For operating the ZXP Series 1 Card Printer in single-card feed mode, the printer requires that
the operator install an optional Manual Front Feed Kit.
In the single-card feed mode, the printer will accept cards through the front slot.

D: CardSense Single Card Feed Option
Installing the CardSense Single Card Feed Roller Kit

Step 1. Turn printer power OFF.
Step 2. Open the lid, and remove the ribbon cartridge.
Important • Make sure the Card Output Hopper remains closed.
Step 3. Install the black roller. Place it between the clips just behind the card entry slot, and
press the roller straight down so it is fully seated.
Step 4. While holding the roller down, turn power ON. You will hear a loud click as the
clips secure the roller.
Step 5. At this point, let go of the roller, and then turn printer power OFF.
Step 6. Open the Cleaning Cartridge. The new Cleaning Cartridge will contain a Cleaning
Roller with its protective wrapping.
New Cleaning
Roller with
Protective
Wrapping

Step 7. Remove the Cleaning Roller from the Cleaning Cartridge, and then remove the
protective wrapper from the Cleaning Roller,
Step 8. Place the Cleaning Roller in the Cartridge, and close the lid.
Step 9. The Cleaning Cartridge is held in place by two clips. While gently squeezing the
clips inward, press the cartridge into place. It will seat with a click.
Step 10. Insert the Ribbon Cartridge with the cleaning roller facing down, so the gears on the
ends of the rollers fit into the appropriate slots.
Step 11. Close the printer lid, and push down until you hear an audible click. If you can not
close the lid, the cleaning cartridge or the ribbon cartridge may be installed wrong.
Step 12. Place the printer power switch in the ON ( | ) position.

Setting Up the Printer Driver

Card Setup tab allows the user to set the single-card feed mode.
To access the Card Setup tab, select Start > Devices and Printers. Right click on the Zebra
ZXP Card Printer listing, then select Printing preferences > Card Setup.
Step 1. Make the appropriate Single Feed option selection from the Current Status
dropdown menu:
• Card feeder: The printer will attempt to a pull a card from the Card Feeder.
If the Card Feeder is empty, the printer will generate an OUT OF CARDS
error message.
• Single feeder slot: For each print job, the printer will generate an INSERT
CARD message. Any cards in the Card Feeder will not be used.
• Auto feed: The printer will attempt to feed cards from Card Feeder first. If
Card Feeder is empty, the printer will generate an INSERT CARD message.
No OUT OF CARDS error message will be generated.
Step 2. Click the Apply button, then click the OK button.
Important • You do not have to remove the components of the Single-Card Feed Kit in order
to operate in normal mode (printing cards from the Card Feeder).

Printing a Single Card

Step 1. Cards are inserted one at a time into the slot on the front of the printer. Do not feed
more than one card at a time. Note that the card must be fully inserted before printer
turns on and accepts the card.
INSERT CARD
ZEBRA ZXP Series 1
Step 2. The card is printed.
Step 3. The printed card is ejected out through the same (input) slot.
Note • If single-card feeding will be the normal mode of operation, you may select that
mode through the driver software. In single-card feed mode, the card will not be printed until
the print job has been sent to the printer and the card to be printed has been inserted into the
single-card feed slot

APPENDIX E
Magnetic Encoder Option
Introduction
This section contains information on the additional operations of the ZXP Series 1 Card
Printer with an optional Magnetic Encoder.
This section covers:
Encoder Settings (Driver) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Media Loading Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Magnetic Encoder Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Magnetic Encoding Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

E: Magnetic Encoder Option
Encoder Settings (Driver)

The Encoder Settings dialog box is used for setting various Magnetic Encoder parameters.
This feature is not enabled if the printer does not have the magnetic encoder option.; see
Encoding Tab on page 65 for details.
Media Loading Orientation
Caution • ONLY USE cards that comply with ISO 7810 & 7811 standards for magnetic
stripe cards. The magnetic stripe must be flush to the surface of the card to work properly.
Never use cards which have taped-on magnetic stripes.
Note • Zebra-approved HiCo & LoCo PVC cards are available; see http://www.zebra.com/
supplies for details.
When loading cards with magnetic stripes into the card feeder, please ensure that the magnetic
stripe is facing the left side of the printer, and closest to the bottom edge of the card feeder; see
Loading Cards on page 71 for details.
Magnetic Encoder Cleaning

Use the standard cleaning card process as described in Section 6, Preventive Maintenance.
This cleans the most important parts of the printer; including the Printhead, Transport Roller,
and Magnetic Stripe Encoder.

