Question about Zebracard P420I Thermal Card Printer

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Zebra P240i will not print test card or feed cards

Zebra P240i will not print test card. If there is a card in the feed hopper on initialization, the card will feed but get stuck in the duplexer. Firmware and drivers are current based on Zebra website.

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This may be caused by a broken card sensor. On Zebra P420i card printers if there is a card inside the flipper or under the printhead when you power it on, the printer ejects 1card from its mechanism. Once it's already turned on, if its not printing, the printer is thinking there is a card jam error.

-- The Pros at

Posted on Feb 10, 2012

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    DiscountIDStore Feb 10, 2012

    Could also be your roller on the flipper, those rollers wear out after about 300,000 prints.
    -- The Pros at


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I need the cardfive driver for my zebra P420i card printer.

Posted on Jun 10, 2009


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Posted on Jan 02, 2017

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Sticky back card static causing them to stick togeather and not feed from the hopper

Hello Richard,

Sorry for the delay in replying to your request.

Feeding cards (especially self-adhesive types) from the rear hopper, can sometimes be frustrating. You have done the right thing by separating the cards (this applies to all cards - just fan down both sides like a dealer would with a pack of cards). This important.

Please try the following additional trick though;

Remove the rear hopper.
On the front panel, select Menu -> Test Card -> Yes (to confirm).
The rear hopper roller will start to rotate.
Take a fresh cleaning card (from the cleaning kit - 3633-0053) out of its wrapper. It MUST be damp.
Fold it into a loop and manually hold the cleaning card against the hopper roller as it turns (with gentle hand pressure). The idea of folding the cleaning card is to prevent it from being accidentally dragged into the rear of the printer.
After about 12 seconds, an Out of Cards 02:00 error will be displayed. Press Retry.
Turn the card over and repeat until there are no Black marks left of the cleaning card. Repeat as necessary moving to a fresh part of the cleaning card each time.
If the card should accidentally go too far into the printer, a Card Jam 06:05 error will be shown. Just open the lid, and close it again to clear the card jam error. The sequence will carry on from the previous stage (the hopper roller will start turning again shortly after closing the lid).
Once you are happy the roller is thoroughly clean, on the next Out of Cards error, press Cancel.
Discard the cleaning card which will probably have dried out by this point. Replace the rear hopper.

Card feeding should then be trouble-free.

If the problem should persist, contact your local Magicard support centre.

Kind Regards,


Nov 21, 2013 | Magicard Rio Pro Single Sided Photo ID...

2 Answers

Zebra P110i printer is making a noise when cards are feeding through to be printed and sometimes says Mechanical error. Print quality is fine but, cards occasionally do not fully drop out when print job is...

Check the type of cards you are using, they might be too thick. If you are using the regular 30mil PVC Cards then make sure before you load the cards you "fan" them, meaning try to separate the cards as when they build static electricity and "glue" to each other.

If that does not solver your problem, then you should send the printer for repairs, check your warranty status with your ID Printer Vendor.

Also, sometimes if you are using the Adhesive cards, the paper back of the card does not feed into the roller system of the printer.

-- The Pros at

Oct 11, 2011 | Zebra P110i ID Card Printer

1 Answer

I have a zebra p520i and it will print a one sided card then go into mechanical error, I then can press the select button and it will travel the card past the laminator section and into the exit hopper and...

This sounds like the feed rollers need cleaning. You can use the correct cleaning cards (your dealer should be able to get them for you - but make sure you follow the instructions on the card carefully) or use IPA fluid.on a lint free cloth.

Jun 03, 2011 | Office Equipment & Supplies

1 Answer

Just had machine serviced (reset sensors, recalibrated ribbon, belts checked and orings) I've printed about 20 cards, now I keep getting a "out of cards" message or mechanical error . Thanks

Mechanical error is a message that comes up for many reasons, probably in this case it is because the rollers are turning and a card is not getting to the appropriate sensor on time. Out of cards is shown when the sensor in the feed hopper thinks there are no cards present. Try blowing any dust off the sensors. Perhaps the connection has come loose when the printer was in transit. It could have been knocked if the service agent removed all of the covers to service it.

Nov 04, 2010 | Zebra P330i Thermal Card Printer

1 Answer

P330i - The printer says Ready on the LCD but the computer reads Out of Paper? There are cards ready in the hopper?

please install the driver again, then send the command IM (print testcard)
If not work, Try to send !SA command and then try to print the card.

Oct 08, 2010 | Zebra P330i Thermal Card Printer

1 Answer


Hi and thank you for using fixya:
You need to buy a new ribbon for the machine

Jun 03, 2010 | Zebra P420i Thermal Card Printer

1 Answer

Keeps printing on 1 spot

I am a bit unlear of the QUestion Here.

But let me say it sounds as if it it tring to print in color.
The back and forth motion is what tells me that.

Feb 14, 2009 | Zebra Eltron P310 Thermal Printer

2 Answers

Resolving a Card not fed error (Cards will not feed off the Hopper)

Make sure that your hopper card thickness guage (located on the right side of the hopper) is set to 30 ml or above if you are using standard 30 ml PVC cards. You may also need to clean the printer with a Fargo printer cleaning kit for this printer.

Also check to make sure to check your PVC cards. Sometimes they have too much static and can stick together not allowing them to feed. Fan the cards before placing them back in the hopper to make sure they are not sticking. In this process, try not to touch the printing surface of the cards as oils from skin will cause defective printing results.

For more id card printer tips, visit our technical assistance blog at

Nov 05, 2008 | Fargo DTC525 ID Card Printer

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