E: Magnetic Encoder Option
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.).

APPENDIX F
Half-Panel Ribbon
Operation
Introduction
Half-Panel YMCKO Color Ribbons are used if you do not need full color printing over the entire
surface of a card. These ribbons have half panels of YMC for ID pictures, logos, etc., for printing a
38mm wide window on the front of the card. The remaining panels are
full-size black resin and clear overlay so black text and protection can be applied over the entire
surface of the card. The position of the half panel is adjustable.
The command is HALF p1 where p1 sets the start position of the print window. The position of the
window is with respect to the leading edge of the card; i.e., the edge of card which exits the printer
first. To reset the driver, the command is simply HALF without the p1 parameter.
DIRECTION OF PRINT
Leading-Edge
of the Card
HALF 0 HALF 568
P1 = 0 P1 = 568
Parameters p1 ranges from -38 to 1024. Values below 0 will move the window off the leading edge
of the card, and values over 568 will move the window off the trailing edge of the card. Note
that 12 points = 1mm.

F: Half-Panel Ribbon Operation
Setup and Operation

Step 1. Install a Half-Panel YMCKO Ribbon Cartridge; see Installing the Ribbon Cartridge
on page 69.
Step 2. Configure Driver Printing Preferences:
a. Select Start > Devices and Printers. Right click on the Zebra ZXP Card Printer
listing. Select Printing preferences > Card Setup.
b. Click on the K Panel Options button (arrow above).

c. From the Black Panel Options dialog box, make the following selections
(arrows below).
d. Click the OK button to close the Black Panel Options dialog box.
e. Click the OK button to exit Printing Preferences.

Step 3. Set Driver Printer Properties:
a. Select Start > Devices and Printers. Right click on the Zebra ZXP Card Printer
listing. Select Printer properties > Device Settings.
b. Click the Tools button (arrow above). This will bring up the Tools dialog box.

Step 4. Enter the half-panel command.
a. From the Tools dialog box, type the command in the “Command to send to
printer” field to position the print window on the card; e.g., HALF 0.
Type the
command
here ... HALF 0
... then
click the
Execute
button.
b. Click the Execute button. If successful the printer will respond with <ACK> in
the Printer Status field directly under the “Command to send to printer” field.
c. Click the Close button to close the Tools dialog box.
d. Click the OK button to exit the Printer Properties.
Step 5. From your card printing application, print your card(s).

Appendix G
Upgrade Kit Instructions
This section contains detailed instructions for the following upgrade kits:
Ethernet PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Manual Front Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

G: Upgrade Kit Instructions
Ethernet PCBA
Spare / Upgrade Kit Instructions
Caution • This 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 Ethernet Spare / Upgrade Kit P1031925-001 in a Zebra
ZXP Series 1 Card Printer.
be performed by reversing the removal steps.

Parts List
UPGRADE KIT: P1031925-001; KIT, ETHERNET PCBA
QTY PART NUMBER DESCRIPTION
1 P1028338-001 KIT, ETHERNET
4 806822-001 FOOT,CYLINDRICAL,ADH-BACKED
Special Tools
• Flat-blade Screwdriver
• TORX T10 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.

Preliminary Steps
Remove the Bottom Cover
Step 1. Turn the printer over, bottom-side up.
Step 2. With a Flat-blade Screwdriver, carefully pry off the four rubber feet (they are held in
place with adhesive). Note that the feet cover access holes to the screws holding the
Bottom Cover in place.
Step 3. With a TORX T10 driver, remove the four bottom-cover screws (arrows above).

Removal
Step 1. With a TORX T10 driver, remove the four screws (arrows below) holding the
Ethernet Plate to the Ground Plate.
Step 2. Remove the Ethernet PCBA and Plate.
Replacement
Replacement is performed by reversing the removal steps.

Manual Front Feed

Upgrade Kit Instructions
Caution • This 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 Manual Front Feed Upgrade Kit P1031925-100 in a
Zebra ZXP Series 1 Card Printer.
be performed by reversing the removal steps.

Parts List
Upgrade Kit: P1031925-100; KIT, UPGRADE, MANUAL FRONT FEED
QTY PART NUMBER DESCRIPTION
1 210320-005 PANEL, FRONT, ZXP1
2 210321-005 MOUNT, SENSOR, ATM, ZXP1
1 806597G-204 SCR, PH, TORX, PLAST, 2-.25, ZN
1 P1060010 C/A, ATM INTERRUPTOR, ZXP1
1 P1061567 ASSY, CLEANNG CARTRIDGE
4 806822-001 FOOT,CYLINDRICAL,ADH-BACKED
Special Tools
• TORX T10 Driver
• Flat-blade Screwdriver
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.
Preliminary Steps
Do the following:
a. Remove the Left Side Cover - - - - - - - - - - - - - - - - - - 237

b. Remove the Right Side Cover - - - - - - - - - - - - - - - - - 238
c. Remove the Bottom Cover - - - - - - - - - - - - - - - - - - - 239
d. Remove the Front Bezel - - - - - - - - - - - - - - - - - - - - 240

Remove the Left Side Cover

Step 1. Press the Lid Release Button, and raise the Lid.
Step 2. Locate the two screws (circled below) that hold the Left Side Cover in place.
Step 3. With a TORX T10 driver, loosen the two screws. When reinstalling the cover,
tighten the screws to 9.0 in-lbs.
Step 4. Remove the Left Side Cover.

Remove the Right Side Cover

Step 1. Locate the two screws (circled below) that hold the Right Side Cover in place.
Step 2. With a TORX T10 driver, loosen the two screws. When reinstalling the cover,
tighten the screws to 9.0 in-lbs.
Step 3. Remove the Right Side Cover.
Step 4. Close the Lid.

Remove the Bottom Cover

Step 1. Turn the Printer over, bottom-side up.
Step 2. With a flat-blade screwdriver, carefully pry off the four rubber feet (they are held
in place with adhesive).
Step 3. With a TORX T10 driver, remove the four screws (SCR, PLAST, 4-.37L,7.0 in-lb);
see arrows above.
Step 5. Turn the Printer over.
Step 6. Raise the Lid.

Remove the Front Bezel

Step 1. With a TORX T10 driver, remove the four screws, two per side, holding the Left
and Right Bezels to the Frame; the two left-side screws are circled below.
Step 2. Remove the Front Bezels (and card catcher).
Step 3. Set the Front Bezels aside.

Installation
Step 1. With four screws (removed when removing the Front Bezel), attach the Front Feed
Bezel. Tighten the screws to 4.0 in-lb.
Step 2. Close the Lid.
Step 3. Turn the Printer over, bottom-side up.
Step 4. Route sensor cable from the bezel to the Main PCBA.
Step 5. Plug the sensor connector into J1 on the Main PCBA (arrow below).
BOTTOM SIDE
J1

Step 6. Turn the Printer over.
Step 7. Raise the Printer Lid.
Step 8. Place the black Cleaner Roller into the tabs (circled below) at the front of the printer.
Step 9. While holding the black Cleaner Roller down FIRMLY, turn the printer ON. The
printer will initialize, raise the blue tabs, and snap the roller into place.
Step 10. Install the Cleaning Cartridge Housing, and open the lid. An alignment tab is located
on the left side of the Cleaning Cartridge Housing to ensure proper installation.

Step 11. Peel protective wrapper from the adhesive Cleaning Roller by gently pulling on the
blue tape, and discard the wrapper.
Step 12. Insert the Cleaning Roller into the Cleaning Cartridge Housing.
Step 13. Close the lid of the Cleaning Cartridge Housing.
Step 14. Close the Printer Lid.

Reassembly
Replacement is performed by reversing the removal steps.
NOTE • Torque values are specified in the corresponding removal step.
Step 1. Install the Encode Front Bezel.
Step 2. Install the Bottom Cover.
Step 3. Install the Right Side Cover.
Step 4. Install the Left Side Cover.

Configuration Update
After installing this upgrade, the Printer must be configured to recognize it. This is done by
issuing a command via the Printer Driver.
Step 1. Select Start > Devices and Printers. Right click on the Zebra ZXP Card Printer
listing. Select Printer properties > Device Settings.
Step 2. Click on the Tools button (arrow above).

Step 3. This brings up the Tools display.
Type the
command
here ... ... then
click the
Execute
button.
Step 4. In the Command to send to printer field, type MANFEED.
Step 5. Click on the Execute button.
Step 6. <ACK> should appear in the Printer Status field indicating that the MANFEED
command was successfully completed.
Step 7. In the Command to send to printer field, type SDATA to save the value entered
in Step 4.
Step 8. <ACK> should appear in the Printer Status field indicating that the command
was successfully completed.
Step 10. The configuration update is complete.

APPENDIX H
Spares List
Introduction
This section lists the Spare Parts Kits and Upgrade Kits that are available for the ZXP Series 1
Card Printer.

H: Spares List
Before ordering, be sure to check the Partner Zone on www.zebra.com for the latest Spare
part kits listing.
Kit, # Description
P1031925-001 Kit, Upgrade, Ethernet PCBA
P1031925-007 Kit, MLB Single-sided
P1031925-010 Kit, LCDisplay PCBA
P1031925-011 Kit, Mag Head
P1031925-012 Kit, Ribbon Sensor
P1031925-014 Kit, ATM Sensor
P1031925-015 Kit, Lid & Ribbon Encoder Sensors
P1031925-018 Kit, Motor, Head Lift
P1031925-019 Kit, Ribbon Motor
P1031925-021 Kit, Linkage Springs
P1031925-023 Kit, Ribbon Drive System
P1031925-025 Kit, Belts & O-Rings for Print Engine
P1031925-026 Kit, Encoder Disk
P1031925-029 Kit, Cleaning Roller Assembly
P1031925-038 Kit, Latch for Feeder
P1031925-040 Kit, Ground Plate
P1031925-042 Kit, Cover for Feeder
P1031925-046 Kit, Feet for Printer
P1031925-047 Kit, Covers for Frame
P1031925-048 Kit, Cables Electronics
P1031925-049 Kit, Power Supply
P1031925-050 Kit, Packaging
P1031925-052 Kit, Miscellaneous Hardware
P1031925-053 Kit, Feed Cover Sensor
P1031925-054 Kit, Sync Sensor
P1031925-055 Kit, Flipper Sensor
P1031925-070 Kit, Printhead
P1031925-071 Kit, Cooling Fans
P1031925-072 Kit, Drive Linkage
P1031925-073 Kit, Drive Gears & Camshaft
P1031925-074 Kit, Pressure Rollers
P1031925-076 Kit Flipper Assembly
P1031925-100 Kit Upgrade Manual Front Feed
P1031925-137 Kit, Button For Door
P1031925-141 Kit, Top Cover And Badge
P1031925-143 Kit, Side Panels Bezels
P1031925-217 Kit, Motor Card Drive
P1031925-224 Kit, Drive System
P1031925-228 Kit Platens For Print Engine
P1031925-230 Kit, Feeder Assembly
P1031925-233 Kit, Carrier And Drive For Flipper
P1031925-235 Kit, Inner Top Assembly
P1031925-244 Kit, Output Hopper Non-Encode

H: Spares List
# Aftermarket Kit P1031925-xxx QTY

1 part of -141 Top Cover and Badge 1
2 -137 Button for Door 1
3 -042 Cover for Feeder 1

H: Spares List
# Aftermarket Kit P1031925-xxx Qty

1 -042 Cover for Feeder 1
2 -010 LCD PCBA 1
3 part of -141 Top Cover and Badge 1
4 -137 Button for Door 1

H: Spares List

1 -070 Printhead 1
2 -012 Ribbon Sensor 1

H: Spares List

1 -053 Feeder Cover Sensor 1
2 -038 Latch for Feeder 1
3 -071 Cooling Fans 2
4 -244 Output Hopper 1

H: Spares List

1 part of -073 Drive Gears and Camshaft 1
2 part of -072 Drive Linkage 1
3 part of -224 Drive System 1
4 part of -020 Springs for Linkage 1
7 part of -228 Platen Rollers 1

H: Spares List

1 part of -074 Pressure Rollers 1
2 part of -228 Platens for Print Engine 1
3 part of -074 Pressure Rollers 1

H: Spares List

1 -076 Flipper Assembly 1
2 -055 Flipper Sensor 1
3 -233 Carrier and Drive for Flipper 1

H: Spares List

2 -018 Head Lift Motor 1
6 part of -073 Drive Gears and Camshaft 1
7 -019 Ribbon Motor 1
8 part of -021 Springs for Linkage 1
9 part of -023 Ribbon Drive System 1
11 -026 Encoder Disk 1

H: Spares List

1 -011 Mag Head 1
2 -019 Ribbon Motor 1
3 -217 Card Drive Motor 1
4 -018 Head Lift Motor 1
5 -054 Sync Sensor 1

H: Spares List

1 -001 Ethernet PCBA 1
2 -007 Main Logic PCBA 1
3 -040 Ground Plate 1
4 part of -143 Side Panels, Bezels 1
5 -046 Feet (4) 1

H: Spares List

1 -230 Feeder Assembly 1
2 -014 ATM Sensor 1
3 part of -015 Lid & Ribbon Sensors 1
4 part of -047 Covers for Frame 1
5 part of -015 Lid & Ribbon Sensors 1
6 part of -047 Covers for Frame 1
7 -009 Cryptographic PCBA 1

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: ts1@zebra.com
North America and Latin America - Repair Services

Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-of-
warranty repair, contact Repair Services for a 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: repair@zebra.com

I: Worldwide Support
Europe, Middle East, and Africa - Technical Support
Language Phone Email

Arabic +971 (0)46058220 zebraCareUAE@zebra.com
Dutch +31 (0)33 450 50 48 ZebraCareBNL@zebra.com
English (UK) +44 (0)1628 556 225 zebraCareUK@zebra.com
(Sweden) +46 (0)8 594 709 88 zebraCareUK@zebra.com
+27 (0)11 201 7712 /
(South Africa) zebracareSA@zebra.com
0860 393272
French +33 (0) 1 53 48 12 74 zebraCareFR@zebra.com
German +49 (0) 2159 676 870 zebraCareDE@zebra.com
Hebrew +97 236 498 140 ZebraCareIL@zebra.com
Italian +39 0 2 575 06388 ZebraCareIT@zebra.com
Polish +48 223 801 980 zebraCarePL@zebra.com
Russian +7 495 739 5993 ZebraCareRU@zebra.com
Spanish +34 (0) 917 992 896 zebraCareES@zebra.com
Turkish +90 212 314 1010 zebraCareTR@zebra.com
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: cardts@zebra.com

Europe, Middle East, and Africa - Repair Services

Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-of-
warranty repair, contact 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 zebracareDE@zebra.com
Austria, Switzerland
Depot Repair in France +33 (0) 1 53 48 12 74 zebracareFR@zebra.com
Depot and On-Site Repair in

+44 (0) 1628 556 225 zebracareUK@zebra.com
UK and Ireland
Depot Repair in South Africa +27 (0) 11 201 7777 -
Depot Repair in Middle East +971 (0) 46058220 support_dxb@emitac.ae
For further assistance, contact:

For assistance anywhere in the EMEA, contact After Sales Customer Services at:
T: + 44 (0) 177 2 69 3069

E: ukrma@zebra.com

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: tsasiapacific@zebra.com
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: APACRepair@zebra.com
Zebra Website
http://www.zebra.com
km.zebra.com (Knowledge Base)

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This document contains information proprietary to Zebra Technologies Corporation. This

Product Disposal Information • Do not dispose of this product in unsorted municipal

P1061942-001 ZXP Series 1 Card Printer Service Manual iii

iv ZXP Series 1 Card Printer Service Manual P1061942-001

5.6.30 Rocker - Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

A • Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

P1061942-001 ZXP Series 1 Card Printer Service Manual v

P1061942-001 Zebra ZXP Series 1 Card Printer Service Manual 1

1.2 Features, Controls, and Indicators

Card Output Zebra Print

• Multi-Function Control Button - The Multi-Function Control Button initiates several

2 Zebra ZXP Series 1 Card Printer Service Manual P1061942-001

Rear Panel Connectors, Controls, and Indicators

Standard USB Connection

Link LED Power LED

The Ethernet Connector has two LED status indicators:

• Power LED (amber): When illuminated, indicates power is on.

P1061942-001 Zebra ZXP Series 1 Card Printer Service Manual 3

Multi-Function LCD Panel

4 Zebra ZXP Series 1 Card Printer Service Manual P1061942-001

WARNINGS (Printer will still operate)

ERRORS (Printer will not operate)

P1061942-001 Zebra ZXP Series 1 Card Printer Service Manual 5

• Eco-Friendly Load-N-Go™ drop-in ribbon ZXP Series 1 cartridges

• Dye-sublimation thermal transfer direct to card

6 Zebra ZXP Series 1 Card Printer Service Manual P1061942-001

Encoding Options and Specifications

• CardSense™ Single-Card Feed Roller Kit - optional, field upgradable

• USB V2.0 (cable included) - standard

Physical Specifications (standard model)

• Auto-switching single-phase AC power

P1061942-001 Zebra ZXP Series 1 Card Printer Service Manual 7

True Colours ix Series ZXP Series 1 Ribbon Options

• Operating Temperature: 60º F to 86º F (15º C to/30º C)

8 Zebra ZXP Series 1 Card Printer Service Manual P1061942-001

2004/108/EC EMC Directive, EN55022:2010 Class A,

99/5/EC R&TTE Directive, EN 301 489-3 V1.4.1,

P1061942-001 Zebra ZXP Series 1 Card Printer Service Manual 9

1.4 ISO Standard Card Dimensions

Dimensions for Magnetic Stripe Card ISO Standard 7811

0.623 in (15.82 mm) min

0.218 in (5.54 mm) max

0~0.115 in (2.92 mm) 0~0.115 in (2.92 mm)

10 Zebra ZXP Series 1 Card Printer Service Manual P1061942-001

1.5 Compliance Information

1. This device may not cause harmful interference, and

FCC Radiation Exposure Statement (RLAN)

Canadian DOC Compliance Statement

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

P1061942-001 Zebra ZXP Series 1 Card Printer Service Manual 11

European Union and EFTA

Operation in band 5150 – 5350 MHz shall be

NCC Warning Message

Brasil - Aviso da Anatel

Para maiores informações, consulte o site da ANATEL www.anatel.gov.br

12 Zebra ZXP Series 1 Card Printer Service Manual P1061942-001

Note • Indicates information that emphasizes or supplements important points of the

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

Electrostatic Discharge Caution • Warns you of the potential for electrostatic

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

1.2 Zebra Supplies

P1061942-001 Zebra ZXP Series 1 Card Printer Service Manual 13